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Installation and Setup Manual for Hypertherm Touchscreen Shape Cutting Controls

806410 Revision 1

Phoenix Software V9.5

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Hypertherm, Inc.Etna Road, PO Box 5010Hanover, NH 03755 USAPhone: 603-643-3441Fax: 603-643-5352

D ISCLAIMER The information in this document is subject to change without notice and should not beconstrued as a commitment by Hypertherm, Inc. Hypertherm Inc. assumes noresponsibility for any errors that appear.

T RADEMARKS

Command, EDGE, HT 4400, HD3070 HyDefinition Plasma and HD4070 HyDefinitionPlasma, HyperCAD, HyperNet, HyperNest, Phoenix, and ShapeWizard are registeredtrademarks of Hypertherm, Inc.

Align, APC, ArcGlide, CutPro, EDGE Pro, FAST Laser, Gemini, HPR130, HPR260HyPerformance Plasma, HyPath, Mariner, Nester, Remote Help, Sensor, and Voyagerare trademarks of Hypertherm, Inc.

HASP is a registered trademark of Aladdin Knowledge Systems Ltd.

Indramat is a trademark of Bosch Rexroth.

Pacific Scientific is a trademark of Danaher Motion.

Pentium and Celeron are registered trademarks of Intel Corporation.

Virus Scan is a registered trademark of McAfee Associates, Inc.

Microsoft, the Microsoft logo, and Windows are registered trademarks of MicrosoftCorporation.

NJWIN is a registered trademark of NJStar Software Corporation.

SERCOS Interface is a trademark of SERCOS North America.

Norton AntiVirus and Norton Ghost are trademarks of Symantec Corporation.

Other trademarks are the property of their respective holders.

C OPYRIGHT 2010 by Hypertherm, Inc. All rights Reserved

Printed in USA

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iii

ContentsSafety .......................................................................................................................... S-1

Read This Manual ................................................................................................... S-1

Product Listings ...................................................................................................... S-1

Recognize Safety Information ................................................................................. S-2

Follow Safety Instructions ....................................................................................... S-2

Cutting Can Cause Fire or Explosion ...................................................................... S-2

Electric Shock Can Kill ............................................................................................ S-3

Static Electricity Can Damage Circuit Boards ......................................................... S-3

Toxic Fumes Can Cause Injury or Death ................................................................ S-4

A Plasma Arc Can Cause Injury and Burns ............................................................ S-5

Arc Rays Can Burn Eyes and Skin ......................................................................... S-5Grounding Safety .................................................................................................... S-5

Compressed Gas Equipment Safety ....................................................................... S-6

Gas Cylinders Can Explode if Damaged ................................................................. S-6

Noise Can Damage Hearing ................................................................................... S-6

Pacemaker and Hearing Aid Operation .................................................................. S-6

A Plasma Arc Can Damage Frozen Pipes .............................................................. S-6

Warning Label ......................................................................................................... S-7

Sys tem Too ls .............................................................................................................. 1-1

CNC Performance Information ................................................................................ 1-2

Backup Hard Drive .................................................................................................. 1-3

Scan Hard Disk ....................................................................................................... 1-4

Antivirus ............................................................................................................. 1-5

Defragment Hard Disk ............................................................................................ 1-6

Format Floppy Disk ................................................................................................. 1-7

Reset Setups .......................................................................................................... 1-7

Saving the Setup File ........................................................................................ 1-7

Network Tools ....................................................................................................... 1-10

Mapping the CNC to a Network Drive .............................................................. 1-10

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Installation and Setup Manual

iv

Machine Setup ............................................................................................................ 2-1

Defining System Orientation and Features ............................................................. 2-1

Setting Speeds ....................................................................................................... 2-4

CBH Speed Setups ........................................................................................... 2-6

THC Speed Setups ............................................................................................ 2-7

Tilt/Rotator Speed Setup ................................................................................... 2-8

Torch Height Disable .............................................................................................. 2-9

Configuring Ports .................................................................................................. 2-11

Basic Configuration ......................................................................................... 2-12

Phoenix Link Configuration .............................................................................. 2-15

Command THC Port Designation .................................................................... 2-17

Configuring I/O ...................................................................................................... 2-18

Digital Input Definitions ....................................................................................... 20

Digital Output Definitions .................................................................................... 25

THC I/O .............................................................................................................. 29

Speed Pot and Joystick Setup ................................................................................. 30

Configuring SERCOS .................................................................................................... 31

Configuring System Axes ......................................................................................... 34

Transverse or Rail Axis ...................................................................................... 34

SERCOS Axis ..................................................................................................... 38SERCOS Sensor THC Axis ................................................................................ 41

Dual Gantry Axis ................................................................................................. 44

ArcGlide THC Axis .............................................................................................. 47

Sensor THC Axis ................................................................................................ 54

CBH Axis ............................................................................................................ 58

Rotate Axis ......................................................................................................... 61

Tilt Axis ............................................................................................................... 64

Transverse 2 Axis ............................................................................................... 67

Spec ial Setu p .............................................................................................................. 3-1

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Contents

v

Stat ion Setup .............................................................................................................. 4-1

Support for Command THC .................................................................................... 4-3

Support for HD4070 ................................................................................................ 4-4

Support for FineLine 100 / 200 ............................................................................... 4-4

Support for Stations in Part Programs .................................................................... 4-5

Au tomated Plasma Setup .......................................................................................... 5-1

HPR and HD4070 Interface .................................................................................... 5-1

Cut Charts .............................................................................................................. 5-2

Custom Cut Charts ............................................................................................ 5-6

Changing Consumables .......................................................................................... 5-9

I/O and Diagnostics ............................................................................................... 5-10

HD4070 Diagnostics ............................................................................................. 5-10

HPR Diagnostics ................................................................................................... 5-11

Power Supply Inputs ........................................................................................ 5-12

Gas Console Inputs ......................................................................................... 5-13

Power Supply Outputs ..................................................................................... 5-14

Gas Console Outputs ...................................................................................... 5-15

Serial Communication Interface ............................................................................ 5-16

Multiple Plasma Supplies ...................................................................................... 5-16Inputs and Outputs .......................................................................................... 5-17

HD3070 Auto Gas Interface .................................................................................. 5-19

HD3070 Auto Gas I/O ...................................................................................... 5-21

FineLine Plasma Supply ....................................................................................... 5-22

Station Configuration ....................................................................................... 5-23

Cut Chart ......................................................................................................... 5-24

Change Consumable ....................................................................................... 5-27

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vi

Diagnost ic s ................................................................................................................. 6-1

Remote Help ........................................................................................................... 6-1

Installing Shared View ....................................................................................... 6-1

Using Remote Help ........................................................................................... 6-2

Load Additional Manuals ......................................................................................... 6-4

Machine Interface Tests .......................................................................................... 6-5

Serial Test ......................................................................................................... 6-6

USB Test ........................................................................................................... 6-7

HyPath I/O Test ................................................................................................. 6-8

HyPath Axis Test ............................................................................................... 6-9

HyPath Sensor THC Test ................................................................................ 6-10

Operator Interface Test ......................................................................................... 6-12

I/O ........................................................................................................................ 6-13

Inputs ............................................................................................................... 6-13

Outputs ............................................................................................................ 6-14

Expanded I/O ................................................................................................... 6-15

Analog Input Diagnostics ...................................................................................... 6-16

Inputs ............................................................................................................... 6-16

Analog Inputs ................................................................................................... 6-16

Drives and Motors ................................................................................................. 6-17SERCOS Drives and Motors Test ......................................................................... 6-19

DriveTop from Indramat ................................................................................... 6-20

PacSci 800Tools from Pacific Scientific ........................................................... 6-22

Using Norton Ghost Utility ..................................................................................... 6-22

Creating a Ghost Recovery File ....................................................................... 6-22

Retrieving an Image File .................................................................................. 6-23

Al igning Plat es ........................................................................................................... 7-1Five-Point Alignment ............................................................................................... 7-2

Three Point Alignment ............................................................................................ 7-3

Program Code ................................................................................................... 7-3

Motion Path ....................................................................................................... 7-3

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Contents

vii

Motion Con trol ............................................................................................................ 8-1

Closed Loop Servo Control ..................................................................................... 8-1

Typical Velocity and Position Loop System ....................................................... 8-2

Encoders ................................................................................................................. 8-2

Following Error .................................................................................................. 8-3

Position and Servo Error ................................................................................... 8-4

Encoder Counts and Maximum Machine Speed ..................................................... 8-4

Determining Maximum Machine Speed ............................................................. 8-4

Gain ................................................................................................................... 8-5

Feed Forward .................................................................................................... 8-6

Velocity Gain ..................................................................................................... 8-6

Tuning Procedures .................................................................................................. 8-6

Tuning for Velocity Drives .................................................................................. 8-6

Tuning for Current Drives .................................................................................. 8-7

Motion Tuning Watch Windows............................................................................... 8-9

SERCOS Interface Overview ................................................................................ 8-11

Netw orking .................................................................................................................. 9-1

Network Operating System ..................................................................................... 9-1

Configuring the Network Interface Card .................................................................. 9-1Connecting the CNC to a Network .......................................................................... 9-2

Mapping a Connection to a Network Share ............................................................ 9-2

Connecting the CNC to a Workgroup ...................................................................... 9-5

Hardware Considerations ....................................................................................... 9-7

Serial Por ts ............................................................................................................... 10-1

Control RS-232C DB-9 Pinout .............................................................................. 10-1

RS-232C Connections to Host PC with 9-pin D-type Connector ........................... 10-2RS-232C Connections to Host PC with 25-pin D-type Connector ......................... 10-2

Control RS-422 DB-9 Pinout ................................................................................. 10-2

RS-422 Connections to Host PC with 9-pin D-type Connector ............................. 10-3

RS-422 Connections to Host PC with 25-pin D-type Connector ........................... 10-3

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viii

Phoenix Link ............................................................................................................. 11-1

Files Menu ............................................................................................................ 11-2

Settings Menu ....................................................................................................... 11-4

Installation ............................................................................................................. 11-5

Minimum System Requirements ...................................................................... 11-5

Software .......................................................................................................... 11-5

Change Master Folder .......................................................................................... 11-6

Operating Multiple Links ....................................................................................... 11-8

Hardware .............................................................................................................. 11-9

Operating Phoenix Link ......................................................................................... 11-9

Common Errors ................................................................................................... 11-10

Error Messages................................................................................................... 11-10

Appendix A: Release Notes for Phoenix V9.50 Sof tware ....................................... A-1

Version 9.50 ............................................................................................................ A-1

Software Enhancements ................................................................................... A-1

Software Resolutions ......................................................................................... A-2

Version 9.00.1 ......................................................................................................... A-2


Software Resolutions ......................................................................................... A-2Version 9.0 .............................................................................................................. A-3



Version 8.50.1 ......................................................................................................... A-6



Version 8.5 .............................................................................................................. A-7

Software Enhancements ................................................................................... A-7Software Resolutions ......................................................................................... A-8

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Safety

Read This Manual

Read and understand this instructional manual, the cutting machine manuals, and youremployers safety practices.

Note: This product is not designed to be field serviceable. Please return to an authorized repaircenter for any required service.

Product Listings

MicroEdge and Voyager III

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

Edge TI

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

Please contact Hypertherm Automation for further safety listing information.

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Operator's Manual

RECOGNIZE SAFETY INFORMATION

The symbols shown in this section are used toidentify potential hazards. When you see a safetysymbol in this manual or on your machine, understand

the potential for personal injury, and follow the relatedinstructions to avoid the hazard.

FOLLOW SAFETY INSTRUCTIONS

Read carefully all safety messages in this manual andsafety labels on your machine.

Keep the safety labels on your machine in goodcondition. Replace missing or damaged labelsimmediately.

Learn how to operate the machine and how to usethe controls properly. Do not let anyone operate itwithout instruction.

Keep your machine in proper working condition.Unauthorized modifications to the machine mayaffect safety and machine service life.

DANGER WARNING CAUTION

A signal word DANGER or WARNING is used with asafety symbol. DANGER identifies the most serioushazards.

DANGER and WARNING safety labels are locatedon your machine near specific hazards.

WARNING safety messages precede relatedinstruc tions in this manual that may result in injuryor death if not followed correctly.

CAUTION safety messages precede relatedinstructions in this manual that may result indamage to equipment if not followed correctly.

Fire Prevention Be sure the area is safe before doing any cutting.

Keep a fire extinguisher nearby. Remove all flammables within 35 feet (10 m) of the

cutting area. Quench hot metal or allow it to cool before handling

or before letting it touch combustible materials. Never cut containers with potentially flammable

materials inside they must be emptied andproperly cleaned first.

Ventilate potentially flammable atmospheres beforecutting.

When cutting with oxygen as the plasma gas, anexhaust ventilation system is required.

Explosion Prevention Do not use the plasma system if explosive dust or

vapors may be present. Do not cut pressurized cylinders, pipes, or any

closed container. Do not cut containers that have held combustible

materials.

CUTTING CAN CAUSE FIRE OR EXPLOSION

WARNING

Explosion HazardArgon-Hydrogen and Methane

Hydrogen and methane are flammable gases thatpresent an explosion hazard. Keep flames away fromcylinders and hoses that contain methane or hydrogenmixtures. Keep flames and sparks away from the torchwhen using methane or argon-hydrogen plasma.

WARNINGHydrogen Detonation with Aluminum Cutting

When cutting aluminum underwater, or with thewater touching the underside of the aluminum, freehydrogen gas may collect under the workpiece anddetonate during plasma cutting operations.

Install an aeration manifold on the floor of the watertable to eliminate the possibility of hydrogendetonation. Refer to the Appendix section of thismanual for aeration manifold details.

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Safety

Touching live electrical parts can cause a fatal shockor severe burn.

Operating the plasma system completes anelectrical circuit between the torch and theworkpiece. The workpiece and anything touchingthe workpiece are part of the electrical circuit.

Never touch the torch body, workpiece or the waterin a water table when the plasma system isoperating.

Electric Shock Prevention

All Hypertherm plasma systems use high voltagein the cutting process (200 to 400 VDC arecommon). Take the following precautions when

operating this system: Wear insulated gloves and boots, and keep yourbody and clothing dry.

Do not stand, sit or lie on or touch any wetsurface when using the plasma system.

Insulate yourself from work and ground using dryinsulating mats or covers big enough to prevent anyphysical contact with the work or ground. If you mustwork in or near a damp area, use extreme caution.

Provide a disconnect switch close to the powersupply with properly sized fuses. This switch allowsthe operator to turn off the power supply quickly inan emergency situation.

When using a water table, be sure that it is correctlyconnected to earth ground.

ELECTRIC SHOCK CAN KILL

Install and ground this equipment according to theinstruction manual and in accordance with nationaland local codes.

Inspect the input power cord frequently for damageor cracking of the cover. Replace a damaged powercord immediately. Bare wiring can kill.

Inspect and replace any worn or damaged torchleads.

Do not pick up the workpiece, including the wastecutoff, while you cut. Leave the workpiece in placeor on the workbench with the work cable attachedduring the cutting process.

Before checking, cleaning or changing torch parts,disconnect the main power or unplug the powersupply.

Never bypass or shortcut the safety interlocks. Before removing any power supply or systemenclosure cover, disconnect electrical input power.Wait 5 minutes after disconnecting the main powerto allow capacitors to discharge.

Never operate the plasma system unless the powersupply covers are in place. Exposed power supplyconnections present a severe electrical hazard.

When making input connections, attach propergrounding conductor first.

Each Hypertherm plasma system is designed to beused only with specific Hypertherm torches. Do notsubstitute other torches which could overheat and

present a safety hazard.

Use proper precautions when handling printedcircuit boards.

STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS

Store PC boards in anti-static containers. Wear a grounded wrist strap when handling

PC boards.

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Operator's Manual

The plasma arc by itself is the heat source used forcutting. Accordingly, although the plasma arc has notbeen identified as a source of toxic fumes, thematerial being cut can be a source of toxic fumes orgases that deplete oxygen.

Fumes produced vary depending on the metal that iscut. Metals that may release toxic fumes include, butare not limited to, stainless steel, carbon steel, zinc(galvanized), and copper.

In some cases, the metal may be coated with a

substance that could release toxic fumes. Toxiccoatings include, but are not limited to, lead (in somepaints), cadmium (in some paints and fillers), andberyllium.

Gases produced by plasma cutting vary based on thematerial to be cut and the method of cutting, but mayinclude ozone, oxides of nitrogen, hexavalentchromium, hydrogen, and other substances if suchare contained in or released by the material being cut.

Caution should be taken to minimize exposure tofumes produced by any industrial process. Depending

upon the chemical composition and concentration ofthe fumes (as well as other factors, such asventilation), there may be a risk of physical illness,such as birth defects or cancer.

It is the responsibility of the equipment and site ownerto test the air quality in the area where the equipmentis used and to ensure that the air quality in theworkplace meets all local and national standardsand regulations.

TOXIC FUMES CAN CAUSE INJURY OR DEATH

The air quality level in any relevant workplacedepends on site-specific variables such as: Table design (wet, dry, underwater). Material composition, surface finish, and

composition of coatings. Volume of material removed. Duration of cutting or gouging. Size, air volume, ventilation and filtration of the

work area. Personal protective equipment. Number of welding and cutting systems in

operation. Other site processes that may produce fumes.

If the workplace must conform to national or localregulations, only monitoring or testing done at the sitecan determine whether the site is above or belowallowable levels.

To reduce the risk of exposure to fumes: Remove all coatings and solvents from the metal

before cutting. Use local exhaust ventilation to remove fumes from

the air. Do not inhale fumes. Wear an air-supplied

respirator when cutting any metal coated with,containing, or suspected to contain toxic elements.

Assure that those using welding or cuttingequipment, as well as air-supplied respirationdevices, are qualified and trained in the proper useof such equipment.

Never cut containers with potentially toxic materialsinside. Empty and properly clean the container first.

Monitor or test the air quality at the site as needed. Consult with a local expert to implement a site plan

to ensure safe air quality.

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Safety

Instant-On TorchesPlasma arc comes on immediately when the torchswitch is activated.

A PLASMA ARC CAN CAUSE INJURY AND BURNS

The plasma arc will cut quickly through gloves andskin. Keep away from the torch tip. Do not hold metal near the cutting path. Never point the torch toward yourself or others.

Eye Protection Plasma arc rays produce intensevisible and invisible (ultraviolet and infrared) rays thatcan burn eyes and skin. Use eye protection in accordance with applicable

national or local codes. Wear eye protection (safety glasses or goggles with

side shields, and a welding helmet) with appropriatelens shading to protect your eyes from the arcsultraviolet and infrared rays.

Lens ShadeArc Current AWS (USA) ISO 4850

Up to 100 A No. 8 No. 11100-200 A No. 10 No. 11-12

200-400 A No. 12 No. 13Over 400 A No. 14 No. 14

ARC RAYS CAN BURN EYES AND SKIN

Skin Protection Wear protective clothing to protectagainst burns caused by ultraviolet light, sparks andhot metal. Gauntlet gloves, safety shoes and hat. Flame-retardant clothing to cover all exposed areas. Cuffless trousers to prevent entry of sparks and

slag. Remove any combustibles, such as a butane lighter

or matches, from your pockets before cutting.

Cutting Area Prepare the cutting area to reducereflection and transmission of ultraviolet light: Paint walls and other surfaces with dark colors to

reduce reflection.

Use protective screens or barriers to protect othersfrom flash and glare. Warn others not to watch the arc. Use placards or

signs.

Work Cable Attach the work cable securely to theworkpiece or the work table with good metal-to-metalcontact. Do not connect it to the piece that will fallaway when the cut is complete.

Work Table Connect the work table to an earthground, in accordance with appropriate national orlocal electrical codes.

GROUNDING SAFETY Input Power Be sure to connect the power cord ground wire to

the ground in the disconnect box. If installation of the plasma system involves

connecting the power cord to the power supply, besure to connect the power cord ground wireproperly.

Place the power cord's ground wire on the stud first,then place any other ground wires on top of thepower cord ground. Fasten the retaining nut tightly.

Tighten all electrical connections to avoid excessiveheating.

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Operator's Manual

ADDITIONAL SAFETY INFORMATION

1. ANSI Standard Z49.1, Safety in Welding and Cutting, AmericanWelding Society, 550 LeJeune RoadP.O. Box 351020, Miami, FL 33135

2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and Welding Processes, American National Standards Institute1430 Broadway, New York, NY 10018

3. ANSI Standard Z87.1, Safe Practices for Occupation and Educational Eye and Face Protection, American NationalStandards Institute, 1430 Broadway, New York, NY 10018

4. AWS F4.1, Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances, American Welding Society550 LeJeune Road, P.O. Box 351040, Miami, FL 33135

5. AWS F5.2, Recommended Safe Practices for Plasma ArcCutting, American Welding Society550 LeJeune Road, P.O. Box 351040, Miami, FL 33135

6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in Cylinders, Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202

7. CSA Standard W117.2, Code for Safety in Welding and Cutting,Canadian Standards Association Standard Sales178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada

8. NFPA Standard 51B, Cutting and Welding Processes, NationalFire Protection Association470 Atlantic Avenue, Boston, MA 02210

9. NFPA Standard 701978, National Electrical Code, National FireProtection Association, 470 Atlantic Avenue, Boston, MA 02210

10. OSHA, Safety and Health Standards, 29FR 1910U.S. Government Printing Office, Washington, D.C. 20402

Never lubricate cylinder valves or regulators with oilor grease.

Use only correct gas cylinders, regulators, hoses

and fittings designed for the specific application. Maintain all compressed gas equipment andassociated parts in good condition.

Label and color-code all gas hoses to identify thetype of gas in each hose. Consult applicablenational or local codes.

GAS CYLINDERS CANEXPLODE IF DAMAGED

COMPRESSED GAS EQUIPMENT SAFETY

Gas cylinders contain gas under high pressure. Ifdamaged, a cylinder can explode.

Handle and use compressed gas cylinders inaccordance with applicable national or local codes. Never use a cylinder that is not upright and secured

in place. Keep the protective cap in place over valve except

when the cylinder is in use or connected for use. Never allow electrical contact between the plasma

arc and a cylinder. Never expose cylinders to excessive heat, sparks,

slag or open flame. Never use a hammer, wrench or other tool to open

a stuck cylinder valve.

Prolonged exposure to noise from cutting or gougingcan damage hearing. Use approved ear protection when using plasma

system. Warn others nearby about the noise hazard.

NOISE CAN DAMAGE HEARING

Pacemaker and hearing aid operation can be affectedby magnetic fields from high currents.Pacemaker and hearing aid wearers should consult adoctor before going near any plasma arc cutting andgouging operations.

To reduce magnetic field hazards: Keep both the work cable and the torch lead to one

side, away from your body. Route the torch leads as close as possible to the

work cable. Do not wrap or drape the torch lead or work cable

around your body. Keep as far away from the power supply as

possible.

PACEMAKER AND HEARINGAID OPERATION

A PLASMA ARC CANDAMAGE FROZEN PIPES

Frozen pipes may be damaged or can burst if youattempt to thaw them with a plasma torch.

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Safety

WARNING LABELThis warning label is affixed to some power supplies. It isimportant that the operator and maintenance technicianunderstand the intent of these warning symbols as described.The numbered text corresponds to the numbered boxes onthe label.

1. Cutting sparks can cause explosion or fire.

1.1 Keep flammables away from cutting.

1.2 Keep a fire extinguisher nearby, and havea watchperson ready to use it.

1.3 Do not cut on any closed containers.

2. The plasma arc can cause injury andburns.

2.1 Turn off power before disassembling torch.

2.2 Do not hold the material near cutting path.

2.3 Wear complete body protection.

3. Electric shock from torch or wiring can kill.Protect yourself from electric shock.

3.1 Wear insulating gloves. Do not wear wet ordamaged gloves.

3.2 Insulate yourself from work and ground.

3.3 Disconnect input plug or power beforeworking on machine.

4. Breathing cutting fumes can be hazardousto your health.

4.1 Keep your head out of the fumes.

4.2 Use forced ventilation or local exhaust to

remove the fumes.

4.3 Use ventilating fan to remove the fumes.

5. Arc rays can burn eyes and injure skin.

5.1 Wear hat and safety glasses. Use earprotection and button shirt collar. Usewelding helmet with correct shade of filter.Wear complete body protection.

6. Become trained and read the instructionsbefore working on the machine or cutting.

7. Do not remove or paint over (cover)warning labels.www.hypertherm.com/weee

110647 Rev. A

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1-1

System Tools

Note: The CNC Systems Tools require operational knowledge of the Windows XPoperating system and should only be performed by qualified personnel.

A mouse and keyboard are required and should be connected to the CNC beforeaccessing System Tools.

Parameter Description

AutomatedBackup Select the frequency of the automatic reminder for the backup ofinformation on the main hard drive. At the selected time, the systemdisplays a prompt to back up the system when you turn it on.

TableManufacturerInformation

Enter the contact information for the cutting table manufacturer. Thisinformation is displayed when Remote Help starts up so thisinformation should be the contact information for users of RemoteHelp.

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1-2

CNC Performance Information

The CNC Performance Information parameters display information about processeswithin the CNC that can contribute to unreliable motion control. Consult theseparameters if the CNC: Loads files slower than you expect Takes longer to perform operations than it did when it was originally installed

Each parameter in the group box provides the valid range for a process that operateswithin the CNC. Time values next to each parameter display the longest time that hasbeen recorded for that process since the CNC was turned on. Values in blue are withinthe valid range; values in red are outside the valid range.

To verify your CNC performance:

1. From the Main screen, select Setups > Password and enter the Special password.

2. Click or press the System soft key.

3. If the numbers for all parameters are blue, the CNC is operating as designed.

4. If the number for any parameter is red, restart the CNC.

5. Return to the System screen.

6. If the numbers are blue, the CNC is operating as designed.

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System Tools

1-3

7. If any of the numbers are red, other programs that are running on the CNC may beaffecting its performance. Shut down all programs except Phoenix.

8. If Phoenix is the only program running and numbers continue to display in red, callTechnical Service for additional troubleshooting.

Back up Hard DriveTo back up the hard drive:

1. From the Main screen, press or click Setups > Password and enter the Specialpassword.

2. Press or click the System soft key.

Press the Backup Hard Drive soft key to save the contents of the main hard drive to aspecified location on the CNC hard drive or mapped location using the Norton GhostUtility.

Note: After using Norton Ghost, all files on Drive C: will be replaced. CNC setups mustbe reloaded.

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1-4

Scan Hard DiskTo scan the hard disk for viruses or disk errors using Norton antivirus software:


2. Press or click System > Scan Hard Disk.

3. Select Yes on the verification popup to start the scan.

4. Select No to scan the hard drive for errors and correct them using the Windows XPCHKDSK (check disk) utility.

This task should be performed approximately every three months depending on thenumber of files loaded to and removed from the CNC.

5. The Check Disk (CHKDSK) function cannot operate while the CNC software is inoperation. Press Y (for yes) to check the disk the next time that the CNC boots up.

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System Tools

1-5

Antivi rusThe AntiVirus feature allows you to search files that are loaded on the CNC for knownviruses.

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1-6

Defragment Hard DiskThe defragmentation operation scans the CNC hard disk for file locations andrearranges them for optimum performance.

This task should be performed approximately every three months.

To defragment the hard disk:


2. Press or click System > Defragment Hard Disk.

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System Tools

1-7

Format Floppy DiskFormats a floppy disk if the CNC has difficulty reading a floppy disk formatted by acomputer.

Important: Formatting the diskette removes all files that are stored on the diskette.

Note: Not all CNCs have a floppy disk drive.

Reset SetupsDeletes the current setup file and reloads default values. A new setup file can then beloaded on the CNC through the Special Password screen.

If the CNC supplier has installed a customized setup file that contains informationspecific to the cutting table, the soft key is renamed Restore Setups. This custom setupfile is the default setup file and if you press the Restore Setup soft key, the customsetup file is restored.

Saving the Setup FileWhen you configure a CNC for a cutting system, every setting is saved in a file namedPhoenix.ini that ships with the system. This file is located in the Phoenix folder on the C:partition of the hard drive. The system also ships with a copy of the Phoenix.ini file thatis called Default.ini.

The CNC uses the settings in the Phoenix.ini file during operation. Whenever youchange, or customize, a setting on one of the Phoenix screens, the system saves thechange in the Phoenix.ini file. Therefore, the Phoenix.ini file contains settings thatshipped with the system as well as customized settings for your operations. When theCNC powers up and launches Phoenix, it also opens the Phoenix.ini file and configuresthe software according to the file settings there.

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The CNC uses the settings in the Default.ini file if the Phoenix.ini file becomes corruptedand cannot be used for configuring settings. In this case, Phoenix displays an errormessage when power is turned ON to inform you that setup settings could be corruptedor lost and offers you the chance to use the settings in the Default.ini file.

However, changes to Phoenix.ini are not automatically saved in Default.ini. Therefore, itis essential that you save your most recent Phoenix.ini file and name it Default.ini sothat you can always return to your most recent set of uncorrupted configuration settings.

In addition, when you power up your CNC or after you reload software, the system

displays a message asking if you want to configure the system using the Default.ini file.If you have not saved Phoenix.ini to Default.ini, you must reconfigure all your operatingsettings.

For security and convenience, save five copies of the Phoenix.ini file:

1. From the Main screen, select Setups > Password and enter the Special password.2. Press the Save Setups soft key.3. Select Hard Drive from the Save setups to dropdown list.

4. In the Setups file name field, enter the customer name and date incustomernameMM-DD-YY format .

5. Press OK.

6. Press the Save Setups soft key again.7. Select Hard Drive from the Save setups to dropdown list.

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8. In the Setups file name field, enter Default.9. Press OK.10. Press the Save Setups soft key again.11. Select Backup HD Setups from the Save setups to dropdown list.

12. In the Setups file name field, enter the customer name and date incustomernameMM-DD-YY format.

13. Press OK.14. Save a copy each of customernameMM-DD-YY.ini and Default.ini to removable

memory devices, such as a floppy disk or flash drive.

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Network ToolsNetwork tools allow the CNC to be incorporated directly into an office PC Network forpart allocation. This feature is available on the controls Windows XP operating systemand requires a factory supplied network card to be installed. Contact your CNC vendor

for additional details on adding this feature.The optional networking feature is supported for: Window NT servers Window NT workgroups Window 98 workgroups

Note: The Network Tools require operational knowledge of the Windows XPoperating system and should only be performed by qualified personnel.

Press the Network Tools soft key on the System screen to access the Windows XPNetwork Connection utility.

Mapping the CNC to a Network DriveTo map a file location:

1. From the Main screen, select Setups > Password and enter the Special password.

2. Click or press OK.

3. Enable Mapping Drives on the special password screen.

4. Click or press OK.5. Return to the Main screen and select Files.

6. Double click on the Load from dropdown list or press the + key.

7. In the popup window, select Mapped Drive.

8. In the Drive Name field, enter a drive name.

9. In the Drive Path field, enter a drive path.

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Machine Setup

2-2

Dual GantryInstalled

Select Yes to enable the dual gantry axis and allow configuration ofthat axis.

CBH Installed Select Yes to enable the contour bevel head axis and allowconfiguration of that axis.

X and YMotor/Encoder

Select Swapped to swap the X and Y Axis encoder signals internally.This feature simplifies the installation of systems with alternativewiring configurations.

Auto TorchSpacing

Select Yes to enable the automatic torch spacing feature. This featureuses embedded part program codes and dedicated outputs to controlindividual torch stations to set spacing and clamping of direct andmirrored cutting. For more information, refer to the ProgrammersReference .

Tilt RotatorInstalled Enables use of the Tilt Rotator feature. Tilt Rotator is a uniquerotational cutting tool that combines a rotational axis with a tilt (bevel)axis that performs for compound cutting.

Note: The Tilt Rotator feature executes the tilt-angle motion over thelength of the line segment.

Dual-TiltRotatorInstalled

This parameter enables use of a second tilt rotator feature. A secondtransverse axis is enabled and allows individual, parallel, and mirrorcutting.

Auto Home at

Power Up

Determines if the contour bevel head (CBH) and tilt or rotate axes

automatically go into the homing routine when the CNC powers up.FollowerInitially

Determines whether the CBH and rotate features are always enabledafter power up or are enabled through the part program.

Dual TiltingRotator Mode

Defines the tilt rotator to use two tilt axes rather than a rotation axisand tilt axis for rotational bevel cutting. The Tilt Rotator Installed mustbe selected for this feature.

Key PressLogging

Records key press and other related information in a daily log file.This log is intended for use by Service Technicians when a faultoccurs to help review events before the fault occurs. When logging isenabled, the log file is saved to the hard drive so it can be retrieved bytransfer to a floppy diskette or USB memory. Usually this parameter isset to NO.

Table Size Enter a value for the active cutting area for the X and Y axis. Thesevalues limit the plate size parameter in the cutting setup screen to themaximum size of the table.

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ArcGlide THCsInstalled

Defines the number of ArcGlide THC axes assigned for operation atthe CNC

UseHypertherm

Ethernet

Sets up the CNC to communicate with the ArcGlide over Hypernet.

THCs Installed Defines the total number of Sensor THC axes assigned for operationat the CNC.

THC InstalledOn Axis /

Analog

Defines the THC axis. Select the THC, which axis it is installed on,and the analog input to use (arc voltage feedback).

Note: For more information on the setup and use of the Sensor THC,refer to the other sections in this chapter, as well as the Sensor THCSetup chapter in the Operators Manual .

Ignore TorchCollision DuringIHS

Allows the system to ignore input about a torch collision during theinitial height sense cycle. This may be helpful for some THCmechanics.

CommandTHCs Installed

Enables the Command THC serial link. For more information on thisfeature, refer to the Configuring Ports section of this chapter. Shownin Type P mode only.

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Machine Setup

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Setting SpeedsThe Speeds setup screen is where you set the machine speeds for the operatingmodes.

The CNC is capable of operating over a wide range of speeds, depending on the drives,motors, gearboxes and mechanics of the system.


Speed 0 To Specifies speed ranges and customizes the acceleration rates forthese speeds. When a speed range that is lower than the maximumspeed is entered, a new range at the maximum machine speedsetting is created. You can set a maximum of 5 speed ranges.

To reduce the number of Speed To ranges, enter the maximum speedin the highest range and the additional range fields will be removedfrom the screen.

AccelerationRate

Determine both the acceleration and deceleration rate for all motion.

All mechanical systems have different acceleration and decelerationrates to move the cutting device smoothly. The higher theacceleration rate, the quicker the machine will get up to speed. The

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lower the acceleration rate the smoother the machine will position thecutting device.

Enter a value in milliGs for the desired acceleration rate. One milliG isapproximately 0.384 inches per second 2. A recommended, initialvalue for this field is 10 mGs.

Fast StopDecelerationRate

This parameter is activated by the Fast Stop or Torch Collision Inputand specifies in milliGs how quickly the system will stop when theFast Stop Input is active. Generally, this value is much higher than theacceleration rate.

One milliG is approximately 0.384 inches per second 2.

MaximumMachine Speed

Enter the maximum value at which the system is capable ofcontouring. This parameter is used to limit the range of all subsequentspeed entries. In addition, it is used to scale the speedometer in theWatch window during runtime operation.

The maximum speed at which the CNC can contour can be calculatedwith the following equation.

Maximum Contouring Rate (IPM) =60 seconds 1 Inch 100,000 edges

minute User edges second

For example: the CNC could command a cutting machine with 4000edges per inch resolution at 1,500 IPM.

LimitedMachine Speed

Defines maximum machine speed when the Limited Speed Input isactive. This is commonly used to set a reduced machine speed forincreased safety during machine testing or maintenance.

High JogSpeed

Defines the high speed for manual motion.

Medium JogSpeed

Defines the medium speed for manual motion.

Low Jog Speed Defines the low speed for manual motion.

Minimum

Corner Speed

Defines the minimum speed to use when negotiating corners. The

CNC has centripetal velocity and acceleration contouring algorithmswhich provide optimal cut quality for most cut operations. In somesituations, a minimum corner speed prevents over-burning at corners.In normal operations, this parameter should be set to zero.

Fast HomeSpeed

Defines the speed that the CNC uses during the first phase of thehoming sequence. During the first phase, the cutting device movestoward the home limit switches at the fast rate.

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Machine Setup

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Slow HomeSpeed

Defines the speed that the CNC uses during the second phase of thehoming sequence. During the second phase, the cutting devicemoves off the home limit switch and proceeds to the marker pulse.When the CNC detects the marker pulse, it decelerates to a stop andperforms a small move in the opposite direction to the marker pulse.

Creep SpeedPercentage

Defines what percentage of the machine cut speed will be used whencreeping. Generally, creep speed is 25% of the cut speed.

Plasma Hi/LoSpeedPercentage

Specifies the percentage of the process cut speed at which the CNCactivates the Torch Height Disable output. The plasma system usesthis output to switch from low to high current or to disable the heightcontrol. For more information, see the Torch Height Disable section inthis chapter.

Note: The Dual Grid/THC feature must be enabled at the PlasmaSetups Screen.

PlasmaDistance ToCorner

Specifies the distance before turning a corner at which the plasmasystem should switch from high current to low current and disable theautomated height sensor. Distance to Corner is active whenever thespeed drops below the Plasma Hi/Lo Percentage, or segmentsintersect at an angle greater than the tangent angle.

Note: The Dual Grid/THC feature must be enabled at the PlasmaSetups Screen.

PlasmaDistance FromCorner

Specifies the distance after turning a corner at which the plasmasystem should enable the Automated Height Sensor. Distance fromCorner is active whenever the speed drops below the Plasma Hi/LoPercentage, or segments intersect at an angle greater than thetangent angle.

Note: The Dual Grid/THC feature must first be enabled at the PlasmaSetups Screen.

CBH Speed SetupsThe CBH speed setup parameters display only if they have been enabled.

Parameter DescriptionCBH

AccelerationRate

Specifies the acceleration rate for smooth and stable movement of thecontoured bevel head. The higher the acceleration rate, the quickerthe CBH will get up to speed. The lower the acceleration rate, thesmoother the machine will position the cutting device. Values areentered in revolutions/second 2.

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Maximum CBHSpeed

Specifies the maximum speed for the CBH rotation inrevolutions/minute.

CBH High Jog /Home Speed Specifies the manual CBH jog and fast Home speed.

CBH Low Jog /Home Speed

Specifies the CBH slow home speed.

THC Speed SetupsThe THC speed setup parameters display only if they have been enabled.


THC AccelerationRate

Specifies the acceleration rate for smooth and stable movement of theSensor THC. The higher the acceleration rate, the quicker the THCwill get up to speed. The lower the acceleration rate, the smoother themachine will position the cutting device. Values are entered in milliGs.

Maximum THCSpeed

Specifies the maximum speed for the Sensor THC in inches / minute.

THC JogSpeed

Specifies the THC jog speed.

THCHome/Fast IHSSpeed

Specifies the speed that is used to home the torch at the top of theslide and to move the torch from the selected IHS height towards theplate, looking for the surface of the plate.

THC Slow IHSSpeed

Specifies the speed that is used to retract the torch after the plate hasbeen sensed. The torch retracts at this speed until contact sense islost. This determines the exact distance to the plate regardless of anyflexing of the plate. A very low speed is recommended for optimalaccuracy.

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Machine Setup

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Tilt/Rotator Speed SetupThe following Speeds setup parameters are available when Tilt Rotator has beenenabled.


Rotate AccelerationRate

Specifies the acceleration rate for smooth and stable movement of thecontoured bevel head. The higher the acceleration rate, the quickerthe Rotate Axis gets up to speed. The lower the acceleration rate, thesmoother the machine will position the cutting device. Values areentered in revolutions/second 2.

MaximumRotate Speed

Specifies the maximum speed for the Rotate Axis rotation inrevolutions/minute.

Rotate HighJog Speed

Specifies the high speed for the rotate axis jog.

Rotate Low JogSpeed

Specifies the low speed for the rotate axis jog.

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Tilt AccelerationRate

Specifies the acceleration rate for smooth and stable movement of thecontoured bevel head. The higher the acceleration rate, the quickerthe tilt axis gets up to speed. The lower the acceleration rate, the

smoother the machine positions the cutting device. Values areentered in revolutions/second 2.

Maximum TiltSpeed

Specifies the maximum speed for the tilt axis, in revolutions/minute.

Tilt High JogSpeed

Specifies the high speed for tilt axis jog.

Tilt Low JogSpeed

Specifies the low speed for tilt axis jog.

Torch Height DisableThe Torch Height Disable feature activates the Torch Height Disable output andfreezes, or disables, the automatic adjustment of the automated torch height controlsystem to prevent diving or crashing of the torch in corners.

Note: The Dual Grid/THC feature must first be enabled in the Plasma Setups screen.

The CNC activates the Torch Height Disable output based on the values of the followingparameters:

Plasma Hi/Lo % of Cut Speed Plasma Distance to Corner Plasma Distance from Corner

When any one of these conditions is met, the Torch Height Disable feature isimplemented. The definition of a corner is based on the tangent angle in the specialpassword screen and the value of the Plasma Hi/Lo speed.


Tangent Angle

Specifies the degree of the tangent angle for motion control. Segmentswithin a part that intersect at angles greater than the selected tangentangle will decelerate to zero or the minimum corner speed. Segmentswithin a part that intersect at angles less than or equal to the selectedtangent angle do not decelerate unless the next segment is a speed-limited arc.

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Machine Setup

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Plasma Hi/LoSpeedPercentage

Specifies the percentage of the cut speed below which the CNC willactivate the Torch Height Disable output. The plasma system can usethis output to switch from low to high current or to disable the height

control.

PlasmaDistance ToCorner

Specifies the distance before turning a corner at which the plasmasystem should switch from low current to high current or disable the

Automated Height Sensor. Distance to Corner is active when thespeed drops below the Plasma Hi/Lo Percentage, or when segmentsintersect at an angle greater than the tangent angle.

PlasmaDistance FromCorner

Specifies the distance after turning a corner at which the plasmasystem should enable the Automated Height Sensor. Distance fromCorner is active whenever the speed drops below the Plasma Hi/Lo

Percentage, or segments intersect at an angle greater than thetangent angle.

In the following illustration, the Torch Height Disable output is activated based on thevalues of the setup parameters.

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Parameter Value

Plasma Hi/Lo Speed Percentage Value 90%

Distance to Corner Value 5 inches

Distance from Corner Value .5 inches

Tangent Angle Value 20 degrees

For these values, the Torch Height Disable output is active 0.5 inch before and 0.5 inchafter each 90 degree corner. This output is also activated as the torch accelerates awayfrom the pierce and through the arc because the speed is below the Plasma Hi/Lovalue. Finally, because the arc intersects at greater than the 20-degree tangent angle,the Torch Height Disable output is activated for 0.5 inches before and after thebeginning of the arc, and is activated for 0.5 inches before and after the end of the arc.

Configuring PortsEach CNC comes standard with two serial ports. Depending on the model, your CNC isconfigured for RS-232C or RS-422 serial communication. For more information abouthow to change the serial port configuration on your CNC, refer to the Serial Portschapter.

The serial ports are designed with opto-isolation and filtering to minimize EMI/RFI noiseproblems that are common in many cutting operations. Parameters are enabled anddisabled depending on port feature selections.

The CNC can be configured to use the communication link provided on the CNC or the

user can enter information to create a custom communication link on the Link screen tocommunicate with a host computer. Information on how to access the Phoenix softwareis provided later in this section.

A maximum of eight ports can be configured for use in software. Hardware providedwith your CNC may support a lower number of communication ports.

The following parameters are available to help configure the serial ports for your specificcommunications package and selected communication features.

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Machine Setup

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Basic Configuration

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Machine Setup

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File DumpMode

Select On to configure the link communication protocol tocommunicate with link programs that operate in File Dump Mode. Thisallows the CNC to accept part programs as a single uninterruptedstream of information as with a tape reader style link.

Allow M65 AutoReload

Available when a generic link communication has been enabled andallows you to select whether the EIA M65 code is used as an auto-reload code or is ignored.

Home before Auto Reload

Automatically homes the machine before the next auto reload (EIAM65 code), either serial link, USB memory or from diskette, isexecuted

Dialog Start Enter the ASCII code equivalent to the character or symbol used bythe host computer for dialog start.

Dialog Done Enter the ASCII code equivalent to the character or symbol used bythe host computer for dialog done.

Dialog Acknowledge

Enter the ASCII code equivalent to the character or symbol used bythe host computer for dialog acknowledgement.

End ofTransmission

Enter the ASCII code equivalent to the character or symbol used bythe host computer for dialog acknowledge.

Dialog Prompt Enter the ASCII code equivalent to the character or symbol used bythe host computer for dialog prompt.

Dialog Pause Enter the ASCII code equivalent to the character or symbol used bythe host computer for dialog pause.

Rewind This field is only enabled when Link File Dump Mode has beenenabled. Enter the ASCII code equivalent to the character or symbolused by the host computer for tape rewind at the host tape drivesystem. Enter 0 to eliminate the rewind command.

The following additional parameters are available when Serial Messaging has beenenabled. For more information see Serial Messaging in the Programmers Reference .

Flow control Select None, Xon/Xoff or Hardware.During Jog onPath

Select whether the CNC sends messages when jogging Forward orBackward on Path while at the Pause screen.

Notes:

All messaging stops when the Stop Key has been pressed orwhen the Remote Pause input becomes active.

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Auto Homebefore AutoReload

Automatically homes the machine before the next auto reload (EIAM65 code), either serial link, USB memory or from diskette, isexecuted

DownloadUpdates

Allows the operator to download CNC software updates through thelink communication to the host PC.

The Using Phoenix Link parameter must be set to YES. The newupdate file must be placed in the same folder location as the Linksoftware. When the Update Software soft key is pressed on theSpecial Password screen, the CNC searches for the new softwareupdate through the link rather than the floppy drive.

Command THC Port Designation

Warning! Configure the port for RS-422 operation before connecting to theCommand THC. The Command THC Link must first be enabled in Machine Setups forType P controls and at the Station configuration for type V controls. Refer to theSerial Port section of this guide for additional information on configuring the serial portfor RS-422 communication.

RS422 Connections to Command THC with 25 pin Dtype Connector

Command THC CNC

Signal Name DB-9 Pin Signal Name DB-9 Pin

RxD - 1 TxD - 2

TxD - 2 RxD - 3

RxD + 20 TxD + 4

TxD + 21 RxD + 7

For improved noise immunity, cable shields for communication should be tied to ground.Ferrite bead with several wraps on the cable may also be used.

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Machine Setup

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Configuring I/O After you enter the Machine password and can view the Machine setup screen, pressthe I/O soft key to configure the inputs and outputs for the shape cutting table.

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Machine Setup

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on the CNC interface. All controls are shipped with the defaultselection of inputs and interface locations for the selected controlinterface (I/O) configuration.

Torch Collision

Uses

Determines the type of response that is used when the Torch

Collision input is active. You can select to use a Fast Stop Decelvalue or the Fault Ramp time that has been selected for the individualaxis.

Inputs Inverted Defines which inputs are used by the CNC and their physical locationon the CNC interface. All controls are shipped with the defaultselection of inputs and interface locations for the selected controlinterface (I/O) configuration.

Analog Offset1- 12

Corrects for any imbalance or zeroes the incoming analog voltage tothe analog input card.

Note: To calibrate the analog inputs, jumper the two pins specific tothe input together and view the incoming voltage on the Diagnostics Analog I/O screen. The incoming voltage should be 0. If any voltage isdisplayed at the diagnostic screen, an offset voltage equal to theincoming voltage being read can be entered here to make theincoming voltage 0.

Outputs The CNC comes standard with up to 32 discrete digital outputs. TheOutput Logic parameter is used as a mask to determine whether ornot the output is to be treated as a normally open contact or as anormally closed contact.

Outputs Logic The Logic Selection Box allows the user to select the Logic state foreach input to be either normally open or normally closed. The logicstate for the inputs can be switched by selecting the desired Outputand pressing the space key.

Output LogicSelection Box

The Output Selection box feature is used to define which inputs willbe used by the control, and their physical location on the controlinterface. All controls are shipped with the default selection of Outputsand interface locations for the selected control Interface (I/O)configuration.

Drive Enables Determines how the CNC responds to drive faults. If you selectSeries, all axes must complete their individual fault ramp times beforethe drives are disabled. If you select Independent, each drive isdisabled as soon as its axis fault ramp time is finished.

Initial FeedbackDelay

Allows the initial feedback from the drive system to be held off afterinitial power up. This allows the drive system to become fully enabled

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Station SelectInput

Indicates which Sensor THCs is active when multiple Sensor THCsare commanded by the CNC as separate axes. Also tracksconsumable data for the specified plasma or oxy torch. Stations 1-8are designated for plasma; stations 9-20 are designated for oxy fuel.Type V control.

X Home Switch Indicates that the machine has traveled to its X axis home position. Ifthe X axis Use Home Limit Switch parameter is set to YES and ahoming function is performed, the X axis moves in the specifiedhome direction at the fast home speed until the input is activated.The X axis then decelerates to a stop and moves in the oppositedirection at the slow home speed until the switch is deactivated. Afterthe switch is deactivated, the X axis decelerates to a stop or, if theUse Marker Pulse parameter is set to YES, continues until theencoder marker pulse is detected.

Y Home Switch Indicates that the machine has traveled to its Y axis home position. Ifthe Y axis Use Home Limit Switch parameter is set to Yes and ahoming function is performed, the Y axis moves in the specifiedhome direction at the fast home speed until the input is activated.The Y axis then decelerates to a stop and moves in the oppositedirection at the slow home speed until the switch is deactivated. Afterthe switch is deactivated, the Y axis decelerates to a stop or, if theUse Marker Pulse parameter is set to Yes, continues until theencoder marker pulse is detected.

Z Home Switch Indicates that the machine has traveled to its Z axis home position. If

the Z axis Use Home Limit Switch parameter is set to Yes and ahoming function is performed, the Z axis moves in the specifiedhome direction at the fast home speed until the input is activated.The Z axis then decelerates to a stop and moves in the oppositedirection at the slow home speed until the switch is deactivated. Afterthe switch is deactivated, the Z axis decelerates to a stop or, if theUse Marker Pulse parameter is set to Yes, continues until theencoder marker pulse is detected.

Y OvertravelSwitch

Indicates that the machine has traveled into its full positive travel of aY axis. If hardware overtravels are enabled and this input isactivated, the CNC stops all motion and generates a fault message.Motion is not re-enabled until the switch is deactivated.

X OvertravelSwitch

Indicates that the machine has traveled into its full positive travel of aX axis. If hardware overtravels are enabled and this input isactivated, the CNC stops all motion and generates a fault message.Motion is not re-enabled until the switch is deactivated.

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Assist Gas Used exclusively with the laser cut logic to activate the assist gas.

Digital Beam Used exclusively with the laser cut logic to activate the digital beam.

Laser Start Used exclusively with the laser cut logic to activate the laser system.

AbrasiveControl

Used exclusively with water jet cut logic and activates the abrasivecontrol, adding abrasive to the cut stream while cutting, or forcharging the abrasive prior to cutting.

PlasmaEnables

Used for external logic. The appropriate output(s) is on during plasmacutting, based on the Plasma Select inputs.

Marker Enables Used for external logic. The appropriate output(s) is on duringmarking, based on the Marker Select inputs.

Nozzle ContactEnable

Active during Sensor THC IHS. This input is tied back to the CNCthrough the external voltage divider card. This output can also beused to switch an external drive system to low output mode (ifequipped) during IHS for stall force plate sensing.

Hold Ignition Is part of the Sensor THC operation to hold ignition of the externalPlasma Supply. This output can be tied back to the CNC through theexternal voltage divider card or direct to the power supply dependingon configuration.

Gas Flow Set 1 100

Used as part of the HD3070 automatic gas console communications(BCD) to set gas flow rates.

Valve Select 1 8

Used as part of the HD3070 automatic gas console communicationsto select the appropriate valves for operation.

Gas ControlWrite

Used as part of the HD3070 automatic gas console communicationsto configure the unit for operation.

Remote TestOperate

Used as part of the HD3070 automatic gas console communicationsto initiate the remote test.

Remote Test

Preflow

Used as part of the HD3070 automatic gas console communications

to test operation of preflow gases.Remote AirPlasma

Used as part of the HD3070 automatic gas console communicationsto signal the Air Plasma output.

Remote H35/N2 Plasma

Used as part of the HD3070 automatic gas console communicationsto signal the H35/N2 output.

Remote O2 Used as part of the HD3070 automatic gas console communications

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Plasma to signal the O2 Output.

ChangeConsumable

Activates when a consumable data value on the Change ConsumableScreen has reached its preset maximum. Generally, this output is tiedto an external indicator light or audible alarm to prompt the system

operator to change the appropriate consumable. The affectedconsumable data must be reset on the Change Consumable Screento clear the output.

Current SetBCD

Sets the current at the plasma power supply or marker supply. Theseoutputs are tied to the BCD inputs. Combinations of the current valuesare used to attain the desired current set point.

Marker Control Activates the marker tool during the marking process. Traditionally,the marker tool is activated through the combination of Marker Enableand Cut Control outputs. All the noted options are available and canbe configured on the Marker Setup screen for the desired processtiming and operational results.

ProgramRunning

Active any time the CNC is operating within a part program.

Station Enable1-20

Activates any function specific to a torch station and are controlledthrough M37T and M38T codes within a part program. Typically,these codes generally enable a torch station for use. Stations Usually,stations 1-8 are configured with plasma and stations 9-20 areconfigured with oxy fuel or other types of fuel. However, plasma canonly be configured on stations 1-8.

Station Lock 1-19

Are part of the Automated Torch Spacing feature. The station locklocks the unused torch station to the gantry or beam when the torch isnot in use.

Station Clamp1-19

Used as part of the Automated Torch Spacing feature. The StationClamp is used to clamp the selected torch station to the transverseaxis for standard cutting.

Station Mirror1-19

Used as part of the Automated Torch Spacing feature. The stationmirror is used to clamp the selected torch station to the transverse

axis for mirrored cutting. Auto OHC 1-20 Instructs the Sensor OHC to operate the specified station in automatic

mode

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THC I/O


Analog Offset1 - 12

The Analog Offsets 1 through 12 are used to correct for anyimbalance or zero the incoming analog voltage to the Analog InputCard. Analog inputs are assigned to the THC Axis and the AnalogOffsets for the appropriate THC Analog input may be adjusted here.To calibrate the Analog Inputs, jumper the two pins specific to theinput together and view the incoming voltage at the Diagnostics

Analog I/O screen. The incoming voltage should be zero. If anyvoltage is displayed at the diagnostic screen, an Offset Voltageequal to the incoming voltage being read can be entered here to

zero the incoming voltage.

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Machine Setup

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Speed PotInstalled On

Assigns speed potentiometer inputs to the desired Analog Input if adedicated speed potentiometer input is not available on the analoginput card.

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Configuring SERCOSThe SERCOS interface requires configuration to establish communications for motionand I/O.

The following drives are supported and are preferred:

Indramat/Bosch

IndraDrive Mi

IndraDrive C basic drive

IndraDrive C basic drive with MA1 option

IndraDrive C advanced drive

IndraDrive C advanced drive with MA1 option

Kollmorgen

ServoStar 300The following drives are also supported:

Indramat/Bosch

IndraDrive M Double Drive (I/O on drives is not supported)

EcoDrive 03

EcoDrive Cs

Kollmorgen/Danaher

ServoStar 600

SSCDYaskawa

Sigma II with TRIO SERCOS adapter

PacSci

PC840 Series

The SERCOS I/O modules that are supported include:

1 Reco Inline SERCOS node

1 Reco 02.2 SERCOS node

1 Beckhoff SERCOS node

1 Hypertherm Automation I/O SERCOS node

Note: A single Hypertherm Automation I/O node can be configured with either 1 Recoor 1 Beckhoff node. No more than one Reco or Beckhoff I/O node can be enabled.

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RECO/BeckoffI/O at Address50

Select Yes if the Indramat RECO or Bechkoff I/O module is beingused to expand the total number of I/O on the fiber optic ring.

Note: The RECO I/O will populate the general purpose I/O (bothanalog and digital) following all drive I/O.

HPR/4070 ataddress 60

Select Yes if the optional SERCOS interface for HPR/4070 is beingused.

HTA I/O at Address 70

Select Yes if the optional Hypertherm SERCOS interface card isbeing used.

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Configuring System Axes

Transverse or Rail AxisThe following screen is identical for both the traverse and rail setup.

The CNC comes with both an advanced position and velocity servo loop. The followingparameters are available to help configure the servo loops for your specific drive andmechanical system.


Speed 0 To This parameter allows the technician to input selected speed rangesto customize the gains for the various speeds selected.

Note : These speed parameters are directly tied to the Speed To fieldfor the acceleration rates previously noted on the Speeds setupscreen. Changing these speed parameters replaces the Speed Tovalues entered at the Speeds setup screen.

ProportionalGain

Proportional gain correlates to elastic stiffness in the control loop. Therange of values for this field is 1 to 500, although setting from 40 to 60are usual.

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Increase the proportional gain to increase the static stiffness, butdecrease the response of the servo loop.

Under a proportional loop control, the drive system applies a restoringtorque to the motor in proportion to the position error of the axis.Ifproportional gain too high, the system and axis become unstable.During cutting, the torch can overshoot the path. This is also called ahot control loop.

If proportional gain is too low, the system response is not precise.This can be seen in the test pattern when the outside corners becomerounded and not all the circle segments meet in the center.

Integral Gain Integral gain improves the positioning accuracy of the control loop.Integral gain can be used to compensate for static friction or gravity.Excessive integral gain can result in system instability.For most shapecutting machines, this parameter should be set to zero (0).

Derivative Gain Derivative gain helps to minimize sudden changes in velocity. Thehigher the derivative gain, the slower the response time to the controlloop. For most velocity loop drives, this parameter is set to zero (0).

FeedforwardGain

Feedforward gain can be used to drive the following error to zeroduring machine motion. In all digital control loops there is a finiteamount of error that is introduced by the velocity command.Increasing feedforward gain can reduce this introduced error.

Velocity Gain When you use a current loop amplifier, you can use the internalvelocity loop in the CNC to provide dampening without an external

tachometer.Use of the internal velocity loop with a current loop amplifier can resultin higher static stiffness, smoother machine motion, and lessovershoot.

Servo ErrorTolerance

Allows the user to program the amount of servo loop following error tobe allowed prior to displaying an error message. The parameter islimited to a maximum value of 5 inches.

EncoderCounts per inch

Enter a value that is the number of encoder edges per inch ofmachine travel. It is possible to enter fractional encoder units and theCNC will keep track of these fractions automatically. Encoder countsper inch are equal to the resolution of the encoder, multiplied by theencoder revolutions per inch or mm (based on the machine drivegearing).

For example, the resolution of a 4X 1000 line encoder counts bothedges (lines) of channel A and channel B to equal 4 counts per linemultiplied by the 1000 lines per revolution would equal 4000 counts

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per revolution. If the encoder revolutions per inch to travel are 1:1, wewould have 4000 encoder counts per inch of travel:

Encoder Counts/ Inch = 4 Counts/ Line x 1000 Lines/ Rev x 1 Rev/ Inch = 4000

Fault Ramp

Time

This parameter sets the motion deceleration time after a fault occurs.

At the end of Fault Ramp Time, The drives will be disabled.

Drive Type This parameter is used to tell the CNC what type of control loop torun. If you are running an external velocity loop drive (indicated byhaving an integrated tachometer in the motor), select Velocity. If youare running in torque mode (no tachometer), select Current.

DAC Polarity This parameter allows changing of the analog output polarity toestablish proper control loop feedback without any wiring changes.

EncoderPolarity

This parameter allows changing of the encoder input polarity toestablish proper counting for positive machine motion without anywiring changes.

EncoderDecode Mode

Currently, the CNC only supports 4X encoder decode mode. This hasbeen done to increase positional accuracy.

Use HardwareOvertravels

Select whether or not the cutting machine will be using HardwareOvertravels. If Hardware Overtravels are used, the CNC will disablefeedback and display an error message if the inputs become active. Itis recommended that Hardware Overtravels be installed.

Backlash

Compensation

The Backlash Compensation parameter is used to offset or

compensate for any backlash in the mechanics of the drive system.

Home The Home parameter is used to activate use of the Home feature.Depending on control I/O configuration, the table may be Homed toeither a designated Home Switch or an Overtravel Switch.

The Home feature is used to set a known absolute physical positionlocation on the cutting table that is used for referencing future manualGo to Home and other motion commands. This is generallyperformed through activation of a home switch positioned on theappropriate axis giving it a known physical location.

When the Homing command is entered at the control, the CNC willmove the axis towards the Home Switches at the Fast Home Speeduntil the switches have been activated. Once the switches have beenactivated, motion stops and then the axis moves in the oppositedirection off switch at the

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