Thermal Dynamics iCNC Performance Service And Installation Manual

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iCNC PERFORMANCE CNC CONTROLLER

INPUT VOLTAGE

24V

Service and Installation Manual

Revision: AB Issue Date: February, 2016 Manual No.: 0-5401

Thermal-Dynamics.com

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Thermal Dynamics product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 1-800-752-7622, or visit us on the web at www.thermal-

dynamics.com.

This Service Manual has been designed to instruct you on the correct use and operation of your Thermal Dynamics product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products.

We distinguish ourselves from our competition through market-leading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.

Above all, we are committed to developing technologically advanced products to achieve a safer working environment within the welding industry.

WARNING

iCNC Performance

Service Manual No. 0-5401

Published by: Thermal Dynamics Corporation. 2800 Airport Rd. Denton, Texas 76207

www.thermal-dynamics.com

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer’s best judgement, the Manufacturer assumes no liability for its use.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this manual, whether such error results from negligence, accident, or any other cause.

Publication Date: September 25, 2015 Revision Date: February, 2016

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date:______________________________________

iCNC Performance Serial #:_______________________________

Be sure this information reaches the operator.

You can get extra copies through your supplier.

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and Gouging,” Booklet 0-5407. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased. This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR

OPERATING.

PROTECT YOURSELF AN D OTHERS!

ASSUREZ-VOUS QUE CETTE INFORMATION EST DISTRIBUÉE À L’OPÉRATEUR.

VOUS POUVEZ OBTENIR DES COPIES SUPPLÉMENTAIRES CHEZ VOTRE FOURNISSEUR.

ATTENTION

Les INSTRUCTIONS suivantes sont destinées aux opérateurs qualiés seulement. Si vous

n’avez pas une connaissance approfondie des principes de fonctionnement et des règles de sécurité pour le soudage à l’arc et l’équipement de coupage, nous vous suggérons de lire notre brochure « Precautions and Safe Practices for Arc Welding, Cutting and Gouging,

» Brochure 0-5407. Ne permettez PAS aux personnes non qualiées d’installer, d’opérer ou

de faire l’entretien de cet équipement. Ne tentez PAS d’installer ou d’opérer cet équipement avant de lire et de bien comprendre ces instructions. Si vous ne comprenez pas bien les instructions, communiquez avec votre fournisseur pour plus de renseignements. Assurez-vous de lire les Règles de Sécurité avant d’installer ou d’opérer cet équipement.

RESPONSABILITÉS DE L’UTILISATEUR

Cet équipement opérera conformément à la description contenue dans ce manuel, les étiquettes d’accompagnement et/ou les feuillets d’information si l’équipement est installé, opéré, entretenu et réparé selon les instructions fournies. Vous devez faire une

vérication périodique de l’équipement. Ne jamais utiliser un équipement qui ne fonctionne pas bien ou n’est pas bien entretenu.

Les pièces qui sont brisées, usées, déformées ou contaminées doivent être remplacées immédiatement. Dans le cas où une réparation ou un remplacement est nécessaire, il est recommandé par le fabricant de faire une demande de conseil de service écrite ou par téléphone chez le Distributeur Autorisé de votre équipement. Cet équipement ou ses pièces ne doivent pas être modiés sans permission préalable écrite par le fabricant. L’utilisateur de l’équipement sera le seul responsable de toute défaillance résultant d’une utilisation incorrecte, un entretien fautif, des dommages, une

réparation incorrecte ou une modication par une personne autre que le fabricant ou un centre de service désigné par le fabricant.

ASSUREZ-VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D’UTILISATION AVANT

D’INSTALLER OU D’OPÉRER L’UNITÉ.

PROTÉGEZ-VOUS ET LES AUTRES!

This Page Intentionally Blank

Declaration of Conformity

We Thermal Dynamics of 2800 Airport Road

Denton, TX 76207 U.S.A.

in accordance with the following Directive(s):

2006/95/EC The Low Voltage Directive

2004/108/EC The Electromagnetic Compatibility Directive

hereby declare that:

Equipment: Plasma Cutting CNC Controller

Model Name/Number: iCNC Performance

Market Release Date: August 19, 2015

is in conformity with the applicable requirements of the following harmonized standards:

Conforms to requirements of IEC 61326-1:2012

IEC 61000-4-2: 2008, Electro Static Discharge Immunity

IEC 61000-4-3:2006 +A1:2007 +A2:2010, Radiated, Radio-Frequency, Electromagnetic Immunity

IEC 61000-4-4:2012, Electrical Fast Transient/Burst Immunity

IEC 61000-4-6: 2008, Conducted Radio-Frequency Electromagnetic Immunity

IEC 61000-4-8:2009, Power Frequency Magnetic Field Immunity

CISPR 11:2009 +A1:2010, AC Mains Conducted Emissions

CISPR 11:2009 +A1:2010, Radiated Emissions

Meets IEC 61010-1:2010 Safety requirements for electrical equipment for measurement, control, and laboratory use - Part 1: General requirements

Classification: The equipment described in this document is Class A and intended for industrial use.

WARNING

This Class A equipment is not intended for use in residential locations where the electrical

power is provided by the public low-voltage supply system. There may be potential difﬁculties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.

Manufacturer’s Authorized Representative

Steve Ward V.P. Europe and General Manager

Address:Victor Technologies International Inc. Europa Building Chorley N Industrial Park Chorley, Lancashire, England PR6 7BX

Date: August 19, 2015

Steve Ward

V.P. Europe and General Manager

(Position)

(Signature)

Full Name

WARNING

This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There may be potential difﬁculties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.

TABLE OF CONTENTS

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

1.01 Safety Precautions - ENGLISH ........................................................................ 1-1

1.02 Précautions de sécurité - FRENCH CANADIAN ............................................... 1-6

SECTION 2: SPECIFICATIONS ............................................................................. 2-1

2.1 System Description ......................................................................................... 2-1

2.2 Speciﬁcation ................................................................................................... 2-1

2.3 Dimensions ..................................................................................................... 2-2

2.4 Basic System Layout ...................................................................................... 2-3

2.5 Grounding and Cable Routing ......................................................................... 2-4

2.5.1 Low Cost Ground Rod Tester ......................................................................... 2-4

2.6 Connector Locations ....................................................................................... 2-6

SECTION 3: I/O DESCRIPTIONS .......................................................................... 3-1

3.1 General ........................................................................................................... 3-1

3.2 J45 Inputs ....................................................................................................... 3-1

3.2.1 Input Pin Arrangement .................................................................................... 3-1

3.2.2 Input Example ................................................................................................. 3-2

3.2.3 Input Naming .................................................................................................. 3-2

3.3 J46 Outputs .................................................................................................... 3-3

3.3.1 Output Pin Arrangement ................................................................................. 3-3

3.3.2 Output Example .............................................................................................. 3-4

3.3.3 Output naming ................................................................................................ 3-4

3.3.4 Wiring Multiple Oxyfuel Lifters ....................................................................... 3-5

3.3.5 Wiring Multiple Stations ................................................................................. 3-6

SECTION 4: MOTION ....................................................................................... 4-1

4.1 Motion in General ........................................................................................... 4-1

4.1.1 Motion Signal Characteristics ......................................................................... 4-1

4.2 J47 Servo Connector ...................................................................................... 4-2

4.2.1 Servo Pin arrangement ................................................................................... 4-2

4.3 J48 Encoder Connector .................................................................................. 4-3

4.3.1 Encoder Pin Arrangement ............................................................................... 4-3

4.4 Servo Connection Examples ........................................................................... 4-4

4.4.1 Analog Speed Signal with Yaskawa SGDV ...................................................... 4-4

4.4.2 Step/Dir Signal with Yaskawa SGDV ............................................................... 4-4

4.4.3 Analog Speed Signal with Panasonic A5 ......................................................... 4-5

4.4.4 Step/Dir with Panasonic A5 w/o Encoder Feedback ........................................ 4-5

4.4.5 Step/Dir Signal without Encoder Feedback ..................................................... 4-6

SECTION 5: INPUT POWER ............................................................................... 5-1

5.1 Power Supply ................................................................................................. 5-1

5.2 Power Connector ............................................................................................ 5-1

5.2.1 Power Connector Pin Arrangement ................................................................. 5-1

SECTION 6: iHC ............................................................................................. 6-1

6.1 Lifter Speciﬁcations ........................................................................................ 6-1

6.1.2 Voltage Divider Dimensions ............................................................................ 6-2

6.2 Connector Locations ....................................................................................... 6-2

6.3 IO Example Connections ................................................................................. 6-3

6.4 J54 Lifter ........................................................................................................ 6-4

6.5 J55 Plasma ..................................................................................................... 6-5

6.6 J53 CNC .......................................................................................................... 6-6

TABLE OF CONTENTS

6.7 iHC Software ................................................................................................... 6-7

6.7.1 Pierce/Cut Sequence ....................................................................................... 6-7

6.7.2 IO Bits Tab ...................................................................................................... 6-8

6.7.3 Service Tab ..................................................................................................... 6-9

6.7.4 Installation Tab .............................................................................................. 6-10

6.7.5 Parameter Limits .......................................................................................... 6-11

SECTION 7: iCNC SETUP .................................................................................. 7-1

7.1 Initial Checks .................................................................................................. 7-1

7.2 Starting iCNC Setup ........................................................................................ 7-2

7.3 Motion, STEP/DIR ........................................................................................... 7-3

7.3.2 Drive and Encoder Polarities Step/Dir ............................................................. 7-4

7.3.3 Encoder Values Step/Dir ................................................................................. 7-5

7.3.4 Max Speed Adjustment Step/Dir ..................................................................... 7-6

7.3.5 Motion Parameters ......................................................................................... 7-6

7.4 Motion, Analog Speed ..................................................................................... 7-8

7.4.1 Drive Conﬁguration Analog Speed .................................................................. 7-8

7.4.2 Drive and Encoder Polarities Analog Speed .................................................... 7-9

7.4.3 Encoder Values Analog Speed ...................................................................... 7-10

7.4.4 Drift Adjustment Analog Speed ..................................................................... 7-11

7.4.5 Max Speed Adjustment Analog Speed .......................................................... 7-11

7.4.6 Max Speed Test Analog Speed ...................................................................... 7-12

7.4.7 Min Speed Test Analog Speed ....................................................................... 7-12

7.4.8 Motion Parameters ....................................................................................... 7-13

7. I/O ................................................................................................................. 7-15

7.5.1 I/O General .................................................................................................... 7-15

7.5.2 I/O and Delay ................................................................................................ 7-17

7.5.2.1 I/O and Delay Plasma Cutting ....................................................................... 7-17

7.5.2.2 Advanced ...................................................................................................... 7-19

7.5.2.3 I/O and Delay Gas Cutting ............................................................................. 7-20

7.5.2.4 Custom ......................................................................................................... 7-21

7.5.2.5 Advanced ...................................................................................................... 7-22

7.5.2.6 I/O and Delay Line Marking ........................................................................... 7-22

7.5.3 Custom ......................................................................................................... 7-23

7.5.4 Advanced ...................................................................................................... 7-24

7.5.5 I/O Point Marking .......................................................................................... 7-25

7.5.6 I/O Outbit Names .......................................................................................... 7-26

7.5.7 I/O Inbit Names ............................................................................................. 7-26

7.6 Cutting Table Data ......................................................................................... 7-27

7.6.1 Homing / Limits ............................................................................................ 7-27

7.6.2 Down Draft ................................................................................................... 7-31

7.7 Others ........................................................................................................... 7-32

7.7.1 General ......................................................................................................... 7-32

7.7.2 THC/Plasma Settings ................................................................................... 7-33

7.7.3 Teach In ....................................................................................................... 7-34

7.7.4 Get Serial Number ........................................................................................ 7-34

7.7.5 Diagnostic Information ................................................................................. 7-34

7.7.6 Advanced Diagnostics ................................................................................... 7-34

7.7.7 Update Software ........................................................................................... 7-34

7.8 Backups ........................................................................................................ 7-34

7.8.1 Backup Machine Settings .............................................................................. 7-34

7.8.2 Restore Machine Settings ............................................................................. 7-35

TABLE OF CONTENTS

7.8.3 Restore Machine Settings from Backwall Backup USB ................................. 7-35

7.8.4 Create a System Image ................................................................................. 7-37

7.8.5 Restore a System Image ............................................................................... 7-38

7.9 Rotating Axis ................................................................................................ 7-38

7.9.1 Tangential Rotation ....................................................................................... 7-38

7.10 Hard Drive Lock ............................................................................................ 7-38

7.10.1 Change Status ............................................................................................... 7-38

8. Tool Offsets ................................................................................................... 7-39

8.1 Measuring the offset using a plasma power supply ...................................... 7-39

8.2 Setting the tool offset values ........................................................................ 7-40

SECTION 8: MAINTENANCE AND TROUBLESHOOTING ............................................... 8-1

8.1 Maintenance ................................................................................................... 8-1

8.2 Troubleshooting .............................................................................................. 8-1

8.2.1 Using Machine Info Screen for Troubleshooting ............................................. 8-1

8.2.1.1 Position and Speed Info .................................................................................. 8-1

8.2.1.2 Outbits Tab ...................................................................................................... 8-2

8.2.1.3 Inbits Tab ........................................................................................................ 8-3

8.2.1.4 Diagnostic Tools Tab ....................................................................................... 8-3

8.2.2 Boot and Power Issues ................................................................................... 8-4

8.2.3 Piercing and Cutting Issues ............................................................................ 8-4

8.2.4 Motion Issues ................................................................................................. 8-5

8.2.5 IO Issues/ Error Messages .............................................................................. 8-5

8.2.6 UI Errors ......................................................................................................... 8-6

8.2.7 Cut Quality ...................................................................................................... 8-6

8.3 Replacement Parts .......................................................................................... 8-7

APPENDIX A ................................................................................................. A-1

A.1 Bios settings ................................................................................................... A-1

A.2 Setting up SDSK Series Motors ...................................................................... A-2

A.2.1 Connecting to the Servo Motor ....................................................................... A-2

A.2.2 Autotune ......................................................................................................... A-4

A.2.3 Settings .......................................................................................................... A-7

A.2.4 Changing Motor Rotation Direction ................................................................ A-8

A.2.5 Final Settings .................................................................................................. A-8

APPENDIX B ................................................................................................. B-1

B.1 Servo Adapter Card (optional) ........................................................................ B-1

B1.1 Dimensions ..................................................................................................... B-1

B.1.2 Output Connectors .......................................................................................... B-2

B.1.3 Encoder Connectors ....................................................................................... B-3

B.1.4 Servo Connectors ........................................................................................... B-3

B.1.5 Input Connectors ............................................................................................ B-4

B.1.6 Teknic Connectors ..........................................................................................B-5

B.1.7 E-Stop Connectors .......................................................................................... B-6

B.1.8 Servo Adapter Card Connection Example........................................................ B-7

B.1.9 Servo Adapter Card Alternative Connections .................................................. B-8

B.2 Motors and Gearboxes .................................................................................... B-9

B.2.1 Teknic Nema23 ............................................................................................... B-9

B.2.2 Neugart PLPE 70 ............................................................................................ B-9

B.2.3 Teknic Nema34 ............................................................................................. B-10

B.2.4 Neugart PLPE 90 .......................................................................................... B-10

B.2.5 Lifter Motor ................................................................................................... B-11

B.2.6 75VDC Power Suply Dimensions .................................................................. B-12

B.3 Thermal Dynamics A-Series Automation PCB ............................................... B-13

B.4 Cable Drawings ............................................................................................. B-14

B.4.1 Yaskawa Speed Loop Example ...................................................................... B-14

B.4.2 Panasonic A5 Speed Loop Example .............................................................. B-15

B.4.3 Panasonic A5 STEP/DIR Example ................................................................. B-16

B.4.4 Lifter Cable ................................................................................................... B-17

B.4.5 Collision Sensor Cable .................................................................................. B-18

B.4.6 Plasma and VDC Adapter Cable .................................................................... B-19

B.4.7 A-series Plasma Adapter Cable ..................................................................... B-20

B.4.8 Auto-Cut 200 XT Plasma Adapter Cable ........................................................ B-21

B.4.9 Ultra-Cut XT & Auto-Cut 300 XT Plasma Adapter Cable ................................ B-22

B.4.10 Ultra-Cut XT Communication Cable .............................................................. B-23

B.4.11 Ultra-Cut & Auto-Cut blue units (Sanrex) Plasma Adapter Cable .................. B-24

B.4.12 Connecting iHC to Panasonic A5 .................................................................. B-25

B.4.13 Y2 Alignment Cable For Teknic Motor ........................................................... B-26

STATEMENT OF WARRANTY

TABLE OF CONTENTS

iCNC Performance

SECTION 1: SAFETY

1.01 Safety Precautions - ENGLISH

WARNING: These Safety Precautions are for your protection. They summarize precautionary information from the references listed in Additional Safety Information section. Before performing any instal-

lation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS -- Some welding, cutting, and gouging processes are noisy and require ear protection. The arc, like the sun, emits ultraviolet (UV) and other radiation and can injure skin and eyes. Hot metal can cause burns. Training in the proper use of the pro-

cesses and equipment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any work area, even if welding helmets, face shields, and goggles are also required.

2. Use a face shield ﬁtted with the correct ﬁlter and cover plates to protect your eyes, face, neck, and ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal.

3. Wear ﬂameproof gauntlet type gloves, heavy long-sleeve shirt, cufﬂess trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal. A ﬂameproof apron may also be desirable as protection against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars should be kept buttoned, and open pockets eliminated from the front of clothing.

5. Protect other personnel from arc rays and hot sparks with a suitable non-ﬂammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can ﬂy far. Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat from ﬂames and arcs can start ﬁres. Hot slag or sparks can also cause ﬁres and explosions. Therefore:

1. Remove all combustible materials well away from the work area or cover the materials with a protective non-ﬂammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or crevices in ﬂoors or wall openings and cause a hidden smoldering ﬁre or ﬁres on the ﬂoor below. Make certain that such openings are protected from hot sparks and metal.“

3. Do not weld, cut or perform other hot work until the work piece has been completely cleaned so that there are no substances on the work piece which might produce ﬂammable or toxic vapors. Do not do hot work on closed containers. They may explode.

4. Have ﬁre extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket, or portable ﬁre extinguisher. Be sure you are trained in its use.

5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create a ﬁre hazard.

6. After completing operations, inspect the work area to make certain there are no hot sparks or hot metal which could cause a later ﬁre. Use ﬁre watchers when necessary.

7. For additional information, refer to NFPA Standard 51B, “Fire Prevention in Use of Cutting and Welding Processes”, available from the National Fire Protection Association, Battery march Park, Quincy, MA 02269.

Manual 0-5401 SAFETY INSTRUCTIONS 1-1

iCNC Performance

ELECTRICAL SHOCK -- Contact with live electrical parts and ground can cause severe injury or death. DO NOT use AC welding current in damp areas, if movement is conﬁned, or if there is danger of falling.

1. Be sure the power source frame (chassis) is connected to the ground system of the input power.

2. Connect the work piece to a good electrical ground.

3. Connect the work cable to the work piece. A poor or missing connection can expose you or others to a fatal shock.

4. Use well-maintained equipment. Replace worn or damaged cables.

5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from work and from ground.

7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for speciﬁc grounding recommendations. Do not mistake the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current ﬂowing through any conductor causes localized Electric and Magnetic Fields (EMF ). Welding and cutting current creates EMF around welding cables and welding machines. Therefore:

1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.

2. Exposure to EMF may have other health effects which are unknown.

3. Welders should use the following procedures to minimize exposure to EMF:

A. Route the electrode and work cables together. Secure them with tape when possible. B. Never coil the torch or work cable around your body. C. Do not place your body between the torch and work cables. Route cables on the same side of your

body. D. Connect the work cable to the work piece as close as possible to the area being welded. E. Keep welding power source and cables as far away from your body as possible.

FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in conﬁned

spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation.

Therefore:

1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut, or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium unless positive mechanical ventilation is provided. Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for speciﬁc ventilation recommendations.

5. WARNING: This product contains chemicals, including lead, known to the State of California to cause birth defects and other reproductive harm. Wash hands after handling.

1-2 SAFETY INSTRUCTIONS Manual 0-5401

iCNC Performance

CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore:

1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and ﬁttings in good condition. Follow manufacturer’s operating instructions for mounting regulator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure cylinders to work tables or ﬁxtures where they may become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and ﬂames. Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1, “Precautions for Safe Handling of Compressed Gases in Cylinders”, which is available from Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. Therefore:

1. Always have qualiﬁed personnel perform the installation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualiﬁed to perform such work.

2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power.

3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position and in good repair.

6. Use equipment only for its intended purpose. Do not modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For more information on safe practices for electric arc welding and cutting equipment, ask your supplier for a copy of “Precautions and Safe Practices for Arc Welding, Cutting and Gouging”, Form 52-529.

The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.

2. AWS C5.1 - “Recommended Practices for Plasma Arc Welding”.

3. AWS C5.2 - “Recommended Practices for Plasma Arc Cutting”.

4. AWS C5.3 - “Recommended Practices for Air Carbon Arc Gouging and Cutting”.

5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.

6. AWS C5.6 - “Recommended Practices for Gas Metal Arc Welding”.

7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, “Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances.”

9. CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.

Manual 0-5401 SAFETY INSTRUCTIONS 1-3

iCNC Performance

DANGER

CAUTION

WARNING

CAUTION

Meaning of symbols - As used throughout this manual: Means Attention! Be Alert! Your safety is involved.

Means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life.

Means potential hazards which could result in personal injury or loss of life.

Means hazards which could result in minor personal injury.

Enclosure Class

The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or water. Protection is provided against touch with a ﬁnger, penetration of solid objects greater than 12mm and against spraying water up to 60 degrees from vertical. Equipment marked IP21S may be stored, but is not intended to be used outside during precipitation unless sheltered.

This product is solely intended for plasma cutting. Any other use may result in personal injury and / or equipment damage.

If equipment is placed on a surface that slopes more than 15°, toppling over may occur. Personal injury and / or signicant damage to equipment is possible.

Art# A-12726

1-4 SAFETY INSTRUCTIONS Manual 0-5401

To avoid personal injury and/or equipment damage, lift using method and attachment points shown here.

Art# A-12736

iCNC Performance

This Page Intentionally Blank

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1.02 Précautions de sécurité - FRENCH CANADIAN

AVERTISSEMENT : Ces règles de sécurité ont pour but d’assurer votre protection. Ils récapitulent les informations de précaution provenant des références dans la section des Informations de sécurité

supplémentaires. Avant de procéder à l’installation ou d’utiliser l’unité, assurez-vous de lire et de suivre les précautions de sécurité ci-dessous, dans les manuels, les ﬁches d’information sur la sécurité du matériel et sur les étiquettes, etc. Tout défaut d’observer ces précautions de sécurité peut entraîner des blessures graves ou mortelles.

PROTÉGEZ-VOUS -- Les processus de soudage, de coupage et de gougeage produisent un niveau de bruit élevé et exige l’emploi d’une protection auditive. L’arc, tout comme le soleil,

émet des rayons ultraviolets en plus d’autre rayons qui peuvent causer des blessures à la peau et les yeux. Le métal incandescent peut causer des brûlures. Une formation reliée à l’usage des processus et de l’équipement est essentielle pour prévenir les accidents. Par conséquent:

1. Portez des lunettes protectrices munies d’écrans latéraux lorsque vous êtes dans l’aire de travail, même si vous devez porter un casque de soudeur, un écran facial ou des lunettes étanches.

2. Portez un écran facial muni de verres ﬁltrants et de plaques protectrices appropriées aﬁn de protéger vos yeux, votre visage, votre cou et vos oreilles des étincelles et des rayons de l’arc lors d’une opération ou lorsque vous observez une opération. Avertissez les personnes se trouvant à proximité de ne pas regarder l’arc et de ne pas s’exposer aux rayons de l’arc électrique ou le métal incandescent.

3. Portez des gants ignifugiés à crispin, une chemise épaisse à manches longues, des pantalons sans rebord et des chaussures montantes aﬁn de vous protéger des rayons de l’arc, des étincelles et du métal incandescent, en plus d’un casque de soudeur ou casquette pour protéger vos cheveux. Il est également recommandé de porter un tablier ininﬂammable aﬁn de vous protéger des étincelles et de la chaleur par rayonnement.

4. Les étincelles et les projections de métal incandescent risquent de se loger dans les manches retroussées, les rebords de pantalons ou les poches. Il est recommandé de garder boutonnés le col et les manches et de porter des vêtements sans poches en avant.

5. Protégez toute personne se trouvant à proximité des étincelles et des rayons de l’arc à l’aide d’un rideau ou d’une cloison ininﬂammable.

6. Portez des lunettes étanches par dessus vos lunettes de sécurité lors des opérations d’écaillage ou de meulage du laitier. Les écailles de laitier incandescent peuvent être projetées à des distances considérables. Les personnes se trouvant à proximité doivent également porter des lunettes étanches par dessus leur lunettes de sécurité.

INCENDIES ET EXPLOSIONS -- La chaleur provenant des ﬂammes ou de l’arc peut provoquer un incendie. Le laitier incandescent ou les étincelles peuvent également provoquer un incendie ou une explosion. Par conséquent :

1. Éloignez sufﬁsamment tous les matériaux combustibles de l’aire de travail et recouvrez les matériaux avec un revêtement protecteur ininﬂammable. Les matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles, les solvants, les peintures et les revêtements, le papier, etc.

2. Les étincelles et les projections de métal incandescent peuvent tomber dans les ﬁssures dans les planchers ou dans les ouvertures des murs et déclencher un incendie couvant à l’étage inférieur Assurez-vous que ces ouvertures sont bien protégées des étincelles et du métal incandescent.

3. N’exécutez pas de soudure, de coupe ou autre travail à chaud avant d’avoir complètement nettoyé la surface de la pièce à traiter de façon à ce qu’il n’ait aucune substance présente qui pourrait produire des vapeurs inﬂammables ou toxiques. N’exécutez pas de travail à chaud sur des contenants fermés car ces derniers pourraient exploser.

4. Assurez-vous qu’un équipement d’extinction d’incendie est disponible et prêt à servir, tel qu’un tuyau d’arrosage, un seau d’eau, un seau de sable ou un extincteur portatif. Assurez-vous d’être bien instruit par rapport à l’usage de cet équipement.

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5. Assurez-vous de ne pas excéder la capacité de l’équipement. Par exemple, un câble de soudage surchargé peut surchauffer et provoquer un incendie.

6. Une fois les opérations terminées, inspectez l’aire de travail pour assurer qu’aucune étincelle ou projection de métal incandescent ne risque de provoquer un incendie ultérieurement. Employez des guetteurs d’incendie au besoin.

7. Pour obtenir des informations supplémentaires, consultez le NFPA Standard 51B, “Fire Prevention in Use of Cutting and Welding Processes”, disponible au National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

CHOC ÉLECTRI QUE -- Le contact avec des pièces électriques ou les pièces de mise à la terre sous tension peut causer des blessures graves ou mortelles. NE PAS utiliser un courant de soudage c.a. dans un endroit humide, en espace restreint ou si un danger de chute se pose.

1. Assurez-vous que le châssis de la source d’alimentation est branché au système de mise à la terre de l’alimentation d’entrée.

2. Branchez la pièce à traiter à une bonne mise de terre électrique.

3. Branchez le câble de masse à la pièce à traiter et assurez une bonne connexion aﬁn d’éviter le risque de choc électrique mortel.

4. Utilisez toujours un équipement correctement entretenu. Remplacez les câbles usés ou endommagés.

5. Veillez à garder votre environnement sec, incluant les vêtements, l’aire de travail, les câbles, le porteélectrode/torche et la source d’alimentation.

6. Assurez-vous que tout votre corps est bien isolé de la pièce à traiter et des pièces de la mise à la terre.

7. Si vous devez effectuer votre travail dans un espace restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur des planches sèches ou une plate-forme isolée et portez des chaussures à semelles de caoutchouc.

8. Avant de mettre l’équipement sous tension, isolez vos mains avec des gants secs et sans trous.

9. Mettez l’équipement hors tension avant d’enlever vos gants.

10. Consultez ANSI/ASC Standard Z49.1 (listé à la page suivante) pour des recommandations spéciﬁques concernant les procédures de mise à la terre. Ne pas confondre le câble de masse avec le câble de mise à la terre.

CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de danger. Le courant électrique qui passe dans n’importe quel conducteur produit des champs électriques et magnétiques localisés. Le soudage et le courant de coupage créent des champs électriques et magnétiques

autour des câbles de soudage et l’équipement. Par conséquent :

1. Un soudeur ayant un stimulateur cardiaque doit consulter son médecin avant d’entreprendre une opération de soudage. Les champs électriques et magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques.

2. L’exposition à des champs électriques et magnétiques peut avoir des effets néfastes inconnus pour la santé.

3. Les soudeurs doivent suivre les procédures suivantes pour minimiser l’exposition aux champs électriques et magnétiques :

A. Acheminez l’électrode et les câbles de masse ensemble. Fixez-les à l’aide d’une bande adhésive

lorsque possible. B. Ne jamais enrouler la torche ou le câble de masse autour de votre corps. C. Ne jamais vous placer entre la torche et les câbles de masse. Acheminez tous les câbles sur le

même côté de votre corps. D. Branchez le câble de masse à la pièce à traiter le plus près possible de la section à souder. E. Veillez à garder la source d’alimentation pour le soudage et les câbles à une distance appropriée

de votre corps.

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LES VAPEURS ET LES GAZ -- peuvent causer un malaise ou des dommages corporels, plus particulièrement dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le gaz de protection risque de causer l’asphyxie.

Par conséquent :

1. Assurez en permanence une ventilation adéquate dans l’aire de travail en maintenant une ventilation naturelle ou à l’aide de moyens mécanique. N’effectuez jamais de travaux de soudage, de coupage ou de gougeage sur des matériaux tels que l’acier galvanisé, l’acier inoxydable, le cuivre, le zinc, le plomb, le berylliym ou le cadmium en l’absence de moyens mécaniques de ventilation efﬁcaces. Ne respirez pas les vapeurs de ces matériaux.

2. N’effectuez jamais de travaux à proximité d’une opération de dégraissage ou de pulvérisation. Lorsque la chaleur ou le rayonnement de l’arc entre en contact avec les vapeurs d’hydrocarbure chloré, ceci peut déclencher la formation de phosgène ou d’autres gaz irritants, tous extrêmement toxiques.

3. Une irritation momentanée des yeux, du nez ou de la gorge au cours d’une opération indique que la ventilation n’est pas adéquate. Cessez votre travail aﬁn de prendre les mesures nécessaires pour améliorer la ventilation dans l’aire de travail. Ne poursuivez pas l’opération si le malaise persiste.

4. Consultez ANSI/ASC Standard Z49.1 (à la page suivante) pour des recommandations spéciﬁques concernant la ventilation.

5. AVERTISSEMENT : Ce produitcontient des produits chimiques, notamment du plomb, reconnu par l’Étatde la Californie pour causerdes malformations congénitaleset d’autresdommages touchant le système reproductif.

MANIPULATION DES CYLINDRES -- La manipulation d’un cylindre, sans observer les précautions nécessaires, peut produire des ﬁssures et un échappement dangereux des gaz. Une brisure soudaine du cylindre, de la soupape ou du dispositif de surpression peut causer des blessures graves

ou mortelles. Par conséquent :

Se laver les mainsaprès manipulation.

1. Utilisez toujours le gaz prévu pour une opération et le détendeur approprié conçu pour utilisation sur les cylindres de gaz comprimé. N’utilisez jamais d’adaptateur. Maintenez en bon état les tuyaux et les raccords. Observez les instructions d’opération du fabricant pour assembler le détendeur sur un cylindre de gaz comprimé.

2. Fixez les cylindres dans une position verticale, à l’aide d’une chaîne ou une sangle, sur un chariot manuel, un châssis de roulement, un banc, un mur, une colonne ou un support convenable. Ne ﬁxez jamais un cylindre à un poste de travail ou toute autre dispositif faisant partie d’un circuit électrique.

3. Lorsque les cylindres ne servent pas, gardez les soupapes fermées. Si le détendeur n’est pas branché, assurez-vous que le bouchon de protection de la soupape est bien en place. Fixez et déplacez les cylindres à l’aide d’un chariot manuel approprié. Toujours manipuler les cylindres avec soin.

4. Placez les cylindres à une distance appropriée de toute source de chaleur, des étincelles et des ﬂammes. Ne jamais amorcer l’arc sur un cylindre.

5. Pour de l’information supplémentaire, consultez CGA Standard P-1, “Precautions for Safe Handling of Compressed Gases in Cylinders”, mis à votre disposition par le Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202.

ENTRETIEN DE L’ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou inadéquate peut causer des blessures graves ou mortelles. Par conséquent :

1. Efforcez-vous de toujours conﬁer les tâches d’installation, de dépannage et d’entretien à un personnel qualiﬁé. N’effectuez aucune réparation électrique à moins d’être qualiﬁé à cet effet.

2. Avant de procéder à une tâche d’entretien à l’intérieur de la source d’alimentation, débranchez l’alimentation électrique.

3. Maintenez les câbles, les ﬁls de mise à la terre, les branchements, le cordon d’alimentation et la source d’alimentation en bon état. N’utilisez jamais un équipement s’il présente une défectuosité quelconque.

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MISE EN GARDE

4. N’utilisez pas l’équipement de façon abusive. Gardez l’équipement à l’écart de toute source de chaleur, notamment des fours, de l’humidité, des ﬂaques d’eau, de l’huile ou de la graisse, des atmosphères corrosives et des intempéries.

5. Laissez en place tous les dispositifs de sécurité et tous les panneaux de la console et maintenez-les en bon état.

6. Utilisez l’équipement conformément à son usage prévu et n’effectuez aucune modiﬁcation.

INFORMATIONS SUPPLÉMENTAIRES RELATI VES À LA SÉCURITÉ -- Pour obtenir de l’information supplémentaire sur les règles de sécurité à observer pour l’équipement de soudage à l’arc électrique et le coupage, demandez un exemplaire du livret “Precautions and Safe Practices for Arc Welding,

Cutting and Gouging”, Form 52-529. Les publications suivantes sont également recommandées et mises à votre disposition par l’American Welding

Society, 550 N.W. LeJuene Road, Miami, FL 33126 :

1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.

2. AWS C5.1 - “Recommended Practices for Plasma Arc Welding”.

3. AWS C5.2 - “Recommended Practices for Plasma Arc Cutting”.

4. AWS C5.3 - “Recommended Practices for Air Carbon Arc Gouging and Cutting”.

5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.

6. AWS C5.6 - “Recommended Practices for Gas Metal Arc Welding”.

7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, “Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances.”

9. CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.

SIGNIFICATION DES SYMBOLES - Ce symbole, utilisé partout dans ce manuel, signie “Attention” ! Soyez vigilant ! Votre sécurité est en jeu.

Signie un danger immédiat. La situation peut entraîner des blessures graves ou

DANGER

MISE EN GARDE

AVERTISSEMENT

mortelles.

Signie un danger potentiel qui peut entraîner des blessures graves ou mortelles.

Signie un danger qui peut entraîner des blessures corporelles mineures.

Classe de protection de l’enveloppe

L’indice de protection (codiﬁcation IP) indique la classe de protection de l’enveloppe, c’est-à-dire, le degré de protection contre les corps solides étrangers ou l’eau. L’enveloppe protège contre le toucher, la pénétration d’objets solides dont le diamètre dépasse 12 mm et contre l’eau pulvérisée à un angle de jusqu’à 60 degrés de la verticale. Les équipements portant la marque IP21S peuvent être entreposés à l’extérieur, mais ne sont pas conçus pour être utilisés à l’extérieur pendant une précipitation à moins d’être à l’abri.

Ce produit a été conçu pour la découpe au plasma seulement. Toute autre utilisation pourrait causer des blessures et/ou endommager l’appareil.

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MISE EN GARDE

L’équipement pourrait basculer s’il est placé sur une surface dont la pente dépasse 15°. Vous pourriez vous blesser ou endommager l’équipement de façon importante.

Art# A-12736

Art# A-12726

Soulevez à l’aide de la méthode et des points d’attache illustrés an d’éviter de vous blesser ou d’endommager l’équipement.

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SECTION 2: SPECIFICATIONS

2.1 System Description

iCNC Performance is intended for shape cutting control. iCNC Performance has motion control, I/O, user interface and an optional plasma height control built all in one package. These units are not ﬁeld repairable. Unauthorized opening of the unit will void the warranty.

2.2 Speciﬁcation

Processor 2, Intel (secondary processor for motion & I/O) Operating system Windows 7 Embedded Ram 2GB Ethernet ports 1 RJ-45 and 1 WLAN USB ports 2, 1 On back wall (USB2.0) + 1 On door (USB2.0) Serial ports 1 RS-422/485 port on d-sub 9 pin Hard drive 120GB SATA SSD Operating console Total of 35 buttons and a digital potentiometer Display 15” With touch panel (resistive) Number of I/O 20 outputs and 16 inputs I/O type Outputs and inputs are grounding Axis available 1-2 Y, 1 X, optional 1Z (iHC) Default drives interface Analog +-10V speed signal, step/direction (2 axis command), incremental encoder inputs Integrated plasma height con-

trol CNC input power volts (amps) 24VDC (5A), with optional iHC 24VDC 6A. CNC protection device Automatic fuse Operating temperature -10 C° - +50 C° / 14°F - 122°F

Optional iHC height control

WARNING

Do not operate or service the device without proper training.

WARNING

Device is not meant to be serviced in the eld. Contact your dealer for repair.

WARNING

DO NOT CONNECT the controller directly to a computer through the RJ45 or RS232 port! Connections must be made with ber optic devices, wireless LAN, short haul modems or other approved devices which provide galvanic isolation, due to ground loops, electrical noise, or high frequency which can destroy electrical components in the controller or host computer. Failure to follow these rules will VOID THE WARRANTY!

This device is provided with an integrated PLC and a Windows based user interface.

1. Use minimum 75 ºC copper wire only

2. Use Copper Conductors Only

3. Suitable for use on a circuit capable of delivering not more than 5000 RMS symmetrical amperes, 230 VAC maximum.

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2.3 Dimensions

iCNC Performance has 4 x 8mm holes for mounting screws. There is a 16mm [0.63in] collar going around the unit.

Dimensions and weight (this does not take in account the dimensions for the connectors or cables): Width: 408 [16.063] Height: 492 [19.37] Depth: 66 [2.598] Weight: Under 7kg [16 lbs.]

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2.4 Basic System Layout

iCNC Performance has connections for inputs, outputs, motion control and a communication port. Usually the outputs (grounding) controls relays and all inputs needs to be dry contact or common grounding inputs (more details on I/O section).

J46-OutputsJ45- Inputs

J48-EncoderJ47-Servo

Power

RS-485

24VDC

J55 - GCM

USER INPUT

J15 - CNC

HEIGHT CONTROL

J54 - TSC /COMM

J59 - RAS

CB2 - 5A 120 VAC

CB3 - 5A 24 VAC

J70 - HE

CB4 - 5A 120 VAC

F1 - 8A SB 230 VAC F2 - 8A SB 230 VAC

PLASMA

J54-LifterJ55-Plasma I/O

24VDC power Supply

Servo Drives

Output Relays

Star Ground

Inputs:

- Limits

- ...

Work

Oxyfuel: - Solenoids

- Lifter

- ...

iHC Lifter

Manual 0-5401 SPECIFICATIONS 2-3

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2.5 Grounding and Cable Routing

Star Ground on Cutting Table

Remote Arc

Starter (RAS-1000)

Cutting Machine / Gantry

iCNC

#4 AWG

Ground

1/0

Ground Cable

(F1)

Cutting Table

Earth Ground

Rod

1/0

Ground Cable Customer supplied A good ground will be less than 3 ohm. Ideal 1.

0 - 10 ft (0 - 3 m) Ideal

20 ft (6 m) Maximum

Lifter

Torch

Gas Control Module

#4 AWG

Ground

‘Star’

Ground

Primary location

#4 AWG

Ground

(F)

3/0 Work Cable

1/0 Ground Cable

Power Supply

Art # A-11875.AC

Note: The gas control module can be mounted on top of the power supply. If it is, it should be grounded directly to the power supply with #4 AWG ground, (F). Any location requires grounding the power supply to the ‘Star’ ground with the 1/0 Ground Cable (F1).

WARNING

Most common issues comes from poor or improper grounding.

- Use a single star ground point where all grounds are connected.

- Do not coil any ground wires.

- Keep ground cables as short as possible.

Good practice is to separate sensitive signal cables (encoder, arc voltage etc.) from HF sources. Never coil any excess cables and use care when routing them.

2.5.1 Low Cost Ground Rod Tester

1. A key component of reduced EMI is a good low resistance earth ground rod. There are several very expensive instruments to measure the ground but cost from several hundred to a few thousand dollars. Below is a low cost alternative which can be constructed by qualiﬁed personnel familiar with established electrical construction and safety practices. Previously suggested method using an incandescent light bulb will not work with GFCI outlets which are increasingly being used and the bulbs are becoming obsolete.

2. This method, as well as the light bulb method and some of the expensive instruments, assumes the utility ground is perfect, Zero ohms. It connects the rod being tested in series with the utility ground and measures the resistance of both in series. If the utility ground is not zero ohms, no matter how good your rod is, you won’t get a low reading due the higher resistance of the utility ground. Fortunately this is rare. Also if your rod is right next to another earth grounded structure you may get a false lower reading of only resistance between that structure and your rod rather than to gnd.

NOTE!

In the United States most standard AC outlets are 120 VAC 60 Hz. Elsewhere most outlets are 220 VAC 50Hz.

3. Obtain a transformer rated for at least 25 VA with primary voltage and frequency matching your standard outlets. The transformer should have an isolated secondary of either 220 VAC (220 -240 is OK) or 120 VAC (110-120 is OK) and be rated for at least 100 ma. The transformer could also have dual 115VAC primaries wired in series for 220V or in parallel for 120 VAC. An example is Triad N-68X, shown below, rated 50VA, 50/60 Hz.

Obtain a power resistor of either 1200 (1.2K) ohms, 15-25W min, if using a 120V secondary or 2200 (2.2K) ohms, 25

-30W for a 220V secondary.

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4. Assemble the transformer and power resistor in a metal box. Connect a 3 wire (w/gnd) power cord with ground wire attached to the metal box for safety. If a plastic box is used instead, connect the transformer core and the resistor mounts to the power cord ground wire. There should be a fuse ¼ - ½ A, in series with the transformer primary. From the transformer secondary connect one wire to the utility safety ground. This could be the cutting table frame, the ground terminal of the 120 or 220 VAC outlet or the test box if grounded as indicated.

An excellent ground measures 1 ohm or less. Up to 3 ohms is often acceptable, higher reduces the effectiveness of the

EMI suppression.

R = 1.2K, 15W

Triad N-68X

115 VAC 115 VAC

(2.2K, 25W for 220 VAC)

Triad N-68X

115 VAC

Ground Rod with other

connecons removed

GND

220 VAC

115 VAC

GND

120 VAC

Utility (building) GND

Art # A-12710

0.1 VAC = 1 OHM,

0.3 VAC = 3 OHM,

etc.

5. Increasing the ground rod length beyond 20 - 30 ft (6.1 – 9.1 m) does not generally increase the effectiveness of the ground rod. A larger diameter rod which has more surface area may help. Sometimes keeping the soil around the ground rod moist by continuously running a small amount of water into it will work. Adding salt to the soil by soaking it in salt water may also reduce its resistance. You may also try a chemical ground rod devise. When these methods are used, periodic checking of the ground resistance is required to make sure the ground is still good.

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1. 2.

3. 4.

10.

BACKUP

DO NOT REMOVE

2.6 Connector Locations

On the back of the iCNC Performance you have connectors for:

Picture reference ID Name Mating connector (example)

1 J45 Inputs 25 pin female D-Sub, Wurth 618 025 249 23 2 J46 Outputs 25 pin male D-Sub, Wurth 618 025 248 23 3 J47 Servo 15 pin female D-Sub, Wurth 618 015 249 23 4 J48 Encoder 15 pin male D-Sub, Wurth 618 015 248 23 5 LAN LAN RJ45 6 USB USB USB 7 Serial RS - 485 9 pin male D-Sub, Wurth 618 009 248 23 8 USB Backup USB 9 Power Power WR-TBL Serie 3437, Wurth 691 343 710 004 10 GND PE GND M6/1/4” ring connector

NOTE!

See full connector and pin description from the appropriate connector section.

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SECTION 3: I/O DESCRIPTIONS

3.1 General

iCNC Performance provides input and output connectors for external devices. This sections covers the back wall connectors. You can change the input or output description name in iCNC Settings, instructions how to change setting are later described in this section.

WARNING

3.2 J45 Inputs

All inputs are active low, so the input will activate when the input is grounded to the input GND.

3.2.1 Input Pin Arrangement

All external relays needs to be powered from the I/O connectors. DO NOT use external power supply to drive external relays!

Pin number Input number Default name Description

1 Inbit 0 X+ Limit Grounding the input to pin #13/#25 will activate the input 2 Inbit 2 Y+ Limit Grounding the input to pin #13/#25 will activate the input 3 Inbit 4 Ok to Move Grounding the input to pin #13/#25 will activate the input 4 Inbit 6 Servo error Y Grounding the input to pin #13/#25 will activate the input 5 Inbit 8 Inbit 8 Grounding the input to pin #13/#25 will activate the input 6 Inbit 10 Inbit 10 Grounding the input to pin #13/#25 will activate the input 7 Inbit 12 Inbit 12 Grounding the input to pin #13/#25 will activate the input 8 Inbit 13 Inbit 13 Grounding the input to pin #13/#25 will activate the input 9 Inbit 14 Inbit 14 Grounding the input to pin #13/#25 will activate the input 10 Inbit 15 Servo Error Grounding the input to pin #13/#25 will activate the input 11 N/A N/A Not used 12 24VDC Output 24VDC Output max combined current with pin #24 1A 13 GND Signal GND 14 Inbit 1 X- Limit Grounding the input to pin #13/#25 will activate the input 15 Inbit 3 Y- Limit Grounding the input to pin #13/#25 will activate the input 16 Inbit 5 Servo error X Grounding the input to pin #13/#25 will activate the input 17 Inbit 7 Servo error Y2 Grounding the input to pin #13/#25 will activate the input 18 Inbit 9 Inbit 9 Grounding the input to pin #13/#25 will activate the input 19 Inbit 11 Inbit 11 Grounding the input to pin #13/#25 will activate the input 20 N/A N/A Not used 21 N/A N/A Not used 22 N/A N/A Not used 23 N/A N/A Not used 24 24VDC Output 24VDC Output max combined current with pin #12 1A 25 GND Signal GND

Manual 0-5401 I/O 3-1

iCNC Performance

3.2.2 Input Example

iCNC Performance

CNC

24V

Input example using a normally closed switch

X-Axis + Over Travel Limit Switch

J45 pin #1

GND (common to all inputs)

J45 pin #13

Input example using a inductive NPN sensor

24VDC

J45 pin #24

X-Axis + Over Travel Limit Switch

J45 pin #1

GND (common to all inputs)

J45 pin #13

Input example using an optocoupler

Limit switch NC

NPN

main circuit

Plasma device controlled output for Ok to Move

Ok to Move J45 pin #3

GND (common to all inputs)

J45 pin #13

3.2.3 Input Naming

iCNC Performance comes with pre named inputs. Input names are just descriptions and most inputs can be mapped to any of the functions available on the device. You can change the input description names in iCNC Settings, see more details on iCNC Settings section.

3-2 I/O Manual 0-5401

iCNC Perfromance

3.3 J46 Outputs

All outputs are active low. So the output pin will be low when active.

3.3.1 Output Pin Arrangement

Pin number Output number Default name Description

1 Outbit 0 Low PreHeat Output pin connected to GND when active 2 Outbit 2 Gas Torch Up Output pin connected to GND when active 3 Outbit 4 Ignition Output pin connected to GND when active 4 Outbit 6 Aux 1 Output pin connected to GND when active 5 Outbit 8 Aux 2 Output pin connected to GND when active 6 Outbit 10 Down Draft Output pin connected to GND when active 7** Outbit 12 Plasma Torch Up** Output pin connected to GND when active 8 Outbit 14 Auto Height Output pin connected to GND when active 9* Outbit 16 Aux 4* Output pin connected to GND when active 10 Outbit 18 Pointer Output pin connected to GND when active 11 24VDC Output 24VDC Output max combined current with pins #11/12/24 1A 12 24VDC Output 24VDC Output max combined current with pins #11/12/24 1A 13 GND Signal GND 14 Outbit 1 Cut Oxygen Output pin connected to GND when active 15 Outbit 3 Gas torch Down Output pin connected to GND when active 16 Outbit 5 Plasma Remote Output pin connected to GND when active 17 Outbit 7 High PreHeat Output pin connected to GND when active 18* Outbit 9 Corner Hold * Output pin connected to GND when active 19** Outbit 11 IHS Start** Output pin connected to GND when active 20** Outbit 13 Plasma Torch Down** Output pin connected to GND when active 21 Outbit 15 Aux 3 Output pin connected to GND when active 22 Outbit 17 Pulse Ignition Output pin connected to GND when active 23* Outbit 19 Marking * Output pin connected to GND when active. 24 24VDC Output 24VDC Output max combined current with pins #11/12/24 1A 25 GND Signal GND

* Outbits only usable with software, no front panel button available. ** If internal height control is used, outbits only usable with software. Corresponding front panel buttons will command

internal height control only.

WARNING

Maximum circuit voltage 24VDC.

Manual 0-5401 I/O 3-3

iCNC Performance

CNC

Output example

Use external 24VDC relays

To Cutting Oxygen Solenoid

Cut Oxygen Voltage

Common

Output

J46 #11 24VDC Output

To High PreHeat Solenoid

To High PreHeat Voltage

Common

Output

J46 #17 Outbit 07 High PreHeat

NO 24VDC Relay with back EMF diode

J46 #14 Outbit 01 Cut Oxygen

iCNC Performance

3.3.2 Output Example

Pins 11/12/24 provides 24VDC outputs to power a relay. Connect the grounding output to the other end of the relay coil to energize it. It is good practice to use a ﬂyback diode close to the relay coil to suppress the back EMF created from switching off an inductive load.

WARNING

All external relays needs to be powered from the I/O connectors. DO NOT use external power supply to drive external relays!

3.3.3 Output naming

iCNC Performance comes with pre named outputs. Output names are just descriptions and most outputs can be mapped to any of the functions available on the device. You can change the output description names in iCNC Settings, see more details on iCNC Settings section.

3-4 I/O Manual 0-5401

iCNC Perfromance

3.3.4 Wiring Multiple Oxyfuel Lifters

Using multiple oxyfuel torches

J46 #24 24VDC Output

J46 #2 Torch Up (all)

J46 #15 Torch Down (all)

J46 #13 GND

External momentary switch

Torch1 Up/Down

Torch2 Up/Down

Torch3 Up/Down

Output

NO 24VDC Relay With Back EMF diode

Common

Output

NO 24VDC Relay With Back EMF diode

Common

Output

NO 24VDC Relay With Back EMF diode

Common

Output

Common

Output

NO 24VDC Relay With Back EMF diode

Common

Output

Torch1 Up

Torch1 Up Common

Torch1 Down

Torch1 Down Common

Torch2 Up

Torch2 Up Common

Torch2 Down

Torch2 Down Common

Torch3 Up

Torch3 Up Common

Torch3 Down

Common

Torch3 Down Common

This example describes how to wire external switches to control torch up/down signals. In this example the front panel up/down buttons will move up/down all torches at the same time. Diodes must be added to avoid driving all relays with any switch, all diodes need to be added by the installer. You can add any number of up/down signals as you need with the same logic as above.

Note!: This example does not include any protection against a situation where the “All UP/Down” outputs are in conﬂict with the command from the manual UP/Down switches. Typically the protection should be done in such a way that activating the UP-relay with any signal will deactivate the Down-relay.

Manual 0-5401 I/O 3-5

iCNC Performance

3.3.5 Wiring Multiple Stations

Using multiple oxyfuel stations with select switches

J46 #14 Cut Oxygen output

J46 #17 High PreHeat output

J46 #24 24VDC Output

Station select 1

1 2

External switch

Station select 2

1 2

External switch

Station select 3

1 2

External switch

NO 24VDC Relay With Back EMF diode

Output

Common

Output

Common

Output

Common

Cutting Oxygen Solenoid Torch 1

Cutting Oxygen Common

Cutting Oxygen Solenoid Torch 2

Cutting Oxygen Common

Cutting Oxygen Solenoid Torch 3

Cutting Oxygen Common

This example describes how to add external switches for station select. In this example the front panel buttons will only activate outputs to the stations switched to the ON position. You can add as many station select switches/signals as you need with the same logic as above. Example relay Tyco/Schrack RT424024 Example diode 1N4007, Digi-Key p/n 1N4007DICT-ND

NO 24VDC Relay With Back EMF diode

Output

Common

Output

Common

Output

Common

High PreHeat Solenoid Torch 1

High PreHeat Common

High PreHeatSolenoid Torch 2

High PreHeat Common

High PreHeat Solenoid Torch 3

High PreHeat Common

3-6 I/O Manual 0-5401

iCNC Perfromance

SECTION 4: MOTION

4.1 Motion in General

iCNC Performance provides motion output for Step/Dir for position loop and +/- 10VDC analog signal for speed loop. iCNC Performance also has an encoder connector for position feedback from a servo drive or encoders.

4.1.1 Motion Signal Characteristics

Signal Type Description

Step

Dir

Speed Analog voltage +/- 10VDC, 15-bit speed signal for speed loop. Encoder Differential 5-12VDC Encoder input, differential (4 wires per drive!). GND needs to be connected

Enable Output Grounding output active LOW 5VDC Output 5VDC output max current 1A 24VDC Output 24VDC output max current 0.5A

Differential Differential step signal for position loop. Max frequency 200kHz. For single ended

operation, use only Step + signals.

Differential Differential direction signal for position loop. Sets motor driving direction. For single

ended use either + or - signal only. To change CCW and CW, swap the + and - signals.

between CNC and servo drive. Maximum input frequency 1MHz.

WARNING

The system uses either step/direction or the analog speed outputs for ALL axis, they cannot be mixed. In 3-axis analog speed mode the Y2 will be synchronized to Y1 using the encoder feedback, while in step/direction mode the Y1 & Y2 signals are paralleled making it impossible to command them independently from each other.

WARNING Step/direction mode can be used without encoder feedback to the CNC. In such case the CNC needs to have a “servo system OK” signal as an input to indicate the status of the drive system.

Manual 0-5401 MOTION 4-1

iCNC Performance

4.2 J47 Servo Connector

4.2.1 Servo Pin arrangement

Pin number Name Description

1 X-Axis Direction + Differential Direction signal for X-Axis. 5V logic 2 X-Axis Step + Differential Step signal for X-Axis. 5V logic 3 Y-Axis Direction + Differential Direction signal Y-Axis. 5V logic. 4 Y-Axis Step + Differential Step signal for Y-Axis. 5V logic 5 X-Axis Speed +/- 10VDC analog speed signal for X-Axis. 6 Y2-Axis Speed +/- 10VDC analog speed signal for Y2-Axis. 7 5VDC 5VDC Output max current 1A 8 GND Signal GND 9 X-Axis Direction - Differential Direction complement for X-Axis. 5V logic 10 X-Axis Step - Differential Step complement for X-Axis. 5V logic 11 Y-Axis Direction - Differential Direction complement for Y-Axis. 5V logic 12 Y-Axis Step - Differential Step complement for Y-Axis. 5V logic 13 Y-Axis Speed +/- 10VDC analog speed signal for Y-Axis. 14 Servo Enable Servo enable signal, active LOW 15 GND Signal GND

4-2 MOTION Manual 0-5401

iCNC Perfromance

4.3 J48 Encoder Connector

4.3.1 Encoder Pin Arrangement

Pin number Name Description

1 X-Axis A+ Differential encoder input signal for X-Axis A+ 2 X-Axis B+ Differential encoder input signal for X-Axis B+ 3 Y-Axis A+ Differential encoder input signal for Y-Axis A+ 4 Y-Axis B+ Differential encoder input signal for Y-Axis B+ 5 Y2-Axis A+ Differential encoder input signal for Y2-Axis A+ 6 Y2-Axis B+ Differential encoder input signal for Y2-Axis B+ 7 5VDC 5VDC Output max current 1A 8 GND Signal GND 9 X-Axis A- Differential encoder input signal for X-Axis A10 X-Axis B- Differential encoder input signal for X-Axis B11 Y-Axis A- Differential encoder input signal for Y-Axis A12 Y-Axis B- Differential encoder input signal for Y-Axis B13 Y2-Axis A- Differential encoder input signal for Y2-Axis A14 Y2-Axis B- Differential encoder input signal for Y2-Axis B15 24VDC 24VDC max current 0.5A

* Addition to A/B encoder signals connect the pin #8 GND signal to the encoder source as well.

Manual 0-5401 MOTION 4-3

iCNC Performance

4.4 Servo Connection Examples

4.4.1 Analog Speed Signal with Yaskawa SGDV

Cable shield to J47 connector casing

J47 GND #8

J47 X- Speed #5

J47 Enable #14

V-REF

Signal GND

/S-ON

Yaskawa SGDV CN1

#40

- Yaskawa max cable length recommendation is 3m [9ft].

- Use cables with shield and twisted pairs.

#33

#34

#35

#36

#47

+24 VIN

Cable shield to J48 connector casing

PAO

/PAO

PBO

/PBO

J48 24VDC #15

J48 A- #9

J48 A+ #1

J48 B- #10

J48 B+ #2

- Shield cables only on the CNC end to avoid ground loops.

4.4.2 Step/Dir Signal with Yaskawa SGDV

Cable shield to J47 connector casing

J47 STEP - #10

J47 STEP + #2

J47 DIR - #9

J47 DIR + #1

J47 Enable #14

PULS

/PULS

SIGN

/SIGN

/S-ON

Yaskawa SGDV CN1

#11

#12

#40

#33

#34

#35

#36

#47

Cable shield to J48 connector casing

PAO

/PA O

PBO

/PBO

Signal GND

+24 VIN

J48 A- #9

J48 A+ #1

J48 B- #10

J48 B+ #2

J48 GND #8

J48 24VDC #15

- Yaskawa max cable length recommendation is 3m [9ft].

- Use cables with shield and twisted pairs.

- Shield cables only on the CNC end to avoid ground loops.

4-4 MOTION Manual 0-5401

iCNC Perfromance

Panasonic A5 X4

SPR

#14

Signal GND

#15

#29

/SRV-ON

COM-

#41

OA+

OA-

OB+

OB-

#21

#22

#48

#49

J47 X- Speed #5

J47 GND #8

Cable shield J47 connector casing

Cable shield J48 connector casing

J48 A+ #1

J48 A- #9

J48 B- #10

J48 B+ #2

J47 Enable #14

J47 GND #15

J48 24VDC #15

4.4.3 Analog Speed Signal with Panasonic A5

- Panasonic max cable length recommendation is 3m [9ft].

- Use cables with shield and twisted pairs.

- Shield cables only on the CNC end to avoid ground loops.

4.4.4 Step/Dir with Panasonic A5 w/o Encoder Feedback

Cable shield to J47 connector casing

J47 STEP - #10

J47 STEP + #2

J47 DIR - #9

J47 DIR + #1

J47 Enable #14

PULS1

PULS2

SIGN1

SIGN2

SRV-ON

Panasonic A5 X4

#29

Cable shield to J45 connector casing

#37

#36

ALM +

ALM -

+24 VIN

J45 Servo Error #10 (Inbit 15)

J45 24VDC #12

J45 GND #13

- Panasonic max cable length recommendation is 3m [9ft].

- Use cables with shield and twisted pairs.

- Shield cables only on the CNC end to avoid ground loops.

Manual 0-5401 MOTION 4-5

iCNC Performance

4.4.5 Step/Dir Signal without Encoder Feedback

Cable shield to J47 connector casing

J47 DIR + #1

J47 STEP + #2

J47 GND #15

J47 5VDC #7

J47 Enable #14

- Use cables with shield and twisted pairs.

Gecko

Direction

Step

Disable

Common

Current Set

NC 24VDC Relay With Back EMF diode

External normally closed 5VDC relay with back EMF diode

G201X/G210

#10

- Shield cables only on the CNC end to avoid ground loops.

- Add a back EMF diode when using relays

WARNING

When real encoder signals are not present you need to disable encoder feedback in iCNCSetup.

4-6 MOTION Manual 0-5401

iCNC Perfromance

SECTION 5: INPUT POWER

5.1 Power Supply

iCNC Performance comes with an optional 24VDC 6.67A power supply. The connector for the main power for the iCNC is an IEC C13, that should be rated for 10A 250V.

CAUTION

5.2 Power Connector

Wire sizes are for reference only. The installation must conform to national and local codes for the type and method of wire being used.

5.2.1 Power Connector Pin Arrangement

GND 24VDC E1 E2

Pin number Name Description

1 GND Power input GND 2 24VDC Power input +24VDC

3 E1

4 E2

External Stop input signal. Provide a dry closing contact to pin #4 to enable I/O and motion outputs.

External Stop input signal. Provide a dry closing contact to pin #3 to enable I/O and motion outputs.

Manual 0-5401 INPUT POWER 5-1

iCNC Performance

This Page Intentionally Blank

5-2 INPUT POWER Manual 0-5401

iCNC Performance

Art # A-12567

SECTION 6: iHC

6.1 Lifter Speciﬁcations

Arc voltage division 1:80 Arc voltage measurement range 0 - 327VDC Arc voltage measurement resolution 0.02V Arc voltage measurement accuracy ± 0.2% Arc voltage set range 50 - 300VDC Motor type Oriental Motor PKP266D28A-L Motor step angle 1.8 ° Motor holding torque 1.4 Nm / 12.391 lb. in Lifter max speed >5000 mm/min with 5 mm ball screw lead (@ 1000rpm)

Art# A-12566

Collision Sensor

Height: 85 mm [3.35in] Width: 100 mm [3.93in] Depth: 125 mm [4.92in]

• Dimensions above are the measurements without motor or other appliances.

• The base plate ﬁrst mounting holes are 38 mm from the bottom. All other mounting holes are distributed evenly after that with 89 mm spacing in accordance to the hole center line. Horizontally the distance between the holes is 114 mm. Use M6 screws with the base plate.

• 8 inch stroke base plate is longer (418 mm instead of 316 mm) and it has one more set of mounting holes on top for M6 screws (again 89 mm up from the pair below).

• Torch holder is available for both 50 mm and 35 mm torch heads.

• Torch holder mounting surface is 100 mm out from the bottom of the Lifter base plate.

Height: 316/418 mm [12.44/16.47in] Width: 127 mm [5.00in] Depth: 100 mm [3.93in]

Lifter Dimensions

Manual 0-5401 iHC 6-1

iCNC Performance

21.50

[0.837]

6.1.2 Voltage Divider Dimensions

6.2 Connector Locations

Art # A-12561

42.50

[1.671]

Art # A-12560

Picture reference ID Name Mating connector (example)

1 J54 Lifter 25pin male D-Sub Wurth 618 025 248 23 2 J55 Plasma 25pin female D-Sub Wurth 618 025 249 23 3 J53 CNC 37pin male D-Sub Wurth 618 037 248 23

CAUTION

When iHC is used with iCNC Performance all CNC to iHC signals are wired internally. Usually there is no need to connect anything to J53 CNC connector.

6-2 iHC Manual 0-5401

iCNC Performance

6.3 IO Example Connections

J55 pin #6

J55 pin #19

Ok to Move Input

Input example using an optocoupler

J55 pin #6

J55 pin #19

Ok to Move Input

iHC XT Internal Plasma Start Relay

GND

Input

GND

Plasma device controlled output

Input example using a relay

J55 pin #15

J55 pin #3

Input

Plasma device controlled external relay

Common

To plasma power supply start input

Output example

Output

To plasma power supply start input

Manual 0-5401 iHC 6-3

iCNC Performance

6.4 J54 Lifter

Pin Name Description

1 Jumper Jumper to J55 pin #1 2 N/A Not in use 3 Shield Cable shield 4 GND Out 2 GND for 5VDC in pin #16 5 Stepper A+ Motor current output 2.5A, max 40V 6 Stepper A- Motor current output 2.5A, max 40V 7 Shield Cable shield 8 Limit In Upper limit input 9 Stepper B+ Motor current output 2.5A, max 40V 10 Stepper B- Motor current output 2.5A, max 40V 11 Motor Step - Differential output signal to external servo drive, max 5V 12 Collision In Collision sensor input 13 Limit Shield Cable shield 14 N/A Not in use 15 N/A Not in use 16 5V Out 5VDC output max 0.5A 17 Laser pointer Input Laser pointer Input 18 Laser pointer NO 24VDC Laser pointer 24VDC output, max 0.5A 19 Laser pointer NO 24V GND Laser pointer 24VDC GND output 20 Limit VCC Limits switch 24VDC output 21 N/A Reserved for future use 22 Motor direction - Differential output signal to external servo drive, max 5V 23 Motor direction + Differential output signal to external servo drive, max 5V 24 Limit GND Limit switch GND 25 Motor Step + Differential output signal to external servo drive, max 5V

6-4 iHC Manual 0-5401

iCNC Performance

6.5 J55 Plasma

Pin Name Description

1 Jumper Jumper to connector J54 pin #1 2 N/A Not in use 3 Plasma Start NO NO Relay contact, max 48V 0.5A 4 IHS active COM NO Relay contact, max 48V 0.5A 5 Marking COM NO Relay contact, max 48V 0.5A 6 Input GND Input GND 7 Laser Pointer In Laser pointer input, activate by providing a dry closing

contact to Input GND pin 8 Arc voltage + Input from voltage divider board, 80:1 divided signal 9 Sense relay 24VDC Output to voltage divider board 10 Plate Contact In Input from voltage divider board 11 N/A Reserved for future use 12 N/A Reserved for future use 13 N/A Reserved for future use 14 N/A Not in use 15 Plasma Start COM NO Relay contact, max 48V 0.5A 16 IHS Active NO NO Relay contact, max 48V 0.5A 17 Marking NO NO Relay contact, max 48V 0.5A 18 IO Shield IO cable shield 19 OK to Move In OK to Move signal input, activate by providing a dry

closing contact to Input GND pin 20 Arc voltage - Input from voltage divider board, 80:1 divided signal 21 Sense relay GND Output to voltage divider board 22 Plate contact GND Input from voltage divider board 23 Divider shield Cable shield 24 N/A Reserved for future use 25 N/A Reserved for future use

Manual 0-5401 iHC 6-5

iCNC Performance

6.6 J53 CNC

CAUTION

When iHC is used with iCNC Performance all CNC to iHC signals are wired internally. Usually there is no need to connect anything to J53 CNC connector.

12345678910111213141516171819

202122232425262728293031323334353637

Pin Name Description

1 IHS Start In IHS Start input, activate by providing a dry closing con-

tact to Input GND2 pin

2 Up In Torch Up input, activate by providing a dry closing con-

tact to Input GND2 pin

3 Marking In Marking input, activate by providing a dry closing con-

tact to Input GND2 pin

4 Laser pointer Laser pointer input, activate by providing a dry closing

contact to Input GND2 pin 5 Input GND2 Input GND2 6 N/A Not used 7 24VDC Out 24VDC Output max 0.5A 8 N/A Not used 9 N/A Not used 10 N/A Not used 11 N/A Not used 12 N/A Not used 13 IO Shield Cable shield 14 OK to Move COM OK to Move output, NO Relay contact, max 48V 0.5A 15 OK to Move NO OK to Move output, NO Relay contact, max 48V 0.5A 16 System Error COM System error output NO Relay contact, max 48V 0.5A 17 System Error NO System error output, NO Relay contact, max 48V 0.5A 18 Optional 1 COM Optional output, NO Relay contact, max 48V 0.5A 19 Optional 1 NO Optional output, NO Relay contact, max 48V 0.5A 20 Hold In Hold input, activate by providing a dry closing contact to

Input GND2 pin 21 Down In Torch down input, activate by providing a dry closing

contact to Input GND2 pin 22 Maintain In Reserved for future use 23 Input GND2 Input GND2 24 IO Shield Cable shield 25 Shield Cable shield 26 GND Out1 GND for 24VDC output in pin #7 27-34 N/A Not used 35-37 N/A Reserved fo future use

6-6 iHC Manual 0-5401

iCNC Performance

6.7 iHC Software

6.7.1 Pierce/Cut Sequence

11.

10.

7. 9.

Pierce/Cut Flow Sequence:

1. IHS Start activated torch starts to ﬁnd the plate.

2. Torch reaches slowdown height and starts to move slowly.

3. Torch touches the plate.

4. Torch moves to ignition height and gives command to start the plasma.

5. Plasma arc ignites and gives ok to move signal to the height controller. Pierce time T1 starts

6. Torch moves to pierce height. Pierce height delay T2 starts

7. After Pierce time T1 ends iHC XT Ok to move signal output activates and cutting motion starts.Torch moves to cut height after pierce height timer ends.

8. AVC control starts after AVC delay T3 ends.

9. Cuth path ends.

10. Torch moves to retract height.

11. If idle for long enough torch retracts to home position.

Manual 0-5401 iHC 6-7

iCNC Performance

6.7.2 IO Bits Tab

This tab displays the status of various system signals for diagnostic purposes. I/O bits are separated to inputs (signals that come from other devices to iHC) and outputs (signals that go from the iHC to iCNC Performance).

Inputs

1. Torch Collision In case the lifter has a breakaway/collision sensor, signals from the sensor can be wired into Torch Collision input. Torch Collision will activate System Error output to CNC

2. Upper Limit Switch Used to ﬁnd home position when iHC is turned on

3. Plate Contact Inbit becomes active on plate contact during IHS or cutting sequence.

4. IHS Start Inbit from CNC becomes active when the IHS sequence starts.

5. Main Arc Inbit from plasma which indicates plasma arc has ignited.

6. Marking Inbit to put height controller to marking mode.

7. Hold AVC turns off when Hold inbit turns active. Hold is used during cutting to prevent the torch from diving into the plate when movement slows down ie: during tight corners.

8. Up Inbit from CNC that moves the torch up.

9. Down Inbit from CNC that moves the torch down.

10. Laser pointer Inbit from CNC to turn on the laser pointer output

11. Motor power Inbit telling is the motor power turned ON.

12. Maintain ARCV Reserved for future use.

13. Optional Reserved for future use.

6-8 iHC Manual 0-5401

iCNC Performance

Outputs

14. System Error (Inverted) Can be connected to CNC controllers external stop

15. Optional Reserved for future use

16. Sense 24V Output for voltage divider board.

17. IHS Active Outbit which is active form the time IHS Start turns active until Ignition Height has been reached.

18. Main Arc Outbit to CNC which becomes active when the main arc inbit is activated and the transfer delay has passed.

19. Marking Outbit to turn ON the marking output.

20. Plasma Start Outbit to tunr on the plasma start output.

21. Stepper Enable Step motion enabled/disabled.

22. Stepper Direction DIR signal active.

23. Stepper Pulse Step pulse signal active.

24. Laser pointer Outbit to turn ON the laser pointer output.

6.7.3 Service Tab

This window contains information about iHC software version, status and errors. Also displays the following:

• Save parameters Saves current parameters, only available in service mode

• Load parameters Loads saved parameters, only available in service mode

• Enter service mode Enables the use of functions and parameters only available in service mode (password 123)

• Select language Select the language in use

Manual 0-5401 iHC 6-9

iCNC Performance

6.7.4 Installation Tab

These parameters are password protected. Some parameters are the same as on the Advanced Tab.

• Encoder pulse edges per meter Determined by the type of encoder and the threaded shaft of the lifter.*

• Full Speed The maximum speed of the lifter. Full Speed is used above Slow Down Height.

• Home Distance The distance of the home position from the limit switch.

• Manual Acceleration & Manual Deceleration Used on jog, when AVC is on.

• Machine Acceleration & Machine Deceleration Used when the software drives the lifter.

• Homing Speed The speed used in the homing process.

• Out Of Limit Speed The speed used when the torch is moving out of limit switch.

• Plate Contact Release Speed The speed used when driving out of plate until contact is released.

• Adjust Speed Used in arc-voltage control process to determine the maximum control speed of the lifter

• Up Limit Timeout When moving up, the torch halts after this timeout if the limit switch is not found.

• Main Arc Lost Timeout Typically 0.1s to avoid losing the cut without real cause.

• Hold OFF AVC Delay Additional delay after Hold OFF which can be useful after piercing and in corners.

• Upper Soft Limit Distance Upper soft limit which is located above the limit switch. The position of the upper soft limit is determined by adding the Upper Soft Limit Distance to the position of the limit switch.

• Lower Soft Limit Distance Lower soft limit which is located below the plate. The position of the lower soft limit is determined by subtracting the Lower Soft Limit Distance from the position of the limit switch. Lower soft limit is supposed to be determined so that short motion below table surface is allowed but limiting the lifter from hitting the hard stop of the lifter.

• Reference Position Error Limit If there is a cumulative error in the position of the limit switch, the Reference Position Error Limit determines how large of an error can be tolerated. If the Reference Position Error Limit is exceeded, the torch performs homing

• Voltage Gain Determines how much force the system uses to correct the difference between the actual voltage and the target voltage.

• P-Gain Used to tune the movement. Too large of a value can cause the lifter to oscillate and too small of a value makes the movement soft and inaccurate.

• I-Gain Used to ﬁne-tune the movement of the lifter.

• Torch collision polarity inverted Select NC or NO use of a collision sensor.

* Encoder value is calculated by: 6400000 / lifter screw rise in mm Example lifter screw is 5 mm rise per 1 motor rotation 6400000 / 5 mm = 128 0000 Encoder value = 1280000

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6.7.5 Parameter Limits

Parameter name Default MIN MAX

Adjust speed 3000mm/min 180 9600 Collision recovery delay 1s 0 10 Collision retract height 1mm 0 100 Cut height 1mm 0.1 50 Cut height AVC delay 0.5s 0 10 Manual acceleration 0.3g 0.01 1 Manual deceleration 0.3g 0.01 1 Encoder pulses per meter 1280000p/m 0 255M Find plate speed 600mm/min 60 5000 Full speed 7000mm/min 120 50000 High jog speed 4020mm/min 60 20000 Hold off AVC delay 0.1s 0 10 Hold off limit 20 0 100 Hold on limit 30 0 100 Home distance -2 -10 50 Homing speed 600 120 20000 Ignition height 2 0.1 50 Low jog speed 300mm/min 10 9600 Lower soft limit distance -212mm -500 0 Machine acceleration 0.1g 0.01 1 Machine deceleration 0.5g 0.01 1 Out of limit speed 180mm/min 60 1200 P-Gain 60 0 200 Pierce down time 0s 0 10 Pierce height 2mm 0.1 50 Pierce height time 1s 0 10 Plate contact release speed 60mm/min 60 9600 Reference position error limit 2mm 0 10 Slow Down Height 10mm 0.1 1000 Transfer Height 50mm 0 500 Transfer Height Timeout 10s 0 20 Up Limit Timeout 20s 1 120 Upper Soft Limit Distance 5mm 0 15 Voltage Gain 50 1 256

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This Page Intentionally Blank

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SECTION 7: iCNC SETUP

1. Motion

2. I/O

3. Cutting table data

5. Others

6. Backups

7. Rotating axis

8. HD Unlocked/Locked

Enter Administrator Mode

Password prompt

1.1. Drive conguration

1.2. Drive and encoder polarities

1.3. Encoder values

1.4. Drift adjustment (only analog speed)

1.5. Max speed adjustment

1.6. Max speed test (only analog speed)

1.7. Min speed test (only analog speed)

1.8. Motion parameters

2.1. General

2.2. IO and Delay

2.3. Outbits

2.4. Inbits

3.1. Homing / limits

3.2. Downdraft

7.1 Initial Checks

Before starting to adjust the settings make sure that:

- All cables are properly connected

5.1. General

5.2. THC / Plasma settings

5.3. Teach In

5.4 Get serial number

5.6 Diagnostic information

5.7 Advanced diagnostics

5.9 Calibrate touch screen

6.1. Backup machine settings

6.2. Restore machine settings

7.1. Tangential Rotation (future use)

8.1. Change Status

- General IO settings are correct (limits, e-stop...) so that you do not have any error messages on the screen, see 7.5.1

- Motors are out of rails

CAUTION

Some settings may cause abrupt machine motion. Take care of your surroundings and make sure the motors can run free.

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7.2 Starting iCNC Setup

iCNC Performance installation settings are done from iCNC setup. You can start iCNC settings by:

1. In Info System Status screen select ﬁle --> iCNCSetup

2. Click Enter Administrator Mode and type in the password when prompted to change settings. Password pmcs1

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7.3 Motion, STEP/DIR

CAUTION

Some settings and windows dier based on your drive conguration at this screen. This section will cover Step/Dir mode.

NOTE!

Check the “Disable servo failure detect” box before running motion tests.

7.3.1 Drive Conﬁguration Step/Dir

Number of axis Select the number of controllable X/Y axes, 2 or 3. Servo command Step/Dir. Encoder feedback Select if you have physical encoder feedback.

Changing the drive conﬁguration, demands doing a Total Restart to make the change valid. Follow the on-screen prompts and wait for the system to shut down and to restart again.

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When the controller reboots, you will be prompted to transfer the newly modiﬁed ROBOPRM1.DAT ﬁle to the background CPU. Select YES and give the password to complete this action. When completed, restart iCNC Setup as explained above.

7.3.2 Drive and Encoder Polarities Step/Dir

• Make sure the Drive Enable on the front of the controller is “OFF”

• Make sure that power is ON to the servo ampliﬁer system and that clutches (if any) are engaged on two axis systems. Remember to keep the Y1 and Y2 pinions out of the rack in three axis systems. In certain applications, you have to set the optical tracing system to the trace state to enable driving simultaneously in both directions.

• Make sure that the controller is in basic status (no lights-on any of the push buttons are illuminated on the front panel.)

Put the Drive Enable Switch on the front of the controller to “ON”

Opening this dialog box opens the positioning loop and allows you to send out speed signals to the drives by using Y+/Y-/ X+/X- buttons and checks the actual rotation of the drive pinion wheels. If rotation is incorrect, change the corresponding polarity in the dialog box and check again.

After all polarities are correct, click the Drive Polarity OK check box.

Next, set the encoder polarity by pressing the Y+ direction for about 2 seconds. If the polarity is incorrect, the software will automatically detect it and change the setting automatically. Repeat for the +X direction. Click OK when completed.

After you are done put the drive enable back to OFF.

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7.3.3 Encoder Values Step/Dir

Put the Drive Enable on the front of the controller to “ON”

It is advisable to use low speeds for testing, decrease speed from speed potentiometer,

Move the machine to the front of the rail or reference mark. Reset the encoder counters by pressing the Reset counters button or the yellow 0,0 button in the panel. Press the “Jog ON/OFF” button to enter manual mode (note: the manual mode button will ﬂash ON-OFF). Using a drive direction button, move the machine as long of a distance as is possible. Measure the machine position from the end of the rail or reference mark, using a metric tape measure. Key this distance, the machine actually moved, into the “Measured distance” box as a metric value and click the “Calculate encoder value” button. Repeat the previous procedure with the other axis for machines with different rack and pinion combination, or simply copy and paste the calculated encoder value in the opposite encoder value box and press “Recalculate”. Click Reset counters then click Apply and OK when done.

The encoder value corresponds with pulse edges per one meter of motion. The bigger you set the encoder value the bigger it will make the programmed ﬁgures.

Example: If you drive a distance of one meter according to your encoder reading, and the actual measured motion distance of the machine is 997 mm, you must divide your current encoder value by 0.997 in order to make the machine cut parts to the correct size.

Normal encoder values are in the 100 000 – 5 000 000 range.

Metric: (1000mm x encoder pulses per revolution x 4 x gear ratio) / (module x π x number of teeth in pinion) = Encoder value

Imperial: (39.37 x encoder pulses per revolution x 4 x gear ratio) / (Effective diameter x π) = Encoder value

If using example Teknic motors without a real encoder feedback, pulses per revolution is multiplied by 2 not 4.

If your measured distance and the distance the CNC measured are different. To recalculate a new encoder value by dividing the current encoder value being used by the actual measured distance and then multiply that by the commanded distance (distance displayed on the Encoder value screen under Position).

• Encoder value in screen =1143818.000

• Actual moved distance = 3000mm

• CNC displayed distance = 1500mm 1143818.000 / 3000= 381.273

• 318.237 x 1500= 571909.5

• Correct encoder value = 571909.5 If needed, redo steps listed above until the correct encoder value has been achieved. (The moved distance should match

the CNC displayed distance).

Click Reset Counters, then Apply and OK.

Put the Drive Enable Switch on the front of the controller to “OFF”

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7.3.4 Max Speed Adjustment Step/Dir

CAUTION

This will let you drive with the maximum speed, making it possible to see the true speeds for each axis. Default Step frequency is 200kHz, decreasing the Max speed percentage will scale down the output pulse frequency. Use this function if the default speed is more than your servo ampliﬁer can handle.

Machine will run with max speed during the test. Keep motors o the rails while performing the test.

Make sure your speed potentiometer is set to 100%

Put the Drive Enable on the front of the controller to “ON”

Pressing any of the directional keys will ramp up the speed to max and drive with full speed until Stop is pressed.

1. After correct maximum speed has been achieved, run the machine to each direction until all directions have a green indication mark (Y+ in the picture).

2. Press Ok to save the true maximum speeds.

7.3.5 Motion Parameters

• Max settable speed is the maximum desired machine speed. This can be the same as set in Max Speed Adjustment, or maximum machine speed can be limited.

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• Max trial run speed is normally set equal to the Max settable speed.

• Min settable speed is set to your lowest dependable speed. The system enters this value in automatically after completing the Min speed test.

• Parking speed is used for max machine positioning and drift correction, either while the machine is standing still, or positioning to a part location. Small values will make it impossible to properly position the machine.

• P-Gain (0 – 255) A critical gain setting controlling system responsiveness and performance. If the encoders are driven directly off the motor shafts, a value of 190-210 works well in most cases. If the encoders are separately mounted and measure off the machine carriage, this value may need to be dropped as low as 75.

• 45° dampening can be increased from the default value of 100 if vibration is seen, especially when driving at a 45° angle.

• External stop slowdown time controls the reaction time between when an external stop input is received, and when the controller halts motion.

• Acceleration and Deceleration controls the responsiveness when positioning the machine. With fast plasma machines, a value of 35-50 mg is normal. If the machine is mechanically very rigid, with near zero backslash and a strong drive system, you might be able to use values as high as over 100 mg. For slow gas cutting machines, a value of 15 mg is normal. Both acceleration and deceleration values are generally adjusted equally.

NOTE!

One G (the value describing how fast an object accelerates when dropped to a free fall on earth) is 9.81 m/s/s. Therefore 10 mg (milli-g) is 0.0981 m/s/s or 9.81 cm/s/s

• Centrifugal acceleration will limit the maximum speed of the machine when driving on small radius arcs or approaching sharp corners. This must be set to a value equal-to or less-than your acceleration or deceleration values, and can be set as low as 3 mg.

• Corner slowdown level value for sharp corners. Affects the allowed speed for sharp corners, too low value will cut away the part being cut, too high value will make rounder corners.

• Corner angle w/o slowdown speciﬁes the maximum corner angle to be driven without any speed limitations. 15000 mdegrees is same as 15 degrees.

• Automatic drift adjustment is not available with step/dir command.

• Acceleration S-Curve Enabled enables/disables S curve acceleration for smoother motion with high acceleration values.

• The Y2 adjust screen is not available with Step/Dir command.

Applying Settings

1. First press Apply to temporarily store the parameters before running the test Rosette.

2. When running the test Rosette, it is necessary to watch actual machine motion, and therefore you should have your drives engaged to the pinion rack.

3. Pressing the Test run button will allow you to run a test Rosette of desired size and speed. The test starts when you click the Start button and press the MOVE AHEAD push button on the controller’s front panel. When motion is ok click Save and Close.

NOTE!

After completing this section, it is advisable to do a total restart and password-save the changes permanently when prompted.

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7.4 Motion, Analog Speed

CAUTION

Some settings and windows dier based on your drive conguration at this screen. This section will cover Analog Speed mode.

NOTE!

Check the “Disable servo failure detect” box before running motion tests.

7.4.1 Drive Conﬁguration Analog Speed

Number of axis Select the number of controllable X/Y axes 2 or 3. Servo command Select motion control type Analog speed Encoder feedback Forced ON if analog speed signal is used.

Changing the drive conﬁguration to a 3-axis system, demands doing a Total Restart to make the change valid. Follow the on-screen prompts and wait for the system to shut down and to restart again.

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When the controller reboots, you will be prompted to transfer the newly modiﬁed ROBOPRM1.DAT ﬁle to the background CPU. Select YES and give the password pmcs1 to complete this action. When completed, restart iCNC Setup as explained in “7.2 Starting iCNC Setup” on page 7-2.

7.4.2 Drive and Encoder Polarities Analog Speed

• Make sure the Drive Enable on the front of the controller is “OFF”

• Make sure that the controller is in basic status (no lights-on in any of the 8 push buttons in front panel.)

• Put the Drive Enable Switch on the front of the controller to “ON”

• Opening this dialog box opens the positioning loop and allows you to send out speed signals to the drives by using Y+/Y-/X+/X- buttons and checks the actual rotation of the drive pinion wheels. If rotation is incorrect, change the corresponding polarity in the dialog box and check again.

• After all polarities are correct, click the Drive Polarity OK check box.

• Next, set the encoder polarity by pressing the Y+ direction for about 2 seconds. If the polarity is incorrect, the software will automatically detect it and change the setting automatically. Repeat for the +X direction. Click OK when completed.

• After test is completed put the drive enable back to OFF.

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7.4.3 Encoder Values Analog Speed

Put the Drive Enable on the front of the controller to “ON”

It is advisable to use low speeds for testing, decrease speed from speed potentiometer,

Move the machine to the front of the rail or reference mark. Reset the encoder counters by pressing the Reset counters button or the yellow 0,0 button in the panel. Press the “Jog ON/OFF” button to enter manual mode (note: the manual mode button will ﬂash ON-OFF). Using a drive direction button, move the machine as long of a distance as is possible. Measure the machine position from the end of the rail or reference mark, using a metric tape measure. Key the distance the machine actually moved into the Measured distance box as a metric value and click the Calculate encoder value button. Repeat the previous procedure with the other axis for machines with different rack and pinion combination, or simply copy and paste the calculated encoder value in the opposite encoder value box and press “Recalculate”. Click Reset counters then click Apply and OK when done.

The encoder value corresponds with pulse edges per one meter of motion. The bigger you set the encoder value the bigger it will make your programmed ﬁgures.

Normal encoder values are in the 100 000 – 5 000 000 range.

Metric: (1000mm x encoder pulses per revolution x 4 x gear ratio) / (module x π x number of teeth in pinion) = Encoder value

Imperial: (39.37 x encoder pulses per revolution x 4 x gear ratio) / (Effective diameter x π) = Encoder value

• Encoder value in screen =1143818.000

• Actual moved distance = 3000mm

• CNC displayed distance = 1500mm 1143818.000 / 3000= 381.273

• 318.237 x 1500= 571909.5

• Correct encoder value = 571909.5 If needed, redo steps listed above until the correct encoder value has been achieved. (The moved distance should match

the CNC displayed distance).

Click Reset Counters, then Apply and OK.

Put the Drive Enable Switch on the front of the controller to “OFF”

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7.4.4 Drift Adjustment Analog Speed

Drift Adjustment from iCNC Setup will open the positioning loop and allow the machine to drift if the electrical settings are not perfect.

Put the Drive Enable on the front of the controller to “ON” and adjust the motion to zero drift using the + and - buttons. Each click will change 0 level by 0.6mV. Use + and - buttons to get the zero level speed as close to 0 as possible for each axis. You can keep the button pressed in to scroll the values. Maximum range for values is +383 - -383.

If you cannot get the machine stable, set the values to 0 and adjust from the servo ampliﬁer.

Default 0 level has been set at the factory.

Clicking OK will save the values.

View machine motion through the position counters in the Drift adjustment window in iCNC Setup.

Press the yellow ZERO push button on the controller before clicking Close. Clicking Close in the Drift adjustment window will close the positioning loop and allow you to resume positional control.

7.4.5 Max Speed Adjustment Analog Speed

This will let you drive with the maximum speed, making it possible to see the true speeds for each axis. Adjust the speed scaling from your servo ampliﬁers if needed. Max speed percentage adjustment and speed check is disabled when using analog speed signal.

Make sure your speed potentiometer is set to 100% and put the Drive Enable on the front of the controller to “ON”.

Pressing any of the directional keys will ramp up the speed to max and drive with full speed until Stop is pressed.

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7.4.6 Max Speed Test Analog Speed

CAUTION

This test is elementary for proper operation of the controller.

In most cases it is safe to do this test with the drives disengaged, because the majority of the system inertia is normally within the motor gearbox, and the machine motion friction is very small. If you can’t disengage the drives and your machine is small in size but fast, you may want to reduce the test time to a smaller number. The default is 4 seconds (4 sec. for acceleration, 4 sec. for constant max speed and 4 sec. for deceleration for a total of 12 sec). Changing this setting to 2 seconds would reduce the space needed for the test dramatically.

Machine will run with max speed during the test. Keep motors o the rails while performing the test.

With 3 axis machines the motors have to be disengaged.

Make sure the speed potentiometer is set to 100% for this test.

Put the Drive Enable on the front of the controller to “ON”.

Select Start test when you are ready. When all four directions and speeds are set, press the ZERO push button on the controller and select OK to complete the test. Set the Max settable speed for the machine to a slightly slower speed than found in the test.

Put the Drive Enable Switch on the front of the controller to “OFF”.

7.4.7 Min Speed Test Analog Speed

Put the Drive Enable Switch on the front of the controller to “ON”.

Make sure the speed potentiometer is set to 100% for this test.

Select Start test and be patient until you see the results posted in the Corrections Speed boxes in all four directions. This may take several minutes. Since the speed value is small, it may be difﬁcult to see anything happening unless watching the motor pinions, or viewing X-Y positional data in the Machine Info screen.

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After the test speeds appear, select Calculate low speed corrections. With optimum drives and perfect adjustment, all the correction values will come in at 1. Press the ZERO push button on the controller, then select OK when ready.

If you are using an old machine with poor response servo ampliﬁers and the machine won’t move with the default settings, you can adjust the minimum speed with Increase and Decrease buttons until the motors actually start to move.

Put the Drive Enable Switch on the front of the controller to “OFF”.

7.4.8 Motion Parameters

• Max settable speed is the maximum desired machine speed. This can be the same as set in Max Speed Test, or maximum machine speed can be limited.

• Max trial run speed is normally set equal to the Max settable speed.

• Min settable speed is set to your lowest dependable speed. The system enters this value in automatically after completing the Min speed test.

• 45° dampening can be increased from the default value of 100 if vibration is seen, especially when driving at a 45° angle.

• External stop slowdown time controls the reaction time between when an external stop input is received, and when the controller halts motion.

• Acceleration and Deceleration controls the Acc/Dec responsiveness when positioning the machine. With fast plasma machines, a value of 35-50 mg is normal. If the machine is mechanically very rigid, with near zero backslash and a strong drive system, you might be able to use values as high as over 100 mg. For slow gas cutting machines, a value of 15 mg is normal. Both acceleration and deceleration values are generally adjusted equally.

NOTE!

One G (the value describing how fast an object accelerates when dropped to a free fall on earth) is 9.81 m/s/s. Therefore 10 mg (milli-g) is 0.0981 m/s/s or 9.81 cm/s/s.

• Centrifugal acceleration will limit the maximum speed of the machine when driving on small radius arcs or approaching sharp corners. This must be set to a value equal-to or less than your acceleration or deceleration values, and can be set as low as 3 mg.

• Corner slowdown level value for sharp corners. Affects the allowed speed for sharp corners, too low value will cut away the part to be cut, too high value will make rounder corners.

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• Corner angle w/o slowdown speciﬁes the maximum corner angle to be driven without any speed limitations. 15000 mdegrees is same as 15 degrees.

• Automatic drift adjustment drift is periodically measured and compensated automatically.

• Acceleration S-Curve Enabled enables/disables S curve acceleration for smoother motion with high acceleration values.

• The Y2 adjust screen is for setting parameters related to synchronization of the ﬁrst longitudinal drive (Y1-master) with the second longitudinal drive (Y2-slave) Please try the Defaults ﬁrst, most machines work well with them. Click the Defaults button in the Y2 adjust screen.

• First step is a control value to be given when there is 1 increment difference in Y1 and Y2 positions. A control value of 1 equals maximum speed signal voltage divided by 16000.

• Static P-Gain gives corrections based only on the magnitude of difference between Y1 and Y2. The correction is linear.

• Static P2-Gain is like the P-gain but is not linear. It has it’s full value at the edge of the adjust window, but with the Y1/ Y2 difference being half of the adjust window, the effect of this parameter is only one quarter.

• Adjust window is given in m (=1mm/1000). The default value is 2000 meaning that the Y1-Y2 distance related values will reach maximum if the Y1-Y2 difference is 2mm or greater.

• Dynamic P-Gain and Dynamic P2-Gain are related not only to the difference of Y1-Y2 but also to the speed. They will have maximum effect at the edge of adjust window if the machine is driving with maximum speed. In low speeds these values have almost no effect to the Y2 correction.

• Error limit will set the Y1-Y2 difference where the machine must be stopped. The default value is 5000 m (=5mm =

0.2”)

• Slowdown time is the time spent to stop the machine from full speed. Default is 50 msec = 0.05 seconds

First press Apply to temporarily store the parameters before running the test Rosette.

When running the test Rosette, it is necessary to watch actual machine motion, and therefore you should have your drives engaged to the pinion rack.

Pressing the Test run button will allow you to run a test Rosette of desired size and speed. The test starts when you click the Start button and press the MOVE AHEAD push button on the front panel of the control. When motion is ok click Save and Close.

NOTE!

After completing this section, it is advisable to do a total restart and password-save the changes permanently when prompted.

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7. I/O

I/O settings determine the behavior of the machine when hitting a limit switch, what happens in the piercing sequence, in/output names etc.

7.5.1 I/O General

• Limit switches If a single input is used, select the input and polarity. If you have separate limit switches for all direction choose separate inputs and set your input conﬁguration for each axis.

• Home switches inbits Set your homing switches. You can use limit switches for homing switches as well, usually there is no need to set additional homing switches. Set homing parameters in the Cutting Table Data settings.

• Align the bridge when homing Select is the alignment done while doing homing. Homing must be enabled to use this function.

• Inbit Inbit number where alignment swith is wired.

• Active outbit during alignment Outbit number that is active during Y2 alignment.Feature used when alignment and STEP/DIR signals are used. See wiring instructions below. Available outbits 06, 16, 19.

• Limit offset Offset from limit switch that is added after limit is found 10mm max.

• Maximum align distance Max distance of travel when trying to ﬁnd limit (after distance value is achieved alignment will be canceled). Maximum value 10mm

• iHC extra external stop Used with internal height control (iHC). This signal will prompt about collision or any other error signals from the internal height control. Should always be enabled when iHC is used.

• Activated outbits during program running Selected outbit will always be turned ON after program start if output has been set to AUTO. Outbit will turn OFF after program has been cut. Usually used for fume extraction.

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• External stop inbits Enable, select external stop trigger inbits and their polarities. Activating an external stop will prompt inbit name, stop motion and cutting.

• Servo error Enable, select servo error trigger inbits and their polarities. Activating a servo error inbit will prompt inbit name, turns enable outbit off and stops cutting process. If the Teknic check box is checked inbit has to turn on after enable output has been turned on.

Y2 alignment with STEP/DIR signals

Wiring from iCNC Performance

iCNC PERFORMANCE SERVO DRIVES

J47 #4 STEP Y+

J47 # 10 STEP Y-

J46 Outbit X

NC 24VDC Double Pole Relay With Back EMF diode

Y2 Servo STEP+ Y2

Y2 Servo STEP- Y2

J46 24VDC #24

Y Servo STEP Y+

Y Servo STEP Y-

Wiring from servo adapter card

Servo adapater PCB SERVO DRIVES

CTRL Y #2 STEP +

CTRL Y #6 STEP Y-

OUTPUTS X #XX-NO (2)

SPEED Y #5 24VDC

NC 24VDC Double Pole Relay With Back EMF diode

Y2 Servo STEP+ Y2

Y2 Servo STEP- Y2

INPUTS X #GND

OUTPUTS X #XX-COM (3)

1) See cable axample for wiring to servo adapter pcb in appendix B

2) Select a spare output from the servo adapter PCB (available outbits 9, 16, 19). Output needs to be set in iCNCsetup --> IO General

3) Select a spare GND from the input connector and wire to output COM that is used in 2)

See appendix B for details about the servo adapater card.

(3)

Y Servo STEP Y-

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7.5.2 I/O and Delay

Here you can map your I/Os and delays. When you open the IO and Delay you might be prompted with a similiar window like below:

This window indicates that the active and displayed settings do not match. In the above example picture gas IO settings differ in the display from the active ones. Choose correct settings for the corresponding mismatch and click Apply and Save.

7.5.2.1 I/O and Delay Plasma Cutting

Here you can map the I/Os and set the delay times for plasma cutting. There are 4 preset parameter sets or you can do a custom one to suit the machine needs.

Set 1 is used with internal height controller iHC. Set 2 is used with a height controller that commands plasma start signal to the plasma. Set 3 is used when the CNC commands plasma start signal to plasma and height controller provides IHS ready signal. Set 4 is reserved for future use.

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Machine moves to next pierce point

SD4

Outbit 7 ON

- IHS Start activates

- Torch starts move down

- Torch rises to ignition height

- Height control res plasma

- Main arc signal from plasma interrupts the delay (inbit 04 turns 1)

in04 interrupt

SD5

Outbit 7 ON

- Pierce Delay

CUT

Outbit 7 ON

- Machine cuts the part

ED1

Outbit 7 OFF

- Wait for arc to extinguish (inbit 04 turns 0)

in04 interrupt

Start Delay is referenced as SD and End delay is referenced as ED.

• Enabled Enable/Disable the Delay. In the example picture above SD1-3 are disabled as they are not used.

• ID Delay ID name.

• Outbits Set outbits that are active (ON) during the delay.

• Time Set the default delay time.

• Name Write a delay description.

• Visible Select is the delay visible in the process selection window.

• Editable Select can the delay time be edited in the process selection window.

* Select if the delay is shown in readjust cutting parameters.

• Interrupted Select is the delay interrupted or just a time based delay.

• Inbit Select the inbit that will be used for delay interruption. In the example picture inbit4 will interrupt SD4 delay when it turns 1. Also ED1 will be interrupted when inbit4 turns back to 0.

• Polarity Set the inbit interrupt polarity.

• Start Not used with plasma cutting. See explanation from gas cutting example.

ED3

Outbit 7 OFF

- Move torch up

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7.5.2.2 Advanced

• External stop if main arc is not ok You can Enable/Disable the feature. When enabled if plasma arc is lost during the cut process CNC will stop motion, turn off cut process IOs and give a message that that arc has been lost during cutting.

• Time out Time out that the main arc input can be off before error message will be given. Used to ﬁlter out small jitters caused by example high frequency noise.

• Dropdown menu Inbit number for main arc signal.

• Bit value when main arc ok Inbit value 1 or 0 when cutting is considered OK.

• Prestop enabled Enable/Disable feature

• Dropdown menu Outbit number that is controlled with prestop event.

• OutBit value when prestop active Is the outbit turned ON or OFF when prestop is triggered.

• Hold activates below Speed % where hold signal is activated.

• Plasma prehold distance Distance from the end of cut where hold signal is activated

• Hold extension Time extension to release hold signal. Used to give a bit of time for the arc to stabilize after example a corner.

• Hold during MoveDelay Enable/Disable hold signal during piercing process (Start Delay 5).

• Hold polarity Hold signal polarity

Prestop is used to shutdown the plasma arc before motion ends. As the current rampdown takes a small amount of time before the arc actually extinguishes, prestop is used to turn the plasma off just before the actual cutting path ends. This way arc will not stay on while the machine sits at the end point. Prestop time is set from the plasma software (time is used as a value and the prestop distance is calculated based on cutting speed and deceleration).

Manual 0-5401 iCNC SETUP 7-19

iCNC Performance

7.5.2.3 I/O and Delay Gas Cutting

Here you can map the I/O’s and set the delay times for oxy fuel cutting. You have 4 pre set parameter sets and a custom to create your own.

Set 1 is used when only preheat, cut oxygen and vent signals are used. Set 2 is used when capacitive height sensing, preheat, cut oxygen, vent and torch up/down while piercing signals are used. Set 3 is used when ignition, capacitive height sensing, preheat, cut oxygen, vent and torch up/down while piercing signals

are used. Set 4 is reserved for future use.

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Machine moves to next pierce point

7.5.2.4 Custom

Machine moves to pierce point

SD3

Outbits 8 and 12 ON

- Preheat solenoids turn ON

- Capacitive height sensing turns ON

- Timer counts down for 5 s. and piercing sequence moves to SD4

Outbits 2, 8 and 12 ON

- Preheat solenoids stays ON

- Capacitive height sensing stays ON

- High Preheat solenoid turns ON

- Timer counts down for 60 s. and piercing sequence moves to SD5

SD4

SD5

Outbits 1, 8, 12 ON

- Machine cuts the part

- Preheat solenoids stays ON

- Capacitive height sensing stays ON

- High Preheat solenoid turns OFF

- Cut oxygen solenoid turns ON

- Pierce Up/Down sequence starts *

- Timer counts down for 1.5 s. and X/Y motion begins

CUT

Outbit 1, 8, 12 ON

ED1

Outbit 14 ON

- Preheat solenoids turn OFF

- Capacitive height sensing sturns OFF

- Cut oxygen solenoid turns OFF

- Vent solenoid turns ON

- Timer counts down for 1.5 s and end sequence moves to ED3

ED3

Outbit 3 ON

- Vent solenoid turns OFF

- Torch up signal turns ON

- Timer counts down for 1 s. and machine moves to next pierce point

Start Delay is referenced as SD and End delay is referenced as ED.

• Enabled Enable/Disable the Delay. In the example picture above SD1-2 are disabled as they are not used.

• ID Delay ID name.

• Outbits Set outbits that are active (ON) during the delay.

• Time Set the default delay time.

• Name Write a delay description.

• Visible Sets if the if the delay visible in the process selection window.

• Editable Sets if the delay can be edited in the process selection window.

* Select if the delay is shown in readjust cutting parameters.

• Interrupted Sets if the delay can be interrupted or just a time based delay.

• Inbit Select the inbit that will be used for delay interruption. In the example above interrupts are not used.

• Polarity Set the inbit interrupt polarity.

• Start Enables/Disables torch Up/Down function. Use this to set the delay that triggers Up, Stay, Down timers.

* In the example picture above Torch Up/Down timers will trigger in SD5. SD timers and Up/Down timers are indepen-

dent, if a delay timer runs out it will move to the next delay even if torch Up/Down timer is running.

The example above will do the following: When pierce sequence moves to SD5 all SD5 related IO’s will work normally

+ Torch will move up for 1.5s, stay in that height for 1s and then moves down for 1.5s. Note that as pierce time is only

1.5s the X/Y movement begins before torch Up/Down sequence is ﬁnished.

Manual 0-5401 iCNC SETUP 7-21

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7.5.2.5 Advanced

• Activated outbits during program running with gas process Enable/Disable the feature. This will turn the selected outbit ON always when gas cutting program is running.

• OutBit Number Outbit that will be turned and kept on when gas cutting process is running

• Pulse ignition Pulse ignition Enabled/Disabled. Pulse ignition will toggle the selected outbit ON/OFF when outbit is acitvated.

• Time on Time that outbit is ON in ms.

• Time off Time that outbit is OFF in ms.

• Inbit Number Inbit that will activate pulsing.

• Outbit Number Outbit that will be pulsed, pulsing frequency/duty cycle is determined by the ON/OFF times.

7.5.2.6 I/O and Delay Line Marking

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- Move delay

7.5.3 Custom

Machine moves to pierce point

SD3

Outbits 6 ON

- Marking outbit ON, plasma and height control put to marking mode

Outbits 6 and 7 ON

- Marking outbit kept ON

- IHS Start activates

- Torch starts move down

- Torch rises to ignition height

- Height control res plasma

- Main arc signal from plasma interrupts the delay (inbit 04 turns 1)

SD4

in04 interrupt

SD5

Outbits 6 and 7 ON

CUT

Outbit 6 and 7 ON

- Machine cuts the part

ED1

Outbit 6 and 7 OFF

- Wait for arc to extinguish (inbit 04 turns 0)

in04 interrupt

Machine moves to next pierce point

Start Delay is referenced as SD and End delay is referenced as ED.

• Enabled You can Enable/Disable the Delay. In the example picture above SD1-2 are disabled as they are not used.

• ID Delay ID name.

• Outbits Set outbits that are active (ON) during the delay.

• Time Set the default delay time.

• Name Write a delay description.

• Visible Sets if the if the delay visible in the process selection window.

• Editable Sets if the delay can be edited in the process selection window. * Select if the delay is shown in readjust cutting parameters.

• Interrupted Sets if the delay can be interrupted or just a time based delay.

• Inbit Select the inbit that will be used for delay interruption. In the example picture Inbit4 will interrupt SD4 delay when it turns 1. Also ED1 will be interrupted when Inbit4 turns back to 0.

• Polarity Set the inbit interrupt polarity.

• Start Not used with plasma cutting. See explanation from gas cutting example.

The example above is a typical I/O map when plasma is used as the marking device.

NOTE!

Only hardwire marking supported.

Manual 0-5401 iCNC SETUP 7-23

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7.5.4 Advanced

These options are the same as Plasma advanced features.

• External stop if main arc is not ok Enable/Disable the feature. When enabled if plasma arc is lost during the cut process CNC will stop motion, turn off cut process IOs and give a message that that arc has been lost during cutting.

• Time out Time out that the main arc input can be off before error message will be given. Used to ﬁlter out small jitters in Inbit caused by example high frequency noise.

• Prestop enabled Enable/Disable feature

• Dropdown menu Outbit number that is controlled with prestop event.

• OutBit value when prestop active Is the outbit turned ON or OFF when prestop is triggered.

• Hold activates below Speed % where hold signal is activated..

• Plasma prehold distance Distance from the end of cut where hold signal is activated

• Hold extension Time extension to release hold signal. Used to give a bit of time for the arc to stabilize after example a corner.

• Hold during MoveDelay Enable/Disable hold signal during piercing process (Start Delay 5).

• Hold polarity Hold signal polarity

• Enabled Enable/Disable feature

• OutBit Number Outbit number that is controlled with prestop event.

• OutBit value when prestop active Is the outbit value turned ON or OFF when prestop is triggered.

• Distance Distance from the cutting path end point when prestop is triggered.

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SD4

SD5

- Drill head stays down

- Drill turns ON

- Timer counts down for 1s before sequence moves to SD5.

- Drill head turns OFF and starts to move up

- Drill turns OFF

- Timer counts down for 20s and waits for inbit 9 to turn ON before sequence moves to SD4.

Outbits 17 and 18 ON

Machine moves to drill point

Machine moves to next pierce point

SD3

Outbit 17 ON

- Drill head commanded down

- Timer counts down for 20s and waits for inbit 8 to turn ON before sequence moves to SD4.

in08 interrupt

7.5.5 I/O Point Marking

Point marking process has only start delays, so the end sequence in the example above is put to Start Delay 4 and Start Delay5. The example above is a typical point marking I/O map when the plasma is used for point marking. This is the same as line

marking but without machine movement.

The example above is a typical point marking I/O map when a drill is used. Here outbit 17 commands the drill head to go down, 18 turns the drill on and inbits 8 and 9 are used to check whether the drill has reach down position or upper position. If neither inbits are received in the 20s time period an error message will be prompted “No inbit 8 Drill Head Down” or “No inbit 9 Drill Head Up” and the drilling sequence will be canceled.

NOTE!

Manual 0-5401 iCNC SETUP 7-25

Only hardwire marking supported.

iCNC Performance

7.5.6 I/O Outbit Names

The reference name of the outbits can be changed here. Note that this does not change the pinout at the connector or front panel button mapping.

7.5.7 I/O Inbit Names

The reference name of the inbits can be changed here. Note that this does not change the pin out at the connector.

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7.6 Cutting Table Data

7.6.1 Homing / Limits

• Speed to switches Speed used to ﬁnd the limit switch.

• Speed from switches Speed used to drive out from the limit switch.

• Enable homing Enable/Disable the feature.

• Set absolute zero after homing Enable/Disable automatic absolute zero setting after homing is done.

• Ask homing on startup Enable/Disable message box when system starts asking if homing is performed.

• Homing location Table corner where the home position is.

• Machine home Out of limit switches Distance from limit switches what is used for home position.

• X axis Outer limits X axis travel limit outbound. When this distance from absolute 0is reached motion is not allowed.

• Y axis Outer limits Y axis travel limit outbound. When this distance from absolute 0 is reached motion is not allowed.

• X axis Inner limits Distance from home, after this distance is reached speed is decreased. Calculated from slowdown distance.

• Y axis Inner limits Distance from home, after this distance is reached speed is decreased. Calculated from slowdown distance.

• X axis Slowdown distance Distance from outer limit where speed is gradually decreased.*

• Y axis Slowdown distance Distance from outer limit where speed is gradually decreased.*

* After inner limit is reached and machine moves towards outer limit the maximum speed will be gradually restricted.

Example : Slow down distance is set to 100mm and machine maximum speed is 20 000mm/min. After moving 10mm over the inner limit (90mm from the outer limit) the machine maximum speed is restricted to 18 000mm/min (10%). If movement is kept to the same direction and the machine is driven 80mm over the inner limit (20mm from the outer limit) the maximum speed is restricted to 4000mm/min (80%).

Manual 0-5401 iCNC SETUP 7-27

iCNC Performance

Example on setting software limits:

1. Set you homing switches in I/O General. Typically the X/Y limits switches are used and there is no need for separate homing switches.

2. Be sure that “Enable Homing” is checked and “Ask for Homing on Startup” is checked. Speed to Switches default is 3500mm/min and from is 500 mm/min. These are the recommended values but can be changed if needed. Set “Homing Location” default is “Lower Left”.

3. Set “Machine Home: Out of Limit Switches”. Here we will set it for 3 inches off of both X and Y switches in homing. 3 x 25.4mm/in = 76.2. Using the illustration as a reference we will set the Outer - limits where the teal circle is Absolute 0,0 (3” positive off X switch and 3” positive off Y switch in this example). In this example, we will set X- and Y- Outer to 2” negative in both axis (51mm), or 1 inch before the physical limit switch.

NOTE!

In this example, the parameters for the software limits are set for 51mm (2 in) which will only leave roughly 25mm (1 in) of “safety distance” before coming in contact with the electrical limit switch. Dierent machine may need dierent values here depending on how close to limit switch needed to run machine in normal cutting conditions.

4. Verify X-axis slowdown distance and Y-axis slowdown distance is applicable for the machines capability. See NOTE below. Click “OK”.

NOTE!

In this example we have set the slowdown distance to default of 100mm (4 in). This is practical value in most cases, but this means that the machine is going to have to go from max speed to 0 in 100mm. If machine is set to run 1200ipm rapid, the machine will have to come to full stop in roughly 0.4s.

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5.Put drive enable button to ON.

6. Open “Next job preview” window and click .

7. Click “Home Machine”.

8. After homing is done press the button and move the machine using the directional buttons to the positive Y and X until you reach the position where the software limit will be. Write down the coordinate values shown in the “Info screen”.

9. The machine moved positive 2600mm on the X axis and positive 6200mm on the Y axis. These values will be put in option 3 and option 7 for our OUTER limits. Click OK, turn Drive Switch OFF and perform System Restart.

Manual 0-5401 iCNC SETUP 7-29

iCNC Performance

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7.6.2 Down Draft

• Use down draft Enable/Disable down draft feature.

• Start Homing Starts homing procedure to conﬁgure sections.

• Torch in position Apply position from home position to transfer point of 1st and 2nd section

• Number of segments Give the number of sections.

• Outbits Outbits for sections. Type in the outbits that are tied to their respective sections.

• Use down draft Enable/Disable down draft feature.

• Lenght of one segment Deﬁne section length.

• Overlapping Deﬁne how much active overlap there is between sections (both sections open).

NOTE!

Adjust proper homing settings before setting down draft control. You need to do a total restart and send the les when prompted for the function to activate.

Manual 0-5401 iCNC SETUP 7-31

iCNC Performance

7.7 Others

7.7.1 General

• Backward hold Enabled When enabled keeping backward button pressed in for the duration of Timeout backward movement will be performed even if button is released.

• Timeout Time it takes to enable backward hold (see above).

• Reduce speed potentiometer rapid speed Speed that backward movement will be performed.

• Speed increments Gas Speed + and - increment when gas process is running for single click on the blue speed up/ down buttons.

• Speed increments PlasmaSpeed + and - increment when plasma process is running for single click on the blue speed up/down buttons.

• Joystick hold time Time it takes for the directional button to latch. If a direction is pressed longer than the hold time directional movement will be performed even if button is released. Machine motion will stop if any direction is pressed while machine is moving.

• Manual mode acceleration % of acceleration set in motion parameters when moving in manual mode. Can be over 100%.

• When new process starts stop and give message for: Shows settings how programmed stops are managed if switching between processes.

• On-Screen Keyboard Enable automatic pop up of software keyboard

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7.7.2 THC/Plasma Settings

• Reset Resets THC and plasma conﬁguration settings.

• THC THC type None or internal iHC.

• Plasma Plasma power source model selection.

Manual 0-5401 iCNC SETUP 7-33

iCNC Performance

7.7.3 Teach In

Reserved for future use

7.7.4 Get Serial Number

This will show the hardware ID and revision. Used for diagnostic purposes

7.7.5 Diagnostic Information

Saves diagnostic information to c:\robo\Diags\. Used for debugging purposes.

7.7.6 Advanced Diagnostics

Used to debug front panel buttons.

7.7.7 Update Software

Reserved for future use

7.8 Backups

7.8.1 Backup Machine Settings

• Pick target folder Select location where to make the backup

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• Make backup Make a backup to selected folder

• Close Closes the window

NOTE!

If the backup is not saved in the root of the device it needs to be put there before doing a restore. Restore can only be done from the root of the device.

7.8.2 Restore Machine Settings

• Selected folder Folder where the backup is loaded from (picture shows usb in drive letter K).

• Selected backup Select the backup by date that will be loaded.

• Restore licenses Select if license ﬁles will be loaded or not.

• Restore custome processes Select if custom made processes will be loaded or not.

• Restore Restores ﬁles with selected options.

• Close Closes the screen.

• Restore old Restores legacy backups.

NOTE!

Selected folder only allows to select devices where the backup folder is in the root. If backup is saved else where please move it to root before trying to restore it. Example in the picture the backup folder is in the root of a USB thumb drive K:\

7.8.3 Restore Machine Settings from Backwall Backup USB

1. Plug in the backup USB.

2. Open iCNC Setup

Manual 0-5401 iCNC SETUP 7-35

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3. Enter administrator mode (password pmcs1).

4. Navigate to 6. Backups --> 6.2 Restore machine settings.

5. In selected folder choose the USB drive.

6. In selected backup choose the appropriate date (usually latest one works the best).

7. Restore licenses should only be used if the hardware is the same as the one the backup was made from.

8. Check box Restore custom processes.

9. Click Restore

10. Select Restart system software

11. Click Yes

11. Send the ﬁle when prompted by clicking yes and then typing the password pmcs1

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12. Do the same for all ﬁles requested to be sent.

13. Some default settings will not activate before a process is applied and a cutting program has started.

• Apply a process

• Press the blue speed up button until it has reaches maximum value.

• Put the speed potentiometer to 0%, put drive enable to ON and press program start.

• Cancel the program

14. Done.

7.8.4 Create a System Image

1. Open control panel

2. Select backup your computer

Manual 0-5401 iCNC SETUP 7-37

iCNC Performance

3. Select create a system image

4. Wait until search is done, select drive D: and click Next.

5. Wait until image is created.

7.8.5 Restore a System Image

If the CNC is unable to properly boot in to windows the system image recovery is launched automatically. Follow instructions on screen to ﬁnish the restore procedure.

7.9 Rotating Axis

7.9.1 Tangential Rotation

Reserved for future use

7.10 Hard Drive Lock

7.10.1 Change Status

Hard drive lock is a feature that protects the ﬁle system. When hard drive lock is enabled most changes are reverted back to original state, after power down. This feature allows a clean boot every time. If you need to save eg. cutting ﬁles c:\Cutting programs\ folder is “open” and allows saving ﬁles. Saving to other locations will be a temporary save and all saved ﬁles will be lost after reboot.

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• Unlock Unlocks the hard drive so changes can be made

• Lock Locks the hard drive Lock/Unlock state change requires a windows reboot. This will be done automatically after you have conﬁrmed your action.

8. Tool Offsets

Deﬁning tool offsets gives the option to use example a laser pointer as the zero reference. This way the laser pointer can be used to show the zero reference point of the cutting program. After tool offsets have been correctly set the CNC will automatically take in account the difference between the cutting head and the pointer device.

8.1 Measuring the offset using a plasma power supply

1. Make sure the plasma is operational, correct plasma process has been selected and there is a piece of metal that can

be pierced.

2. Make sure the and are ON and then move the machine with the directional keys so that

the plasma torch is above the plate.

3. Zero the position counters by pressing the . button.

4. Make sure the is set to AUTO.

5. Press the to manually start the IHS sequence.

6. Immediately stop the pierce sequence after the arc transfers to the plate by pressing the button again.

Manual 0-5401 iCNC SETUP 7-39

iCNC Performance

7. Double check that the position counters are zero.

8. Turn ON the pointer device. Normally activated by the button.

9. Now manually jog the machine so that the pointer device is in the center of the pierced hole.

10. Check the coordinates from the Info screen. These coordinates will show the tool offset value.

NOTE!

Make sure to note the possible - sign in the coordinate as this will have an aect how the distance is measured.

NOTE!

Default tool oset using Thermal Dynamics lifter is ~X-axis 41mm [1.614”] / Y-axis -43mm [-1.693”]

8.2 Setting the tool offset values

1. You can set the tool offsets in the process selection settings page. Click and select settings.

2. Key in the appropriate values.

3. Click Apply in the settings screen.

4. Go and apply a cutting process (example click the Plasma button that opens your cut process selection screen, select a process and click apply) and the tool offset will be updated.

NOTE!

Copy the plasma tool oset to line and point marking osets If plasma is used as a marking device as well.

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SECTION 8: MAINTENANCE AND TROUBLESHOOTING

8.1 Maintenance

Weekly Check buttons for wear and tear.

Monthly Check cables for wear and tear. Check all connectors are properly connected.

8.2 Troubleshooting

8.2.1 Using Machine Info Screen for Troubleshooting

CAUTION

8.2.1.1 Position and Speed Info

In service mode the I/Os can be forced on by clicking the I/O in the Machine Info window. If devices are connected damage can occur if the I/O is forced on and objects are not clear.

Set position Commanded position of axis. Is position Current position of axis. Control Value Displays digital control value (0-16 000) Speed Displays current speed. Drift Displays current drift value (greyed out if using step/dir for position control).

Manual 0-5401 MAINTENANCE AND TROUBLESHOOTING 8-1

iCNC Performance

0 1

8.2.1.2 Outbits Tab

Outbits Displays outbits and front panel buttons status. Above picture shows the following, plasma remote button turned

ON and backwall output is ON, the down draft is commanded ON by software but the button is set to OFF, drive enable is commanded ON by software but backwall output is OFF and iHC IHS start is commanded ON by software, button set to AUTO and backwall output turned ON.

Software commanded outbit OFF and backwall outbit OFF

Software commanded outbit ON

Backwall output commanded ON

Button set to OFF

Button set to AUTO

Button set to ON

Example combinations:

A Software commanded outbit ON, Button set to AUTO, backwall output turned ON.

Software commended outbit OFF, button set to ON, backwall output turned ON.

NOTE!

Double clicking the white delay value will let you force outbits ON by clicking the desired outbit. When the delay value background is yellow this feature is turned ON.

Rotate Reserved for future use. Delay Delay timer. Heading Displays movement direction. Sync Y2 Options to synchronize Y2 (only available with 3 axis speed loop).

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8.2.1.3 Inbits Tab

Intbits Displays inbit state. Above picture shows that limits switches are active (there is contact between the inputs to

ground).

NOTE!

You can jumper any desired input signal to ground and verify with this window that the CNC sees that the input closes.

8.2.1.4 Diagnostic Tools Tab

External stop when plasma arc is lost Check or uncheck for feature to be turned ON/OFF (default ON). Turning this feature

OFF will let the plasma process continue to be ran even if plasma arc goes OFF. Apply needs to be pressed to activate the change. Changing the setting does not save it permanently, rebooting the CNC will reset it to its original state.

External stop when marking is lost Check or uncheck for feature to be turned ON/OFF (default ON). Turning this feature

OFF will let the marking process continue to be ran even if marking ok signal is lost (if plasma is used for marking same as above). Apply needs to be pressed to activate the change. Changing the setting does not save it permanently, rebooting the CNC will reset it to its original state.

Joystick latch time Time value for direction key to latch. If set to example 5 seconds, keeping left direction button pressed

in for more than 5 seconds, the CNC will continue to drive left even if button is not pressed. Pressing any directional button the machine will stop. Apply needs to be pressed to activate the change. Changing the setting does not save it permanently, rebooting the CNC will reset it to its original state.

Hold activates below programmed speed Speed % value for activating hold signal. Changing the setting does not save it

permanently, rebooting the CNC will reset it to its original state.

Logical status Shows the logical status of external stop and limit switches. Enable drives Forces software enable to ON state. Create diagnostics Creates diag.zip, this contains diagnostic information about the CNC. File is saved to c:\robo\Diags

Manual 0-5401 MAINTENANCE AND TROUBLESHOOTING 8-3

iCNC Performance

8.2.2 Boot and Power Issues

Problem Cause What to check Unit will not power up No main power Measure 24VDC power input, replace power supply.

Poor power connection Check for proper power connector connection. Over current fuse tripped Remove all cables, leave power off for 1min. Connect only the

power cable and try to boot. If CNC powers up connect cables 1 at a time to ﬁnd out which one is causing the issue.

Unit will not boot to windows

Bios settings lost Change correct bios settings. Bios settings at page “A.1

Bios settings” on page A-1

8.2.3 Piercing and Cutting Issues

Problem Cause What to check Plasma will not pierce Worn out consumables Check consumables

Plasma starts but crashes to plate

Plasma arc lost in the middle of a cut

Plasma start time set too short

Plasma set to off Check plasma button is on Auto

Worn out consumables Check consumables

AVC set too low Check arc voltage setting Bad grounding Check for proper grounding to star ground from CNC chassis and

Worn out consumables Check consumables

Error on plasma Check and clear plasma errors Wrong gas pressures Check gas pressures

Check plasma start delay time

plasma work cable

No AVC control AVC disabled Verify AVC chekbox is checked in iHC UI

Hold signal active Verify speed is set to 100%

Wrong arc voltage Wrong or bad consum-

ables Wrong gas pressures Check plasma gas pressures Bad grounding Check for proper grounding to star ground from CNC chassis and

Coiled up work cable Make sure work cable is not coiled

Ohmic sensing does not work

Poor connection Check for proper connection between voltage divider ohmic and

Check consumables

plasma work cable

torch ohmic clip Check for proper connection between torch ohmic clip and con-

sumable

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8.2.4 Motion Issues

Problem Cause What to check Motors won’t move Enable OFF Turn enable switch to ON

SW Enable OFF See error messages. Speed set to 0 Turn the speed potentiometer to 100%, press the speed up button

to increase the speed.

External stop active Check continuity between E1 and E2 in the power connector.

Motors move slowly Limit switch tripped Check limit switches

Collision tripped Check collision sensor Speed set to low Turn the speed potentiometer to 100%, and/or press the speed up

button to increase the speed.

Encoder value wrong Check encoder value is correct

Position Error message after enable is turned ON

Wrong motor or encoder polarity

Drift too high Adjust drift close to zero

Check motor/encoder polarity is correct

8.2.5 IO Issues/ Error Messages

Problem Cause What to check Outbits will not activate External Stop pressed in Release External stop

Limit switches Machine parked to limit Move machine away from the limit switch

No inbit 04 Main arc Torch too far from plate Check ignition height settings

Error in plasma Check and clear plasma errors

Continuous torch collision

No main arc signal from plasma

Dirt in proximity switch-esClean proximity switches

Broken or unplugged cable

Proximity switch out of adjustment

Broken cable, check continuity from plasma to CNC/Height control

Check proximity switch cables

Check correct proximity switch adjustment

Continuous plate contact

System halted outputs disabled

Manual 0-5401 MAINTENANCE AND TROUBLESHOOTING 8-5

Wrong consumables Check consumables

Consumbales incorrectly assembled

Torch sitting on the plate Check torch position Ohmic cable broken Ohmic cable shorted to work, check cable

External stop pressed in Release external stop. Check continuity between E1 and E2 in the

Cehck consumbales are in correct order and seated properly

power connector.

iCNC Performance

8.2.6 UI Errors

Problem Cause What to check

Data on the screen ﬁlls only part of the screen

Bios settings lost Change correct bios settings. Bios settings at page “A.1

Bios settings” on page A-3

Data on the screen ﬁlls only part of the screen

Ghost image on screen Screen saver not used Apply screen saver and leave it on for the night.

Wrong font settings Windows default font size changed.

8.2.7 Cut Quality

Problem Cause What to check

Excessive bevel on cut surface

Excessive dross on cut surface

Holes not round Worn out consumables Check/replace consumables

Worn out consumables Check/replace consumables

Plate/Table not in level Verify plate/table is leveled

Worn out consumables Check/replace consumables

Poor gas pressures Check correct gas pressures Excessive backlash Verify backlash, check motion with pen traces

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Thermal Dynamics iCNC Performance Service And Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SECTION 1: SAFETY

1.01 Safety Precautions - ENGLISH

1.02 Précautions de sécurité - FRENCH CANADIAN

SECTION 2: SPECIFICATIONS

2.1 System Description

2.3 Dimensions

2.4 Basic System Layout

2.5 Grounding and Cable Routing

2.5.1 Low Cost Ground Rod Tester

2.6 Connector Locations

SECTION 3: I/O DESCRIPTIONS

3.1 General

3.2 J45 Inputs

3.2.1 Input Pin Arrangement

3.2.2 Input Example

3.2.3 Input Naming

3.3 J46 Outputs

3.3.1 Output Pin Arrangement

3.3.2 Output Example

3.3.3 Output naming

3.3.4 Wiring Multiple Oxyfuel Lifters

3.3.5 Wiring Multiple Stations

SECTION 4: MOTION

4.1 Motion in General

4.1.1 Motion Signal Characteristics

4.2 J47 Servo Connector

4.2.1 Servo Pin arrangement

4.3 J48 Encoder Connector

4.3.1 Encoder Pin Arrangement

4.4 Servo Connection Examples

4.4.1 Analog Speed Signal with Yaskawa SGDV

4.4.2 Step/Dir Signal with Yaskawa SGDV

4.4.3 Analog Speed Signal with Panasonic A5

4.4.4 Step/Dir with Panasonic A5 w/o Encoder Feedback

4.4.5 Step/Dir Signal without Encoder Feedback

SECTION 5: INPUT POWER

5.1 Power Supply

5.2 Power Connector

5.2.1 Power Connector Pin Arrangement

SECTION 6: iHC

6.1.2 Voltage Divider Dimensions

6.2 Connector Locations

6.3 IO Example Connections

6.4 J54 Lifter

6.5 J55 Plasma

6.6 J53 CNC

6.7 iHC Software

6.7.1 Pierce/Cut Sequence

6.7.2 IO Bits Tab

6.7.3 Service Tab

6.7.4 Installation Tab

6.7.5 Parameter Limits

SECTION 7: iCNC SETUP

7.1 Initial Checks

7.2 Starting iCNC Setup

7.3 Motion, STEP/DIR

7.3.2 Drive and Encoder Polarities Step/Dir

7.3.3 Encoder Values Step/Dir

7.3.4 Max Speed Adjustment Step/Dir

7.3.5 Motion Parameters

7.4 Motion, Analog Speed

7.4.2 Drive and Encoder Polarities Analog Speed

7.4.3 Encoder Values Analog Speed

7.4.4 Drift Adjustment Analog Speed

7.4.5 Max Speed Adjustment Analog Speed

7.4.6 Max Speed Test Analog Speed

7.4.7 Min Speed Test Analog Speed

7.4.8 Motion Parameters

7. I/O

7.5.1 I/O General

7.5.2 I/O and Delay

7.5.2.1 I/O and Delay Plasma Cutting

7.5.2.2 Advanced

7.5.2.3 I/O and Delay Gas Cutting

7.5.2.4 Custom

7.5.2.5 Advanced