Hypertherm Automation

5 Technology Drive, Suite 300

W. Lebanon, NH 03784 USA
Phone: 603-298-7970
Fax: 603-298-7977

Automation

HYPERTHERM SHAPE CUTTING CONTROL

OPERATOR AND INSTALLATION MANUAL
Software Version 8.0 for Touch Screen CNCs

July 2008
DISCLAIMER The information in this document is subject to change without notice and should not be
construed as a commitment by Hypertherm Automation. Hypertherm Automation
assumes no responsibility for any errors that appear.

TRADEMARKS Hypertherm Automation is a wholly owned subsidiary of Hypertherm, Inc.

Command, HT 4400, HD3070 HyDefinition Plasma and HD4070 HyDefinition Plasma

are registered trademarks of Hypertherm, Inc.

FASTLaser is a trademark of Hypertherm, Inc.

EDGE, HyperCAD, HyperNet, HyperNest, Phoenix, and ShapeWizard are registered

trademarks of Hypertherm Automation.

Align, APC, CutPro, Gemini, HPR130, HPR260 HyPerformance Plasma, Mariner,

Nester, Remote Help, Sensor, and Voyager are trademarks of Hypertherm Automation.

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 Microsoft
Corporation.

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.

COPYRIGHT 2008 by Hypertherm Automation. All rights Reserved

Printed in USA

ii
 Contents
Safety ............................................................................................................................................ 1
Overview ...................................................................................................................................... 9
CutPro Wizard ........................................................................................................................ 9
Align Wizard ........................................................................................................................... 9
Remote Help ........................................................................................................................... 9
ShapeWizard ........................................................................................................................... 9
Teach/Trace............................................................................................................................. 9
Shape Libraries ..................................................................................................................... 10
Program Upload and Download............................................................................................ 10
SoftMotion ............................................................................................................................ 10
Cutting Options ..................................................................................................................... 10
Programming Features .......................................................................................................... 11
Performance Features............................................................................................................ 12
Installation and Setup Features ............................................................................................. 12
Hardware Specifications ....................................................................................................... 13
Model Numbering System .................................................................................................... 13
Front Panel Layout................................................................................................................ 14
PC Keyboard Layout............................................................................................................. 17
Key and Menu Functions ...................................................................................................... 20
Numeric Keypad ................................................................................................................... 22
Help Screen ........................................................................................................................... 22
Main Screen .......................................................................................................................... 23
Shape Manager Screen .......................................................................................................... 26
Files ....................................................................................................................................... 28
Setups Screen ........................................................................................................................ 30
Change Consumable ............................................................................................................. 31
Remote Help .............................................................................................................................. 33
Install Shared View ............................................................................................................... 33
Use Remote Help .................................................................................................................. 34
Setups ......................................................................................................................................... 37
Cutting................................................................................................................................... 37
Process .................................................................................................................................. 43
Oxy Fuel................................................................................................................................ 44
Plasma ................................................................................................................................... 52
HD3070 Auto Gas Interface ................................................................................................. 56
HD4070 and HPR Overview ................................................................................................ 59
FineLine Overview ............................................................................................................... 65
Marker ................................................................................................................................... 71
Laser Overview ..................................................................................................................... 75
Laser Cut Chart Screen ......................................................................................................... 81
Water Jet ............................................................................................................................... 87
Watch .................................................................................................................................... 89

iii
Shape Manager.......................................................................................................................... 93
Shape Library ........................................................................................................................ 93
Text Editor ............................................................................................................................ 94
Shape Wizard ........................................................................................................................ 95
Teach Trace ........................................................................................................................... 97
Nester .................................................................................................................................. 102
Manual Nesting ................................................................................................................... 103
Nester Setup ........................................................................................................................ 105
Using Nester........................................................................................................................ 106
HyperNest – CNC Automatic Nesting Software ................................................................ 109
Automatic Nesting Setup .................................................................................................... 110
Using HyperNest – CNC .................................................................................................... 112
HyperCAD .......................................................................................................................... 119
HyperNEST......................................................................................................................... 121
Files........................................................................................................................................... 123
Load from Disk ................................................................................................................... 123
Resume Last Part Features .................................................................................................. 125
Save to Disk ........................................................................................................................ 126
Download from Host........................................................................................................... 129
Upload to Host .................................................................................................................... 131
Loading Invalid Files .......................................................................................................... 132
Library Shapes ........................................................................................................................ 135
Rectangle............................................................................................................................. 136
Circle ................................................................................................................................... 138
Triangle ............................................................................................................................... 140
L-Bracket ............................................................................................................................ 142
Trapezoid ............................................................................................................................ 144
Slant Rectangle ................................................................................................................... 146
Gambrel Rectangle.............................................................................................................. 148
Roofed Rectangle ................................................................................................................ 150
4-Sided Polygon .................................................................................................................. 152
5-Sided Polygon .................................................................................................................. 154
Oval ..................................................................................................................................... 156
Circle with Flat Side ........................................................................................................... 158
Circle Slice .......................................................................................................................... 160
Straight Slots ....................................................................................................................... 162
Angled Slots ........................................................................................................................ 164
Horizontal Rip..................................................................................................................... 166
Vertical Rip ......................................................................................................................... 168
Flange .................................................................................................................................. 170
Circle with Rectangular Hole.............................................................................................. 172
Gusset .................................................................................................................................. 174
8-Sided ................................................................................................................................ 176
Rectangle with Convex Corners ......................................................................................... 178
Rectangle with Concave Corners ........................................................................................ 180
L-Bracket with Elbow Radii ............................................................................................... 182

iv
 Slant L-Bracket with Elbow Radii ...................................................................................... 184
Flange Slice ......................................................................................................................... 188
Elbow .................................................................................................................................. 190
Flange Repair Ring ............................................................................................................. 192
Rectangle with Rectangular Hole ....................................................................................... 194
Rectangle with Circular Hole.............................................................................................. 196
Rectangle with Circular Hole and Convex Corners ............................................................ 198
Rectangle with Tab ............................................................................................................. 200
Rectangle with Convex Tab ................................................................................................ 202
Rectangle with Notch .......................................................................................................... 204
Concave Rectangle.............................................................................................................. 212
Triangle with Concave Side ................................................................................................ 214
Polygon with Concave Side ................................................................................................ 216
Slant Rectangle with Radius ............................................................................................... 218
Slant Rectangle with Circular Hole .................................................................................... 220
Slant Rectangle with Beveled Corners ............................................................................... 222
Cross ................................................................................................................................... 224
Cross with Circular Hole and Concave Inside Corners ...................................................... 226
4 Sided Convex Rectangle .................................................................................................. 228
4 Sided Concave Rectangle ................................................................................................ 230
Pipe Mount .......................................................................................................................... 232
Bolt Hole Circle .................................................................................................................. 234
Bolt Hole Flange ................................................................................................................. 236
Bolt Hole Rectangle ............................................................................................................ 238
Bolt Hole Rectangle with Convex Corners......................................................................... 240
Bolt Hole Rectangle with Center Hole ............................................................................... 242
Bolt Hole Rectangle with Center Hole and Convex Corners ............................................. 244
Rounded L-Bracket ............................................................................................................. 246
Horseshoe ............................................................................................................................ 248
Convex Roof Trapezoid with Hole ..................................................................................... 250
Convex Roof Polygon with Hole ........................................................................................ 252
Convex Roof Polygon with Oval Hole and Concave Bottom ............................................ 254
Pulley Cover........................................................................................................................ 256
Paddle Blind ........................................................................................................................ 258
Water Pump Gasket ............................................................................................................ 260
Frame .................................................................................................................................. 262
Pulley .................................................................................................................................. 264
Sprocket .............................................................................................................................. 266
Text ..................................................................................................................................... 268
Test Pattern ......................................................................................................................... 270
Part Options ............................................................................................................................ 271
Repeat ................................................................................................................................. 273
Align ................................................................................................................................... 276
Align Wizard ....................................................................................................................... 276
Manual Part Alignment ....................................................................................................... 277
Automatic Plate Alignment (APA) ..................................................................................... 278

v
Cut Operations ........................................................................................................................ 283
CutPro Wizard .................................................................................................................... 283
Cutting in Manual Mode ..................................................................................................... 283
Multitasking ........................................................................................................................ 287
Pause......................................................................................................................................... 289
Change Consumable ........................................................................................................... 295
Manual ..................................................................................................................................... 297
Manual Options ................................................................................................................... 303
Home Axes.......................................................................................................................... 305
Diagnostics ............................................................................................................................... 307
Control Information ............................................................................................................ 307
I/O ....................................................................................................................................... 309
Analog Input Diagnostics ................................................................................................... 312
Serial Port............................................................................................................................ 313
Drives and Motors............................................................................................................... 315
SERCOS Drives and Motors .............................................................................................. 317
Error Messages.................................................................................................................... 320
Norton Ghost Utility ........................................................................................................... 325
Password Setups ...................................................................................................................... 329
Machine............................................................................................................................... 330
SERCOS ............................................................................................................................. 333
Speeds ................................................................................................................................. 336
CBH Speed Setups .............................................................................................................. 339
THC Speed Setups .............................................................................................................. 339
Torch Height Disable .......................................................................................................... 341
Ports .................................................................................................................................... 343
I/O ....................................................................................................................................... 348
Speed Pot and Joystick Overview ....................................................................................... 350
Axes – Transverse or Rail ................................................................................................... 364
Axes -- Dual Gantry ............................................................................................................ 369
Axes -- CBH ....................................................................................................................... 372
Axes -- Rotate ..................................................................................................................... 375
Axes -- Tilt .......................................................................................................................... 376
Axes -- Transverse 2 ........................................................................................................... 377
Station Configuration .......................................................................................................... 378
Special ................................................................................................................................. 385
System Tools – Windows XP ............................................................................................. 391
Phoenix Link............................................................................................................................ 399
Overview ............................................................................................................................. 399
Files ..................................................................................................................................... 400
Settings................................................................................................................................ 402
Installation........................................................................................................................... 403
Software .............................................................................................................................. 403
Hardware ............................................................................................................................. 407
Operating Phoenix Link ...................................................................................................... 408
Common Errors ................................................................................................................... 408

vi
 Error Messages.................................................................................................................... 409
Sensor THC ............................................................................................................................. 411
Overview ............................................................................................................................. 411
Cut Setups ........................................................................................................................... 412
Plasma Setups ..................................................................................................................... 413
Marker Setups ..................................................................................................................... 417
Process Watch ..................................................................................................................... 419
Main Cut Screen ................................................................................................................. 420
Sensor THC Setups ............................................................................................................. 421
Sensor THC Axis Setups .................................................................................................... 422
THC Speeds ........................................................................................................................ 424
THC I/O .............................................................................................................................. 425
Command THC ....................................................................................................................... 429
Main Cut Screen ................................................................................................................. 433
Diagnostics .......................................................................................................................... 435
Machine Interface ............................................................................................................... 435
Motion Overview ..................................................................................................................... 437 
Closed Loop Servo Control ................................................................................................ 437 
Encoders .............................................................................................................................. 438 
Encoder Counts and Maximum Machine Speed ................................................................. 440 
Motion Tuning Watch Windows ........................................................................................ 445 
SERCOS Interface Overview ............................................................................................. 447 
ASCII Codes ............................................................................................................................ 449
0BProgram Codes ........................................................................................................................ 451
1BEIA RS-274D ...................................................................................................................... 451
2BESSI .................................................................................................................................... 459
3BAdvanced Feature Codes ................................................................................................... 463
4BStation Selects ..................................................................................................................... 464
5BAutomatic Torch Spacing ................................................................................................... 465
6BSensor THC Part Program Support ..................................................................................... 468
7BSubparts............................................................................................................................... 469
8BMarker Font Generator ....................................................................................................... 471
9BSerial Messaging ................................................................................................................. 475
Automated Plasma Interface ................................................................................................. 485
HPR and HD4070 Interface ................................................................................................ 485
Cut Charts ........................................................................................................................... 486
Custom Cut Charts .............................................................................................................. 490
Change Consumable ........................................................................................................... 493
HD4070 Diagnostics ........................................................................................................... 494
HPR Diagnostics ................................................................................................................. 495
HD3070 Auto Gas Interface ............................................................................................... 504
FineLine Overview ............................................................................................................. 507
Serial Ports .............................................................................................................................. 515
Control RS-232C DB-9 Pinout ........................................................................................... 515
RS-232C Connections to Host PC with 9-pin D-type connector........................................ 516
RS-232C Connections to Host PC with 25-pin D-type connector ...................................... 516

vii
Automatic DXF Import .......................................................................................................... 517
Overview ............................................................................................................................. 517
Load DXF Files................................................................................................................... 517
Raw DXF Files ................................................................................................................... 518
Prepared DXF Files............................................................................................................. 520
Networking .............................................................................................................................. 523
Network Operating System ................................................................................................. 523
Configuring the Network Interface Card ............................................................................ 523
Connecting the CNC to a Network ..................................................................................... 524
Mapping a Connection to a Network Share ........................................................................ 524
Connecting the CNC to a Workgroup ................................................................................. 527
Hardware Considerations .................................................................................................... 529
MicroEdge ............................................................................................................................... 535
Overview ............................................................................................................................. 535
Keyboard Layout ................................................................................................................ 536
System Requirements.......................................................................................................... 536
Machine Interface ............................................................................................................... 537
I/O Configuration ................................................................................................................ 538
I/O Interface ........................................................................................................................ 539
THC and Joystick Interface ................................................................................................ 544
Calibration........................................................................................................................... 548
Edge Ti ..................................................................................................................................... 549
Overview ............................................................................................................................. 549
Machine Interface ............................................................................................................... 550
I/O Configuration ................................................................................................................ 551
I/O Interface ........................................................................................................................ 552
Lifter Interface .................................................................................................................... 555
Plasma Interface .................................................................................................................. 556
External Interlock................................................................................................................ 557
Voyager III .............................................................................................................................. 561
Overview ............................................................................................................................. 561
Setups .................................................................................................................................. 563
Common Status Messages .................................................................................................. 564
Machine Interface ............................................................................................................... 565
SERCOS to Analog Conversion Card ................................................................................ 570
Mariner .................................................................................................................................... 573
Overview ............................................................................................................................. 573
Touch Screen ...................................................................................................................... 573
THC, Joystick and Speedpots ............................................................................................. 573
AC Input Pinout .................................................................................................................. 574
E-Stop ................................................................................................................................. 574
Diagram Location Din-02 ................................................................................................... 574
SERCOS Motion and I/O.................................................................................................... 574

viii
  
 

Safety
Product Listings
MicroEdge and Voyager III
 

Note: This product has been designed and manufactured in accordance with CE and UL Safety
Standards.
UL has successfully tested and listed these products in accordance with the applicable U.S. and
Canadian Safety Standards. File number E178333. Note: Suitable for pollution degree 2
environment only.
This appliance has been successfully tested and listed by CE under the following standards; EN
500081-2 1994, EN 61000-6-2 1999, and EN 55011:1998. Certificate number: Retlif R-3909N
Edge TI

Note: This product has been designed and manufactured in accordance with CE and UL Safety
Standards.
UL has successfully tested and listed these products in accordance with the applicable U.S. and
Canadian Safety Standards. File number E307226.
Additional markings:
1. Use minimum 75° C copper wire only.
2. Use copper conductors only.
3. Suitable for use on a circuit capable of delivering not more than 5000rms symmetrical
amperes, 230 volts maximum.
4. Solid state motor overload protection is not provided on this device.
5. Integral solid state short circuit protection does not provide branch circuit protection.
Branch circuit protection provided by integral LISTED branch circuit protection fuse.

This appliance has been successfully tested and listed by CE under the following standards; EN 500081-
2 1994, EN 61000-6-2 1999, and EN 55011:1998. Certificate number: Retlif R-3909N
Please contact Hypertherm Automation for further safety listing information.

1 
 
2 Safety

RECOGNIZE SAFETY INFORMATION • Keep your machine in proper working condition.

Unauthorized modifications to the machine may
The symbols shown in this section are used to affect safety and machine service life.
identify potential hazards. When you see a safety
symbol in this manual or on your machine, understand
the potential for personal injury, and follow the related
instructions to avoid the hazard. DANGER WARNING CAUTION

A signal word DANGER or WARNING is used with a

FOLLOW SAFETY INSTRUCTIONS safety symbol. DANGER identifies the most serious
hazards.

Read carefully all safety messages in this manual and • DANGER and WARNING safety labels are located
safety labels on your machine. on your machine near specific hazards.
• WARNING safety messages precede related
• Keep the safety labels on your machine in good
instructions in this manual that may result in injury
condition. Replace missing or damaged labels
or death if not followed correctly.
immediately.
• CAUTION safety messages precede related
• Learn how to operate the machine and how to use
instructions in this manual that may result in
the controls properly. Do not let anyone operate it
damage to equipment if not followed correctly.
without instruction.

CUTTING CAN CAUSE FIRE OR EXPLOSION

Fire Prevention WARNING

• Be sure the area is safe before doing any cutting. Explosion Hazard
Keep a fire extinguisher nearby. Argon-Hydrogen and Methane
• Remove all flammables within 35 feet (10 m) of the
cutting area. Hydrogen and methane are flammable gases that
• Quench hot metal or allow it to cool before handling present an explosion hazard. Keep flames away from
or before letting it touch combustible materials. cylinders and hoses that contain methane or hydrogen
• Never cut containers with potentially flammable mixtures. Keep flames and sparks away from the torch
materials inside – they must be emptied and when using methane or argon-hydrogen plasma.
properly cleaned first.
• Ventilate potentially flammable atmospheres before
cutting. WARNING
• When cutting with oxygen as the plasma gas, an Hydrogen Detonation with Aluminum Cutting
exhaust ventilation system is required.
• When cutting aluminum underwater, or with the
Explosion Prevention water touching the underside of the aluminum, free
• Do not use the plasma system if explosive dust or hydrogen gas may collect under the workpiece and
vapors may be present. detonate during plasma cutting operations.
• Do not cut pressurized cylinders, pipes, or any • Install an aeration manifold on the floor of the water
closed container. table to eliminate the possibility of hydrogen
• Do not cut containers that have held combustible detonation. Refer to the Appendix section of this
materials. manual for aeration manifold details.
Safety 3

ELECTRIC SHOCK CAN KILL

Touching live electrical parts can cause a fatal shock • Install and ground this equipment according to the
or severe burn. instruction manual and in accordance with national
and local codes.
• Operating the plasma system completes an
• Inspect the input power cord frequently for damage
electrical circuit between the torch and the
or cracking of the cover. Replace a damaged power
workpiece. The workpiece and anything touching
cord immediately. Bare wiring can kill.
the workpiece are part of the electrical circuit.
• Inspect and replace any worn or damaged torch
• Never touch the torch body, workpiece or the water
leads.
in a water table when the plasma system is
• Do not pick up the workpiece, including the waste
operating.
cutoff, while you cut. Leave the workpiece in place
or on the workbench with the work cable attached
Electric Shock Prevention
during the cutting process.
All Hypertherm plasma systems use high voltage • Before checking, cleaning or changing torch parts,
in the cutting process (200 to 400 VDC are disconnect the main power or unplug the power
common). Take the following precautions when supply.
operating this system: • Never bypass or shortcut the safety interlocks.
• Wear insulated gloves and boots, and keep your • Before removing any power supply or system
body and clothing dry. enclosure cover, disconnect electrical input power.
• Do not stand, sit or lie on – or touch – any wet Wait 5 minutes after disconnecting the main power
surface when using the plasma system. to allow capacitors to discharge.
• Insulate yourself from work and ground using dry • Never operate the plasma system unless the power
insulating mats or covers big enough to prevent any supply covers are in place. Exposed power supply
physical contact with the work or ground. If you must connections present a severe electrical hazard.
work in or near a damp area, use extreme caution. • When making input connections, attach proper
• Provide a disconnect switch close to the power grounding conductor first.
supply with properly sized fuses. This switch allows • Each Hypertherm plasma system is designed to be
the operator to turn off the power supply quickly in used only with specific Hypertherm torches. Do not
an emergency situation. substitute other torches which could overheat and
• When using a water table, be sure that it is correctly present a safety hazard.
connected to earth ground.

STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS

• Store PC boards in anti-static containers.

Use proper precautions when handling printed
circuit boards. • Wear a grounded wrist strap when handling
PC boards.
4 Safety

TOXIC FUMES CAN CAUSE INJURY OR DEATH

The plasma arc by itself is the heat source used for The air quality level in any relevant workplace
cutting. Accordingly, although the plasma arc has not depends on site-specific variables such as:
been identified as a source of toxic fumes, the • Table design (wet, dry, underwater).
material being cut can be a source of toxic fumes or • Material composition, surface finish, and
gases that deplete oxygen. composition of coatings.
• Volume of material removed.
Fumes produced vary depending on the metal that is
cut. Metals that may release toxic fumes include, but • Duration of cutting or gouging.
are not limited to, stainless steel, carbon steel, zinc • Size, air volume, ventilation and filtration of the
(galvanized), and copper. work area.
• Personal protective equipment.
In some cases, the metal may be coated with a • Number of welding and cutting systems in
substance that could release toxic fumes. Toxic operation.
coatings include, but are not limited to, lead (in some • Other site processes that may produce fumes.
paints), cadmium (in some paints and fillers), and
beryllium. If the workplace must conform to national or local
regulations, only monitoring or testing done at the site
Gases produced by plasma cutting vary based on the can determine whether the site is above or below
material to be cut and the method of cutting, but may allowable levels.
include ozone, oxides of nitrogen, hexavalent
chromium, hydrogen, and other substances if such To reduce the risk of exposure to fumes:
are contained in or released by the material being cut. • Remove all coatings and solvents from the metal
before cutting.
Caution should be taken to minimize exposure to • Use local exhaust ventilation to remove fumes from
fumes produced by any industrial process. Depending the air.
upon the chemical composition and concentration of
• Do not inhale fumes. Wear an air-supplied
the fumes (as well as other factors, such as
respirator when cutting any metal coated with,
ventilation), there may be a risk of physical illness,
containing, or suspected to contain toxic elements.
such as birth defects or cancer.
• Assure that those using welding or cutting
It is the responsibility of the equipment and site owner equipment, as well as air-supplied respiration
to test the air quality in the area where the equipment devices, are qualified and trained in the proper use
is used and to ensure that the air quality in the of such equipment.
workplace meets all local and national standards • Never cut containers with potentially toxic materials
and regulations. inside. 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.
Safety 5

A PLASMA ARC CAN CAUSE INJURY AND BURNS

Instant-On Torches The plasma arc will cut quickly through gloves and
Plasma arc comes on immediately when the torch skin.
switch is activated. • Keep away from the torch tip.
• Do not hold metal near the cutting path.
• Never point the torch toward yourself or others.

ARC RAYS CAN BURN EYES AND SKIN

Eye Protection Plasma arc rays produce intense Skin Protection Wear protective clothing to protect
visible and invisible (ultraviolet and infrared) rays that against burns caused by ultraviolet light, sparks and
can burn eyes and skin. hot metal.
• Use eye protection in accordance with applicable • Gauntlet gloves, safety shoes and hat.
national or local codes. • Flame-retardant clothing to cover all exposed areas.
• Wear eye protection (safety glasses or goggles with • Cuffless trousers to prevent entry of sparks and
side shields, and a welding helmet) with appropriate slag.
lens shading to protect your eyes from the arcʼs • Remove any combustibles, such as a butane lighter
ultraviolet and infrared rays. or matches, from your pockets before cutting.

Lens Shade Cutting Area Prepare the cutting area to reduce

Arc Current AWS (USA) ISO 4850 reflection and transmission of ultraviolet light:
Up to 100 A No. 8 No. 11 • Paint walls and other surfaces with dark colors to
100-200 A No. 10 No. 11-12 reduce reflection.
200-400 A No. 12 No. 13 • Use protective screens or barriers to protect others
Over 400 A No. 14 No. 14 from flash and glare.
• Warn others not to watch the arc. Use placards or
signs.

GROUNDING SAFETY Input Power

• Be sure to connect the power cord ground wire to
the ground in the disconnect box.
Work Cable Attach the work cable securely to the • If installation of the plasma system involves
workpiece or the work table with good metal-to-metal connecting the power cord to the power supply, be
contact. Do not connect it to the piece that will fall sure to connect the power cord ground wire
away when the cut is complete. properly.
• Place the power cord's ground wire on the stud first,
Work Table Connect the work table to an earth then place any other ground wires on top of the
ground, in accordance with appropriate national or power cord ground. Fasten the retaining nut tightly.
local electrical codes. • Tighten all electrical connections to avoid excessive
heating.
6 Safety

COMPRESSED GAS EQUIPMENT SAFETY GAS CYLINDERS CAN

EXPLODE IF DAMAGED
• Never lubricate cylinder valves or regulators with oil
or grease. Gas cylinders contain gas under high pressure. If
• Use only correct gas cylinders, regulators, hoses damaged, a cylinder can explode.
and fittings designed for the specific application. • Handle and use compressed gas cylinders in
• Maintain all compressed gas equipment and accordance with applicable national or local codes.
associated parts in good condition. • Never use a cylinder that is not upright and secured
• Label and color-code all gas hoses to identify the in place.
type of gas in each hose. Consult applicable • Keep the protective cap in place over valve except
national or local codes. 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.

NOISE CAN DAMAGE HEARING PACEMAKER AND HEARING

AID OPERATION

Pacemaker and hearing aid operation can be affected

Prolonged exposure to noise from cutting or gouging
by magnetic fields from high currents.
can damage hearing.
Pacemaker and hearing aid wearers should consult a
• Use approved ear protection when using plasma
doctor before going near any plasma arc cutting and
system.
gouging operations.
• Warn others nearby about the noise hazard.
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
A PLASMA ARC CAN work cable.
DAMAGE FROZEN PIPES • Do not wrap or drape the torch lead or work cable
around your body.
• Keep as far away from the power supply as
Frozen pipes may be damaged or can burst if you possible.
attempt to thaw them with a plasma torch.

ADDITIONAL SAFETY INFORMATION 5. AWS F5.2, Recommended Safe Practices for Plasma Arc
Cutting, American Welding Society
1. ANSI Standard Z49.1, Safety in Welding and Cutting, American 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135
Welding Society, 550 LeJeune Road 6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in
P.O. Box 351020, Miami, FL 33135 Cylinders, Compressed Gas Association
2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and 1235 Jefferson Davis Highway, Arlington, VA 22202
Welding Processes, American National Standards Institute 7. CSA Standard W117.2, Code for Safety in Welding and Cutting,
1430 Broadway, New York, NY 10018 Canadian Standards Association Standard Sales
3. ANSI Standard Z87.1, Safe Practices for Occupation and 178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada
Educational Eye and Face Protection, American National 8. NFPA Standard 51B, Cutting and Welding Processes, National
Standards Institute, 1430 Broadway, New York, NY 10018 Fire Protection Association
4. AWS F4.1, Recommended Safe Practices for the Preparation for 470 Atlantic Avenue, Boston, MA 02210
Welding and Cutting of Containers and Piping That Have Held 9. NFPA Standard 70–1978, National Electrical Code, National Fire
Hazardous Substances, American Welding Society Protection Association, 470 Atlantic Avenue, Boston, MA 02210
550 LeJeune Road, P.O. Box 351040, Miami, FL 33135 10. OSHA, Safety and Health Standards, 29FR 1910
U.S. Government Printing Office, Washington, D.C. 20402
Safety 7

WARNING LABEL 1. Cutting sparks can cause explosion or fire.

This warning label is affixed to some power supplies. It is
1.1 Keep flammables away from cutting.
important that the operator and maintenance technician
understand the intent of these warning symbols as described.
1.2 Keep a fire extinguisher nearby, and have
The numbered text corresponds to the numbered boxes on a watchperson ready to use it.
the label.
1.3 Do not cut on any closed containers.

2. The plasma arc can cause injury and

burns.

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 or

damaged gloves.

3.2 Insulate yourself from work and ground.

3.3 Disconnect input plug or power before

working on machine.

4. Breathing cutting fumes can be hazardous

to 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 ear

protection and button shirt collar. Use
welding helmet with correct shade of filter.
Wear complete body protection.

6. Become trained and read the instructions

before working on the machine or cutting.
110647 Rev. A
www.hypertherm.com/weee 7. Do not remove or paint over (cover)
warning labels.
8 Safety
Overview
The following sections highlight the features of the Hypertherm Automation CNC and version
8.0 of the Phoenix® software.

CutPro Wizard
The CutPro™ wizard is an interactive tool that simplifies the steps of cutting a part. The CutPro
wizard helps you:

• Load a part program

• Select a cut process
• Align a plate and adjust for skew
• Set scrap clearance
• Select cut mode
• Start the cut directly from the wizard or by pressing the green Start button on the console

The wizard opens automatically from the Main screen after 10 seconds. Automatic activation
can be disabled on the Special password setup screen. However, the wizard is always
accessible by pressing the CutPro Wizard soft key on the Main screen.

Align Wizard
The Align™ wizard is an interactive tool that guides you through the process of aligning a plate
and adjusting for a skewed plate. This wizard can be accessed from the CutPro Wizard or from
the Align screen.

Remote Help
The Remote Help™ facility is an easy-to-use and reliable means of remotely connecting the
Hypertherm Automation CNC to up to 15 users for:

• Observing an operator at the machine

• Reviewing settings and software configurations
• Transferring setup files, part programs, software updates, etc.
• Performing HPR diagnostics
• Training users

ShapeWizard
The ShapeWizard® tool allows you to graphically create simple part programs and store them
on the internal hard disk present in the control.

Teach/Trace

9
Overview

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

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

Program Upload and Download

Communication is an integral part of today’s fabricating shop. All part programs that have
been entered in the control can be uploaded to a remote computer or file server with an
integrated RS-232C/ RS-422 communications link. CAD generated programs can be
downloaded at baud rates of up to 115K baud and visually previewed on the color LCD display.
Visual representation of part programs, along with full alpha-numeric file name support, gives
you the flexibility to manage your data as you see fit. Use of the optional Network Card allows
us to bring the latest in communication technology for increased speed and productivity to your
shape cutting controller. Additionally, built-in Control monitoring features allow current
operational status to be displayed at the host Link screen.

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

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

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

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

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

Repeat function

10
 Overview

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

Programming Features
• English and metric operation for worldwide use. Each axis can have its own encoder-to-
unit edge rate.
• Dynamic kerf compensation with programmable kerf value.
• Automatic corner and plate alignment with programmable scrap clearance.
• Shape Repeat with three grid patterns (straight, stagger, and nested) allows fast cutting of
multiple pieces.
• Part mirroring in both X and Y axes.
• Part rotation.
• Scaling allows quick part resizing to original size.
• Virtually no limit to the number of program names or work file folders that can be stored on
the internal hard disk drive.
• Punch or powder marker control with twelve programmable offsets.
• Choice of industry-standard EIA RS-274D or ISO 6582 ESSI part programming languages.

Manual Data Input (MDI)

• Full screen ASCII text editor.
• Allows writing, editing, and graphical review of part programs at the machine.

Communications Link
• Preview Mode allows machine operator to graphically review and select programs for
download.
• Download part programs from CAD system, remote host computer, or other storage device
via built-in RS-232C/ RS-422 port.
• Can accept EIA RS-274D or ESSI part programs.
• Baud Rates of up to 115K Baud. Communication baud rates of 230K are obtainable using
the communication link software provided with the control.
• Optional network card for connecting directly to a PC Network for part file allocation.

Graphical program display

• Visually display any part program.
• Display of real-time position and I/O information.
• Display of actual cut path while cutting.

Built-in Parametric Shape Library

• Contains 68 commonly used shapes.
• Simple Graphical prompts for entering all part dimensions.

11
Overview

Teach/Trace
• Smart-arc and Smart-Line algorithms for optimum program size and contouring
smoothness.
• Converts your existing optical tracer templates to EIA RS-274D programs, and stored on
the internal hard disk drive.
• Automatic part closure detection.
• Allows multiple pierce points, lead-ins, lead-outs, and rapid traverse segments.
• Upload taught part programs to CAD system, remote host computer, or other storage
device.
• Requires a separate optical tracer control system.

Performance Features
• Digital servo positioning control for any cutting machine. An optional SERCOS Interface
allows expansion of motion axes and distributed I/O.
• Control dynamic accuracy of 0.002 inch (0.051 mm) with 1000 edge/inch encoders.
• Programmable cut speeds up to 3000 IPM (76,200 mmpm).
• Variable segment length look-ahead for optimum contouring performance.
• Automatic corner slowdown and torch height disable for clean, sharp corners.
• Speed Increase/Decrease buttons for optimizing machine cut speed.
• Automatic Plate and Corner Alignment corrects for skewed plates.
• Complete cut-loss recovery with backup and forward along path, off-path re-pierce and
return-to-path, and move pattern functions.
• Rip Mode for straight-line cutting. Jog control cutting.
• Punch, powder or Plasma marker capability.
• Manual jog control with position read-out for positioning torches.
• Nester™ and optional HyperNest® – CNC Automatic Nesting features for increased
productivity and increased plate utilization.
• Automated Torch Spacing feature to position torch station spacing automatically through
the part program for standard and mirrored multi-torch cutting.
• Rush Job Interrupt and Automated Power Loss Recovery features.

Installation and Setup Features

• Selectable axis orientation for compatibility with all cutting machines.
• Built in oxy-fuel interface with programmable pre-heat time, ignition, and creep speed.
• Built in plasma interface with programmable purge time, ignition time, arc-off delay time,
and arc-transferred feedback.
• Built in Laser interface with programmable shutter time, power ramp time and pierce time.
• Built in Water Jet interface with programmable abrasive output and pierce time.

12
 Overview

• Programmable servo gains, speeds, Watch Window, machine parameters, and com-
munication parameters for flexible application.
• Interfaces easily to most optical tracing systems for integrated control.
• Complete built-in diagnostics for checkout and test.

Hardware Specifications
• 15” TFT Touch Screen with 1024 x 768 resolution.
• ≥60Gbyte hard disk
• ≥1.3 GHz Processor.
• 512 Mbytes of RAM.
• Up to 96 lines of interface signals for cutting and motion logic (gas control, tracing system,
markers, homing, etc.) depending on I/O configuration. An optional SERCOS Interface™
allows expansion of I/O configuration.
• Industrial grade enclosure and keypad designed to minimize RFI/EMI interference.
• Surface mount printed circuit board technology.
• Two axes optically isolated ±10VDC drive outputs and incremental encoder inputs which
are expandable to 6 axes of motion. Up to twelve axes of motion and 1024 I/O available
with optional SERCOS Interface. Optional axes available for dual gantry, dual transverse,
contoured bevel head, two rotate, two tilt angle and eight Sensor™ THC applications..
• +5VDC single ended or differential encoder inputs.
• Optically isolated serial ports with programmable baud rates to 115 K baud.
Communication baud rates of 230K are obtainable using the communication link software
provided with the control. Optional Network Card for connecting directly to a PC Network.
• Universal power input (100-240 VAC; 47-63Hz). Individual models may vary. Refer to
machine interface information for details.
• Operating environment: 0 to 50°C (32 to 122°F); 95% relative humidity (non-condensing).
• An optional Chiller for Mariner style controls is available.

Model Numbering System

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

13
Overview

H - - -
Axis Configuration Operating System
2 = 2 Servo Axes 0 = Windows 95 / 98
3 = 3 Servo Axes 1 = Windows NT
4 = 4 Servo Axes 2 = Windows XP
5 = 5 Servo Axes
6 = 6 Servo Axes APC
7 = 7 Servo Axes 0 = None
8 = 8 Servo Axes 1 = Laser
9 = 9 Servo Axes 2 = Plasma
A = 10 Servo Axes
B = 11 Servo Axes THC
C = 12 Servo Axes
0 = None
S = Sercos
1 = 1 THC
2 = 2 THC's
I / O Configuration
B = Burny 3 / 5 Speed Pots
M = MicroPath
0 = None
P = PicoPath
1 = 1 Speed Pot
V = Voyager
2 = 2 Speed Pots
S = Sercos
D = Edge Ti - DC amps
Joystick
Power Supplies 0 = None
1 = Joystick
0 = Standard Logic Supply
2 = Standard Logic Supply & Backup Hard Drive
Auxiliary Supply with
0 = None
+5, +/-12 & +24 vdc
1 = Installed
Pointing Device Processor
0 = None
0 = 166 MHz
1 = Industrial Mouse Memory 1 = 200 MHz
0 = 16 MBytes 2 = 266 MHz
LCD Type 1 = 32 MBytes 3 = 433 MHz
X = None 2 = 64 MBytes 4 = 566 MHz
0 = 10.4" Dual Scan DSTN 3 = 128 MBytes 5 = 1.2 GHz
1 = 10.4" Active Matrix TFT 4 = 256 MBytes 6 = 2.4 GHz
2 = 15" Active Matrix TFT 5 = 512 MBytes 7 = 3.06 GHz
3 = 15" Touch Screen 8 = 1.3 GHz M
4 = 12.1" Active Matrix TFT

Front Panel Layout

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

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

Touch Screen

14
 Overview

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

Front Panel (selected models)

ICON Legend

Emergency Stop

Start

Stop

Forward and Backward on Path

Torch Up / Down

Manual

Speed Pot (Manual Feedrate)

Front Panel Keypad (Voyager III model)

The yellow key labeled with a question mark (?) is for online documentation and help. Simply
press this key at any time and this document will be displayed.

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

The two keys in the center of the keypad are for program start and stop.

15
Overview

The two keys to the right of the yellow help key are for Forward on Path and Backup on Path
while in the Pause screen.

Key Functions

The alpha–numeric keypad is used to enter numeric data or

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

An alternate (ALT) soft key indicates that more

soft keys and features are available by pressing
this soft key on screen.

When the alternate soft key is displayed, the

purple shift can also be used to view additional
soft keys.

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

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

16
 Overview

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

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

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

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

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

17
Overview

Keyboard Functions

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

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

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

18
 Overview

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

Screen Hierarchy
Main Screen

Files Cut Chart Part Options Cut

Load from Disk Change Consumable Repeat Pause

Save to Disk Manual Options Align Change Consumable

Save Log to Disk Manual Manual Options Manual Options

Download from Host Manual Options

Upload to Host Home Axes

Setups

Cut Types Diagnostics Password 1 Cutting

Oxy Fuel Control Information Machine Watch

Timing Diagram I/O Speeds Password 3

Water Jet Inputs Link Station Configuration

Timing Diagram Outputs I/O Password 2

Plasma Analog Inputs Sercos System Tools

Timing Diagram Oscilloscope Axes Backup Hard Drive

Cut Chart Serial Port Transverse Scan Hard Disk

Marker Drives and Motors Rail Defrag Hard Disk

Timing Diagram Plasma System Dual Gantry Format Floppy Disk

Cut Chart Inputs CBH Network Tools

Laser Outputs Tilt Remote Assistant

Timing Diagram Supply Information Rotate

Cut Chart THC

Process Monitoring Lens

Shape Manager

Shape Library Nester Shape Wizard Text Editor

Simple Shape Nester Setups Part Options Teach Trace

View Text Load from Disk Repeat HyperCAD

Part Options Download from Host Align HyperNest

Repeat Shape Library Manual Options

Align Simple Shape

Manual Options

19
Overview

Key and Menu Functions

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

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

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

The touch screen software interface allows direct key input on the screen through the use of
check boxes, radio boxes, dropdown lists and data input.

20
 Overview

Dropdown List
Press the arrow in the dropdown list to view options.

Radio Buttons
Press the round button to select the corresponding option.

Check Box
Press the square box to enable the corresponding option.

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

Alpha Numeric Keypad

21
Overview

Numeric Keypad

Help Screen

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

22
 Overview

Show Bookmarks
Press the Show Bookmarks soft key on the Help screen to view the list of Help topics. Click on
a topic for additional information.

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

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

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

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

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

23
Overview

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

Setups
This soft key takes you to the setup screens.

View Part/View Sheet

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

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

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

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

24
 Overview

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

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

Change Cut Mode

Allows selection of trial, oxy fuel, plasma, water jet and laser cutting modes, depending on the
setup configuration.

Change Consumable
This soft key takes you to the Change Consumable screen.

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

25
Overview

Shape Manager Screen

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

Shape Library
Displays the built-in library of 68 simple shapes.

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

Shape Wizard
Displays the ShapeWizard® a graphical editor window. ShapeWizard allows direct editing of
the selected part program using an easy to use graphical interface to view changes as they are
made.

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

26
 Overview

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

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

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

HyperNEST
The optional HyperNEST feature is a full featured, automatic true shape application designed to
allow quick and simple nesting of profiles onto standard material sizes. With its advanced
Graphical User Interface, HyperNEST greatly improves the output of any shape cutting
operation.

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

To launch the trial software, select the Evaluation Version.

27
Overview

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

Load from Disk

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

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

Download from Host

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

Upload to Host
Allows programs from the internal disk drives to be uploaded to a host computer via the
selected RS-232C/RS-422 serial port.

Resume Last Part

The Resume Last Part soft key will be visible when the Rush Job Interrupt or Automated Power
Loss Recovery feature is in use. These features allow the user to pause the current part program

28
 Overview

and retain the part and current position information. This then allows the user to load and
execute another part program and return to the original part using the Resume Last Part soft
key.

Note: Controllers with SERCOS interface will save position information every minute to the
hard drive. Some motion on path may be required for power or position loss recovery.

Show Certain Files

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

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

Show All Files

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

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

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

Cutting
Allows programming of the different cutting parameters and dwell times.

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

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

Watch
Allows programming of the user definable Watch Window.

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

Diagnostics
Opens the diagnostics menu.

Change to Metric Units/English Units

Changes all parameters over to metric units or English units.

29
Overview

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

New Torch Tip

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

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

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

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

Setups
Press this key to access the control setups for adjustment of the cut process.

Upload Database

30
 Overview

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

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

31
Remote Help
Remote Help allows up to 15 computers or CNCs to be connected in a single internet
session, in which local touch screen, mouse, and keyboard control, as well as screens,
files, and chat information can be passed between all 15 members.

Remote Help insures system security by using a secure connection to the central
SharedView service. If firewall protections require it, SharedView can also use secure
https. In addition, only screen data is shared so viruses cannot be transmitted during
sessions. However, if a session takes advantage of the Handouts feature to share files,
virus protection software should be installed on the CNC.

Some applications for Remote Help are:

• Observe an operator using the machine
• Review settings and setups
• Transmit setup files, part programs, software updates, etc.
• Perform HPR diagnostics
• Train operators on new features
• Use a chat window to discuss features or issues

System Requirements for Remote Help:

• Phoenix Version 6.00.6, 7.50.3, 8.00.0, or higher
• Microsoft SharedView on the user CNC and OEM PC
• Internet connection to the CNC at the end-user site
• Internet connection at OEM remote helper site
• Microsoft SharedView on the user CNC and OEM PC

Install Shared View

To install SharedView on a CNC:

1. Press Remote Help.
2. Press Yes to indicate that you want Remote Help.
3. Press Yes to download SharedView.
4. On the Microsoft website, press the Shared View download field.
5. Press Run on the Free Download popup window.
6. Press Run on the Internet Explorer Security Warning popup.
7. Select Accept on the SharedView Service Agreement and press Next.
8. Remove all checks from the boxes on the SharedView setup window and press
Install.
9. Press Finish after the setup is complete.
10. Close the Internet Explorer window after SharedView is intalled.

33
Remote Help

To install SharedView on a PC:

1. Enter the following URL in your browser’s Address field:
http://www.sharedview.com.
2. On the Microsoft website, press the Shared View download field.
3. Press Run on the Free Download popup window.
4. Press Run on the Internet Explorer Security Warning popup.
5. Select Accept on the SharedView Service Agreement and press Next.
6. Remove all checks from the boxes on the SharedView setup window and press
Install.
7. Press Finish after the setup is complete.

Use Remote Help

Before you launch Remote Help, send an email to the remote helper to request a Remote
Help session. Include the email address of all participants.

To use Remote Help from the console or PC:

Step Operator Remote Helper
1 At the CNC, press the Remote Help
button on the Main screen.
At a PC, launch SharedView using
Windows.
2 Click or press Yes on the message
popup that asks if you need Remote
Help
3 Click or press Yes to use the on-screen
keyboard. This is helpful for users at a
CNC who have no keyboard.
4 Insert your Windows Live ID email and
password. Click Sign In.

Tip: Set up a few hotmail email

accounts to use with Remote Help.
5 Click on Start a new session.
6 Send the session name and the
password to all participants (up to 15).
Click Start.
7 Press or click Join a session.
8 Enter the session name and password
from the Remote Helper.
9 When the session is created, click or
press Join Now.
10 Click Share.
11 Click Share Entire Desktop to share the
CNC with the Remote Helper.

34
 Remote Help

Note: If a participant’s CNC or PC

does not have the latest version of
SharedView, an upgrade message pops
up and the user can upgrade.
12 Click Request Control.
13 Click or press Allow on the message
popup.
Note: If the user clicks anywhere on
the screen after this step, the Remote
Helper loses control and must request it
again.
14 Click or press the message field at the top of the SharedView screen to enter text
messages to other participants.

15 To share files, click or press on Handouts and add or download a handout.

Note: This is the only way a virus can be transmitted during a Remote Help
session. Install virus protection on the CNC if you plan to transmit files using the
Handouts feature.
16 To end a session, click Close this
session.

Notes:
• The remote helper is not allowed to perform control motion unless the control is in
forced simulation mode or is a demo version of software running on a desktop.
However, the remote helper can view motion that is controlled by the user.
• If a user loses the on-screen keyboard:
1. Press Remote Help.
2. Press Yes to use the same session.
3. Press Yes to use the on-screen keyboard.

35
Remote Help

36
Setups
On the Setup screen, you make the selections that determine how you are going to cut.

Cutting
If you press the Cutting soft key, you can adjust the parameters for the cut mode you
want to use. The available modes are:
• Trial (no cutting)
• Oxy-Fuel
• Plasma
• Laser
• Water jet

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

37
Setups

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

Kerf Variable / Kerf Value

Creates a kerf variable table that assigns a variable to a Kerf value. Up to 200 variables
can be entered to create a reference table.
This kerf variable can be used within a part program to define the kerf value and as torch
parts wear, the kerf value changes. If the kerf variable value is updated as the
consumable wears and changes, the new value will be called by the kerf variable
command with all programs loaded that use the variable.
The EIA-274D part code for left kerf variable is the G43 code.

Example: G43 D1 X0.06

Kerf Variable Setting

Kerf Variable
A number from 1-200 can be used

Kerf Data
The selected kerf value

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

Marker 1 / Marker 2 Speed

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

Plate Size
Specifies the dimensions of the current plate. This dimension is used when loading a part
to determine if it will fit on the plate. It is also used for viewing the part in screen view.

Vent Controls 1 - 50
Enter values for up to fifty programmable zones for fume extraction damper control.
Based on the machine position, the vent control outputs to activate dampers at the
selected zone for increased performance.

38
 Setups

Marker Offsets 1 - 12
Enter values for up to twelve programmable marker offsets. The machine is offset by this
amount at maximum speed when the appropriate marker code is detected.

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

Arc Radial Error

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

Dwell Override
When this parameter is enabled, embedded dwell G04 X value codes in an RS-274D
program override the operator-entered dwell time.

Optional Program Stop

Allows overriding of the optional program stop code M01 in the current part program. If
enabled, an M01 code operates identically to M00. If disabled, the M01 code is ignored.

EIA I & J Codes

Selects absolute or incremental RS-274D programming mode. In incremental mode, all
offsets for X, Y, I and J are relative to the current block. In absolute mode, all offsets for
X, Y, I and J are relative to an absolute reference point unless they are changed by using
a G92 (set axis presets) program code.

EIA F-Code Override

When this parameter is enabled, embedded F-codes in an RS-274D program override any
operator-entered cut speed.

Speed +/- Affects F-Codes

When this parameter is enabled, the control applies the speed increase/decrease
percentage to all embedded F-codes that are encountered in the part program.

EIA Decimal Shift

Some programming styles are structured so that the decimal point in the EIA positioning
affecting part sizing is assumed. The EIA decimal shift parameter allows the operator to
select the location of the decimal point when translating parts by selecting normal or
single for the correct translation. The selection should be set to Normal unless your part
programs have only a single digit to the right of the decimal point.

39
Setups

Process Select Override

When enabled, this feature allows the part program to override the process select input.

Station Select Override

When enabled, this feature allows the part program to override the currently selected
station select input.

Auto Torch Spacing Override

When enabled, this feature allows the part program to override the manually selected
torch spacing inputs.

G97 Loop Count Prompt

When enabled, this feature will post a message on the screen to enter the number of loops
or repeats to be selected when an EIA G97 code without a “T” value is encountered in the
part program.

ESAB Multi Torch Support

When enabled, this feature allows ESAB style ESSI part programs to map codes to
specific station selects.
Mapped
ESSI Code EIA Code Description
7 M37 T1 Select station 1
8 M38 T1 Deselect station 1
13 M37 T2 Select station 2
14 M37 T2 Deselect station 2
15 M37 T3 Select station 3
16 M38 T3 Deselect station 3

Force G40 Kerf Disable

In a part program, kerf is enabled and disabled using EIA G41/ G42 and G40 codes.
Standard operation is to disable kerf at the cut off even if the G40 kerf disable is not in a
program. With this parameter, you can turn off the “forced” G40 kerf disable if no G40
is used in the program by disabling the parameter.

G40 Used in Simple Shapes

This parameter is used with the Force Kerf Disable parameter to allow the G40 code that
is normally inserted in to a simple shape from the shape library to be omitted by disabling
the parameter.

Auto Start after APA

This parameter is used with the Automatic Plate Alignment feature to allow cutting to
begin automatically after completion of the automatic plate alignment.

EIA Code 2 Decimal Shift

Some programming styles are structured so that the decimal point in the EIA positioning
affecting part sizing is assumed. The EIA Code 2 Decimal Shift parameter allows the
operator to select the location of the decimal point when translating parts by selecting

40
 Setups

normal or single for correct translation. The selection should be set to Normal unless
your part programs require two decimal shift to the right of the decimal point.

M17, M18 Used as Cut Codes

This allows the EIA-274D M17 and M18 codes to be used for cut on and off commands
when enabled.

M76 Rotary Shortest Path

When enabled, this disables tilt and rotate software overtravels for dual tilt-style bevellers
and allows the EIA-274D M76 Rotate go to Home command to select shortest path.
When disabled it allows motion by longest path when homing. This is advantageous for
some bevel head designs.

Stop on Single Arc Lost

If this setting is enabled, any cut sense input that is lost for longer than the arc off time
during the cut pauses the part program or nest with a Cut Sense Lost message.

Show Traverse Segments

Allows traverse segment lines (displayed in yellow) to be turned OFF or ON during all
part preview displays.

Retain Skew Adjustment

Retains the last calculated plate skew for all subsequent parts that are loaded. If disabled,
any new part that is loaded will remove any previously calculated plate skew.

THC Voltage Offset

The THC Voltage Offset parameter is used to offset the individual Sensor THC arc
voltages from the master set arc voltage. This allows the individual THCs to be adjusted
to compensate for consumable wear and obtain optimum cut quality.

41
Setups

Reenable All Power Supplies

Press this soft key to re-enable any disabled HD4070 or HPR power supply with auto gas.
This key is enabled only if a power supply has been disabled.

42
 Setups

Process
Your CNC comes standard with several styles of built-in cut process logic which allows
the cut process timing to be configured for optimum performance. Selection will vary
due to control configuration.
Example:

In the Plasma Cut Type example provided above, various process timing adjustments
may be made to tune the process to the Plasma System and material being cut for the
desired performance. Pressing the Timing Diagram soft key or the space key on a
keyboard allows the user to view a graphical diagram of the process logic

Additionally, each cut type has the ability to save and load the process setups in a file on
the hard drive or to a floppy Diskette or USB memory stick. Pressing the ALT key
allows the Save Data and Load Data functions to be available.

43
Setups

Oxy Fuel
The system supports configurations with both the Sensor OHC and other OHC lifters. In
such a mixed configuration, stations must be defined and using stations selects, auto/all
selects or manual selects. Although the system allows both types of OHC lifters, only
one type can be used at a time.

The CNC comes with the following built-in control logic for Oxy Fuel cutting. When
oxy fuel is selected, the following parameters are available to customize the logic for the
metal being cut. As these parameters are changed, the timing diagram below changes to
show the new timing parameters. This screen is located under the Cut Types soft key in
the Setups.
Note: Press the Start key twice to bypass all timers and begin the cut.

44
 Setups

Press the Timing Diagram soft key to view the timing diagram from setups.

Ignition Time
Specifies the length of time that the oxy fuel igniter is held on at each ignition of the
flame.

Low Preheat
For those cutting systems that are equipped with a Low Preheat feature, this parameter
allows the operator to input a timing delay to activate the Low Preheat output prior to the
High Preheat.

High Preheat
Specifies the length of time to wait at each pierce position for preheating the piece prior
to piercing. During the run-time, the operator may use the SET, EXTEND, or RELEASE
soft keys to customize the preheat length for the particular metal being cut.

Pierce Time
Specifies the amount of delay after the cutting gas is turned on before lowering the torch
to the cut position.

45
Setups

Moving Pierce Time

The Moving Pierce Time parameter specifies the amount of time that the Pierce Output
remains on while piercing with motion.

Creep Time
Specifies the amount of time after piercing the part that the torch travels at creep speed.
Creep Speed is determined by a setup parameter at the Speeds setup screen and is a
percentage of the programmed cut speed. After the Creep Time is completed, the control
accelerates to full cut speed. This parameter is helpful in allowing the operator to bring
the cutting surface up to temperature and completely pierce the metal before cutting at
full speed.

Note: Depending on the performance of the plasma system, a creep time may be
required to allow for ramp up of the cut voltage after a pierce.

Primary Torch Up Time

Specifies the amount of time used for torch lift after completing each cut. This is
normally used to provide torch head clearance and return the torch to its predefined rest
position.

Primary Torch Down Time

Specifies the amount of time used to lower the torch at the beginning of each new cut.
This is usually longer than the Pierce Torch Down Time as it involves lowering the torch
from its predefined rest position.

Pierce Torch Up Time

Specifies the amount of time used for torch lift during piercing. This parameter is used to
provide distance between the torch tip and metal surface for cutting.

Pierce Torch Down Time

Specifies the amount of time used for torch lowering during piercing.

Cut Off Time

The Cut Off delay parameter species the amount of time the cut on output will remain on
at the end of a cut.

Bleedoff Time
Specifies the amount of time that the cut torch will pause to purge the oxygen at the end
of a cut segment before traversing to the next cut segment.

Igniters
When “No” is selected, this feature will turn the Preheat on between cut segments. This
is to keep the torch lit for those cutting systems that do not have automatic torch igniters.
For those cutting systems which have automatic torch igniters or that control the torch
gases outside of the control, set this parameter to “Yes”. This tells the control not to turn
on the Preheat between cut segments.

46
 Setups

Preheat During Cut

Specifies whether the Preheat will be left on while cutting.

Staged Pierce
This unique feature works with selected outputs to perform the pierce in a staged
progression of gas pressures.
To enable this setting, select one of the three modes and set the three staged pierce
values:

47
Setups

Controlling Oxy Fuel with Analog Outputs

You can select analog outputs on the I/O screen to control oxygen fuel pressures.

48
 Setups

To select the analog signals that are used for oxygen valve pressure control:
1. On the Machine Setups password screen, press the I/O button.

2. Select each control and assign an analog output for it.

The controls are listed in groups. All items in each group should be selected and
matched with an analog output:
• Cut Oxygen
• Preheat Oxygen
• Preheat Fuel

• Cut Oxygen TBT 2

• Preheat Oxygen TBT 2
• Preheat Fuel TBT 2

• Cut Oxygen TBT 3

• Preheat Oxygen TBT 3
• Preheat Fuel TBT 3

• Preheat Oxygen TBPT

• Preheat Fuel TBPT

49
Setups

3. When you finish selecting controls and assigning outputs, press or click OK.
When you return to the Oxy Fuel screen, the parameters for the control you selected
are added to the screen.
4. Edit the values for the parameters to meet the needs of your process.

Oxy Torch Pressures

Select the type of oxy fuel torch for the process.

Oxy Cut Pressure

Enter the pressure, in pounds per square inch, of the oxy fuel during cutting.

Oxy Ramp Up Time

Enter the time, in seconds, that the oxy fuel takes to reach cutting pressure.

Preheat Low Pressure

Enter the pressure, in pounds per square inch, of the oxy fuel at low pressure during
preheat.

Preheat High Pressure

Enter the pressure, in pounds per square inch, of the oxy fuel at high pressure during
preheat.

Preheat Pressure
Enter the preheat pressure, in pounds per square inch, for the triple bevel head.

Preheat Ramp Up Time

Enter the number of seconds that the process takes to move from low to high pressure
during preheat.

Preheat Ramp Down Time

Enter the number of second that the process takes to move from high to low pressure
during preheat.

Fuel Low Pressure

Enter the pressure, in pounds per square inch, of the oxy fuel at low pressure during
cutting.

Fuel High Pressure

Enter the pressure, in pounds per square inch, of the oxy fuel at high pressure during
cutting.

Fuel Pressure
Enter the fuel pressure, in pounds per square inch, for the triple bevel head.

Fuel Ramp Up Time

50
 Setups

Enter the number of seconds that the process takes to move from low to high pressure
during cutting.

Fuel Ramp Down Time

Enter the number of second that the process takes to move from high to low pressure
during cutting.

51
Setups

Plasma
The control comes with the following built in control logic for Plasma cutting. When
Plasma is selected, the following parameters are available to customize the logic for the
particular metal being cut. As these parameters are changed, the timing diagram below
will change to show the new timing parameters.

52
 Setups

Press the Timing Diagram soft key to view the timing diagram from setups.

Purge Time
Specifies the time delay from torch ignition until motion is enabled if Arc On Feedback is
off. Purge Time should be set to zero if Arc On Feedback is on.

Pierce Time
Specifies the time delay from when the torch completes lowering until motion is initiated
at Creep Speed. Used to allow the plasma torch to completely pierce the material before
moving.

Creep Time
Specifies the amount of time after piercing the part that the torch travels at Creep Speed.
Creep Speed is determined by a setup parameter at the Speeds setup screen and is a
percentage of the programmed cut speed. After the Creep Time is completed, the control
accelerates to full cut speed.

Cut Off Time

The Cut Off delay parameter species the amount of time the cut on output will remain on
at the end of a cut. A negative Cut Off time up to one second may be used to terminate
the cut output prior to the end of the cut segment. This is used to compensate for response

53
Setups

delays of the cut gases that will maintain the cut arc and widen the cut path at the end of
the cut segment.

Full Torch Up Time

Specifies the length of time to raise the torch at the beginning and end of each cut to
provide clearance over the cut pieces. If you are using an automatic height control
system, set Torch Up Time to zero.

Partial Torch Up Time

Specifies the length of time for a partial raise of the torch at the beginning and end of
each cut to provide clearance over the cut pieces. If you are using an automatic height
control system, set Torch Up Time to zero. Note: The Partial Raise parameter must be
enabled.

Torch Down Time

Specifies the length of time to lower the torch at the beginning of each cutting cycle. If
you are using an automatic height control system, set Torch Down Time to zero.

Arc Off Time

Specifies the amount of delay to allow prior to indicating a lost cut signal. This can be
useful in helping to minimize nuisance trips when traveling over previously cut paths in
complex nested parts.

Stop Time
Specifies the amount of time that X/Y motion will pause at the end of a cut. This pause is
advantageous for allowing the torch to completely raise and clear any cut irregularities
before continuing to the next cut segment.

Retract Delay
Retract Delay specifies the amount of time X/Y and lifter motion will pause at the end of
a cut. This allows the cut process to finish before lifting the torch and moving to the next
pierce.

Set Arc Current

The Set Arc Current feature allows the user to set the arc current at the plasma supply.
This feature uses the “Set Current BCD” output from the control to activate the BCD
inputs at the plasma supply. The Set Arc Current parameter is also available for the
HD4070 via the serial link. EIA RS-274D part program code G59 Vvalue Fvalue for
setting current is supported.

Corner Current Percent

The Corner Current Percent feature allows the operator to select a reduced current setting
to be executed when cutting corners to improve cut quality. This value is a percentage of
the Set Current (above) and is active when the Torch Height Disable Output is on. The
Corner Current parameter is also available for the HD4070 via the serial link.

54
 Setups

Retry On Transfer Fail

The Retry On Transfer Fail feature is used to specify the number of times the control will
attempt to fire the torch in the event that the torch fails to ignite.

Transfer Time
The Transfer Time parameter specifies the amount of time used to attempt ignition of the
torch. The ignition is confirmed by the Arc Sense Input (Arc on Feedback) to the control.

Arc on Feedback
Specifies whether an arc-on (also called Plasma Go, Current Sense, Arc Transferred)
signal from the plasma system to the control is used. With Arc On Feedback on, the
control waits for Cut Sense input to activate before initiating machine motion.

Ignition
Enables use of the Ignition output for use in igniting the plasma torch. If your plasma
system requires a separate ignition signal, toggle Ignition to ON. If not, leave Ignition
OFF.

Dual Grid/THC
The Dual Grid parameter enables use of the Torch Height Disable output. This output is
used to disable an automatic torch height sensor or reduce the plasma current in a
switchable current plasma system when machine speed is less than Plasma Hi/Lo Speed.

Dual Grid/THC Start

If Dual Grid is ON, the start mode can be configured to start (HI) or (LOW) at ignition
time. For switchable plasma systems, this usually means that in low mode the plasma
system will only deliver 50% of the maximum output power.

Partial Raise
Enabling the Partial Raise feature will execute a tool raise at the end of the cut segment
within a nest for the time specified in the Partial Up Time parameter. Full raise will be
executed at the end of the final cut segment.

Torch Down During Cut

Turning on the Torch Down During Cut feature forces the torch down output to remain
on throughout the cut process. This is advantageous for pneumatic style torch lifters that
require a constant output.

Torch Down Between Cuts

Turning on the Torch Down Between Cuts feature forces the Torch Down Output to
remain on while traversing between cut segments.

55
Setups

HD3070 Auto Gas Interface

This section provides information on the Hypertherm HD3070® Auto Gas Interface. The
Auto Gas screen is available from the Cut Types screen.

Note: The Auto Gas feature must first be enabled at the Special Password screen and is
designed for use with the six valve autogas console only

The top of the Auto Gas screen lists the valve parameter settings for the HD3070. Valve
settings for the 3070 Auto Gas console are documented in the HD3070 manual. When
the values are set, these become the current setting and the operator can choose to save
the file to the diskette, USB memory stick or hard drive.

The settings at the supply are updated at control power up, whenever the settings are
changed at this screen or through commands in a part program Supply settings are also
updated if power is lost and re-enabled at the power supply. There may be a brief delay
as these power supply settings are communicated from the control to the power supply.

Save Data
Pressing the Save Data soft key will allow the operator to save the current Auto Gas
setting to diskette, USB memory stick or hard drive for future use.

56
 Setups

Load Data
Pressing the Load Data soft key will allow the operator to Load stored Auto Gas settings
from diskette, USB memory stick or hard drive for use.

If you save the data, a file is created with G59 codes with the selected valve settings.
Here is an example of the data file where all percentages are set to zero.
G59 V65 B0
G59 V66 B0
G59 V67 B0
G59 V68 B0
G59 V69 B0
G59 V70 B0
G59 V71 B0

Test Cutting Gases

Pressing the Test Cutting Gases soft key allows the operator to test the HD3070 Cut
Gases.

Test Preflow Gases

Pressing the Test Preflow Gases soft key allows the operator to test the HD3070 Preflow
Gases.

57
Setups

HD3070 Auto Gas I/O

The Interface to the HD3070 Auto Gas console is made through of Single Ended and
BCD (Binary Coded Decimal) inputs. The BCD style of interface allows for exact
settings by use of multiple inputs being active at any time. The active BCD inputs values
are summed together to obtain the exact set point.

These I/O points are wired in the same fashion as our other Single Ended I/O points. The
following I/O points are supplied for use of the HD3070 Auto Gas Console

Inputs
Gas Control Read Complete
Gas Control Error

Outputs
Gas Control Write
Remote Test Operate
Remote Test Preflow
Remote Air Plasma
Remote H35/ N2 Plasma
Remote O2 Plasma
Gas Flow Set 1-100 (BCD)
Valve Select 1-8 (BCD)

58
 Setups

HD4070 and HPR Overview

The Mariner ™ and Voyager™ III controls offer the additional option of connecting
directly to the Hypertherm HD4070 HyDefinition®, HPR130™ and HPR260™ plasma
supplies for setup. This feature has the ability to improve power supply setup and
operational accuracy while having the flexibility to fine tune the process specific to the
operator’s needs.

When using this advanced feature, all necessary power supply settings are transmitted
from the control directly to the Plasma Supply configuring it for use via serial
communications. The Plasma Supply setup is performed through the use of a Cut Chart
(cut process parameter database) which is based on eight process variables. The
combination of these eight process variables are tied to the settings for the cut process
parameters (e.g. arc voltage, pierce delay, etc.) that are transmitted to the supply. For
additional convenience, consumable part numbers for the Plasma supply are displayed at
the Change Consumable screen.

This database allows the user to select factory recommended settings or amend the
database for personalized settings. The Cut Chart information may be saved or loaded
via the hard drive or floppy drive. The Cut Chart files containing the factory
recommended settings are available from Hypertherm.

Access to the Cut Chart data is available from the Plasma Cut Types or Marker Cut
Types screen using the shift key, as indicated below. The Plasma Supply parameters
must first be enabled in the password protected Station Configuration setups to allow the
Cut Chart Information for the Plasma Supply to be available for use.

Note: Screen information will vary depending on THC selection.

59
Setups

Cut Chart

The Cut Chart Database (cut process parameters) transmitted to the power supply is
based on the following eight process variables.

Material Type
The Material Type, such as Mild Steel, Stainless Steel or Aluminum, may be selected.

Current Settings
The appropriate current setting for the material thickness and material type may be
selected.

Plasma / Shield Gases

The appropriate Plasma / Shield gases for the desired process may be selected.

Material Thickness
The desired material thickness may be selected.

60
 Setups

The following are the Cut Process parameters within the database which are used to
configure the process. Appropriate parameter information is transmitted to the power
supply.

Cut Speed
Specifies the speed for the selected process variables.

Kerf
Specifies the amount of kerf that is applied to the current part program.

Set Arc Voltage

The operator may input the desired Arc Voltage for the material being cut.

Cut Height
The Cut Height setup parameter is used to select the desired cut distance from the plate.

Pierce Height
The Pierce Height setup parameter is used to select the desired Pierce Height. This may
be entered as a multiplication factor that is calculated times the Cut Height or an actual
Pierce Height distance.

Preflow Setting
The appropriate Plasma / Shield Preflow percentages for the desired process may be
selected.

Cutflow Settings
The appropriate Plasma / Shield Cutflow percentages for the desired process may be
selected.

Preflow Time
Specifies the amount of time the Preflow gases are on.

Purge Time
Specifies the time delay from torch ignition until motion is enabled.

Pierce Time
Specifies the time delay from when torch completes lowering until motion is initiated at
Creep Speed. This parameter allows the plasma torch to completely pierce the material
before moving.

Creep Time
Specifies the amount of time after piercing the part that the torch travels at Creep Speed.
Creep Speed is determined by a setup parameter at the Speeds setup screen and is a
percentage of the programmed cut speed. After the Creep Time is completed, the control
accelerates to full cut speed.

61
Setups

Save Process
Pressing the Save Process soft key allows the user to save the current process settings to
the hard drive and create a custom user database based on the eight process variables
selected.

Reset Process
Pressing the Reset Process soft key allows the user to reset the current settings to factory
recommend factory defaults based on the eight process variables selected.

Save Cut Charts

Pressing the Save Cut Charts soft key allows the user to save the current User and
Factory databases to Diskette or USB memory stick. User files are designated with a .usr
file extension and the factory files are designated with a .fac file extension

Examples of user and factory file names:

Mild Steel-HT4400-HD4070.usr
Mild Steel-HT4400-HD4070.fac

Load Cut Charts

Pressing the load Cut Charts soft key allows the user to load the factory default database
files which are supplied by Hypertherm in a Text file (.txt), user files (.usr) or factory
files (.fac) from Diskette or USB memory stick.

Factory text file names:

Mild Steel Cut Chart Data mschart.txt
Aluminum Cut Chart Data alchart.txt
Stainless Steel Cut Chart Data sschart.txt

It is recommended that the Database be updated through the control rather than the Power
Supply if the serial communications link is enabled.

Test Preflow
Pressing the Test Preflow soft key performs the Test Preflow Gases feature at the Plasma
supply.

Test Cutflow
Pressing the Test Cutflow soft key performs the Test Cutflow Gases feature at the Plasma
supply.

Notes:
• Refer to the power supply operator’s manual for complete information on the
operation and setup of the plasma supply.
• A serial communication port for the plasma supply must first be selected at the port
configuration screen to be enable the feature for use.

62
 Setups

• The Plasma supply parameters must first be enabled in the password protected Station
Configuration screen to allow the cut chart information for the plasma supply to be
available for use.
• Power Supplies equipped with the integrated Command® THC can be used with the
control setups. The Command THC must first be enabled for use in the password
protected Station Configuration Screen.

63
Setups

Change Consumable

When the power supply link feature has been enabled, consumable data information may
be viewed at the Change Consumable screen.

64
 Setups

FineLine Overview
The “Type V” control offers the additional option of interfacing directly to InnerLogic’s
FineLine Power Supply for setup via a user selected RS-422 serial port. This advanced
feature transmits all necessary power supply settings from the control directly to the
FineLine power supply configuring it for use.

The power supply setup is performed through the use of a Cut Chart (cut process
parameter database) which is based on eight process variables. The combination of these
eight process variables are tied to the settings for the cut process parameters (e.g. arc
voltage, pierce delay, etc.) that are transmitted to the supply. For additional convenience,
consumable part numbers for the FineLine are displayed at the Change Consumable
screen.

This database allows the user to select factory recommended settings or amend the
database for personalized settings. The Cut Chart information may be saved or loaded
via the hard drive or floppy drive. Specialized Cut Chart files containing the factory
recommended settings are available from the control vendor.

The Power Supply parameter must first be enabled in the password protected Station
Configuration setups to allow the Cut Chart Information for the feature to be enabled for
use. Once selected at the Station Configurations screen, the port must then be selected
for communications on the Ports setup screen and the selected port must then be
configured as RS-422. For more information on configuration of the port, refer to the
Ports information section of this guide.

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Setups

Station Configuration (example)

Access to the FineLine Cut Chart data is available from the Plasma Cut Types or Marker
Cut Types screen using the shift key, as indicated below.

Note: Screen information will vary depending on THC selection.

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 Setups

Cut Chart

The Cut Chart Database (cut process parameters) transmitted to the power supply is
based on the following eight process variables.

Material Type
The Material Type, such as Mild Steel, Stainless Steel or Aluminum, may be selected.

Current Settings
The appropriate current setting for the material thickness and material type may be
selected.

Plasma / Shield Gases

The appropriate Plasma / Shield gases for the desired process may be selected.

Material Thickness
The desired material thickness may be selected.

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Setups

The following are the Cut Process parameters within the database which are used to
configure the power supply. Appropriate parameter information is transmitted to the
power supply.

1. Material Type – Mild Steel, Stainless Steel, Aluminum, or Mild Steel (Cold Rolled).
2. Thickness
3. Set Current
4. Pierce Delay
5. Set Preflow Pressure
6. Set Plasma Gas type
7. Set Plasma Pressure
8. Set Shield Gas Type
9. Set Shield Pressure
10. Set Process (Cut/Mark)

The following items are stored in the Cut Chart Data file and will be automatically
updated on the control.

Cut Speed
Specifies the speed for the selected process variables.

Kerf
Specifies the amount of kerf that will be applied to the current part program.

Preflow Time
Specifies the amount of time the Preflow gases are on.

Purge Time
Specifies the time delay from torch ignition until motion is enabled.

Pierce Time
Specifies the time delay from when torch completes lowering until motion is initiated at
Creep Speed. This parameter allows the plasma torch to completely pierce the material
before moving.

Creep Time
Specifies the amount of time after piercing the part that the torch travels at Creep Speed.
Creep Speed is determined by a setup parameter at the Speeds setup screen and is a
percentage of the programmed cut speed. After the Creep Time is completed, the control
accelerates to full cut speed.

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 Setups

Database Features

Save Process
Pressing the Save Process soft key allows the user to save the current process settings to
the hard drive creating a custom user database based on the eight process variables
selected.

Reset Process
Pressing the Reset Process soft key allows the user to reset the current settings to factory
recommend factory defaults based on the eight process variables selected.

Save Cut Charts

Pressing the Save Cut Charts soft key allows the user to save the current User and
Factory databases to Diskette or USB memory stick. User files are designated with a .usr
file extension and the factory files are designated with a .fac file extension

Examples of user and factory file names.

Mild Steel-Fineline200-Fineline200.usr
Mild Steel- Fineline200-Fineline200.fac

Load Cut Charts

Pressing the load Cut Charts soft key allows the user to the factory default database files
which are supplied by Hypertherm as a user files (.usr) or factory files (.fac) from
Diskette or USB memory stick.
It is recommended that the Database be updated through the control rather than the Power
Supply if the serial communications link is enabled.

Test Preflow
Pressing the Test Preflow soft key performs the Test Preflow Gases feature at the
HD4070 power supply.

Test Cutflow
Pressing the Test Cutflow soft key performs the Test Cutflow Gases feature at the
HD4070 power supply.

Notes:
• Please refer to the power supply operators manual for complete information on the
operation and setup of the FineLine Power Supply.
• The FineLine Power Supply parameters must first be enabled in the password
protected Station Configuration Screen to allow the Cut Chart Information for the
FineLine to be available for use.
• Serial communications for the FineLine Power supply are established on the user
select communication port. The port must be configured for RS-422 operation.

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Setups

Change Consumable

When the FineLine feature has been enabled, consumable data information may be
viewed at the Change Consumable screen.

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 Setups

Marker
The control comes with the following built in marker control logic for marking. When
marking is selected, the following parameters are available to customize the logic for the
particular metal being marked. As these parameters are changed, the timing diagram
below will change to show the new timing parameters. This screen is located under the
Cut Types soft key in Setups.

Marker Interface
The Marking feature from the control is operated through the use of existing I/O points
for cutting torches on the control I/O connector. These I/O points may be switched from
the cutting torch to the marking tool by use of an external relay(s) activated by the
Marker Output or the Marker Output may be used to activate the marking tool.
Please refer to the Machine Interface section of this guide for exact I/O pinout
information.

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Setups

Press the Timing Diagram soft key to view the timing diagram from setups.

Ignition Time
(Ignition Output) Specifies the length of time that the ignition output is held on at each
ignition point.

Marker On Time
(Time Delay) This parameter allows the operator to insert a time delay, which allows the
marker to prepare for operation prior to the start of Marker motion.

Marker Off Time

(Time Delay) This parameter allows the operator to insert a time delay, which allows the
marker to prepare for operation prior to the end of Marker motion.

Marker Up Time
(Torch Up Output) Specifies the length of time to raise the marker at the beginning and
end of each mark.

Marker Partial Up Time

(Torch Up Output) Specifies the length of time for partial raise of the marker at the
beginning and end of each mark. Note: The Partial Raise parameter must be enabled.

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 Setups

Marker Down Time

(Torch Down Output) Specifies the length of time to lower the marker at the beginning
of each marking cycle.

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Setups

Set Arc Current

The Set Arc Current feature allows the user to set the arc current at the Plasma Marking
supply. This feature uses the “Set Current BCD” output from the control to activate the
BCD inputs at the Plasma Marking supply. EIA RS-274D part program code G59 Vvalue
Fvalue for setting current is supported.

Corner Current Percent

The Corner Current Percent feature allows the operator to select a reduced current setting
to be executed when cutting corners to improve marking quality. This value is a
percentage of the Set Current (above) and is active when the Torch Height Disable
Output is on.

Ignition
(Ignition Output Enable) The Ignition Off/On selection allows the operator to use the
Ignition Output when marking if set to On.

Cut Control Used for Marking

This parameter is used to determine if the Cut Control output is to be used for activating
the Marking tool. If set to no, the Marking Output would be used.

Marker Down/Up With Each Marker On/Off

The Marker Down/Up With Each Marker On/Off will command the send the appropriate
Up/Down Output commands at each Mark On/ Off.

Arc On Feedback
Specifies whether an arc-on signal from a plasma marking system to the control is used.
With Arc On Feedback ON, the control waits for Cut/Mark Sense input to activate before
initiating machine motion.

Partial Raise
Enabling the Partial Raise feature will execute a tool raise at the end of the Mark within a
nest for the time specified in the Partial Up Time parameter. Full raise will be executed
at the end of the final Mark segment.

Down On During Mark

Turning on the Down On During Mark feature forces the torch down output to remain on
throughout the marking process. This is advantageous for pneumatic style torch lifters
that require a constant output.

Down On Between Marks

Turn on the Down On Between Marks feature to force the Torch Down Output to remain
on while traversing between marking segments.
Note: Please refer to the Program Codes section of this guide for information on the
Marker Font Generator feature.

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 Setups

Laser Overview
The Mariner CNC offers a unique Laser process screen directly integrates to the
Hypertherm FAST Laser™ head. This feature has the ability to improve Laser setup and
operational accuracy while having the flexibility to fine tune the process specific to the
operator’s needs.

FAST Laser uses an innovative patent-pending design to create a dual flow zone allowing
significantly higher oxygen assist gas pressures in the tightly defined cut zone established
by the beam geometry, without the uncontrolled burning in the surrounding zone
normally induced by increased assist gas pressures. This accelerated high-velocity
oxygen flow along the beam path not only increases cut speed by fueling the exothermic
reaction, but also reduces sensitivity to common plate fabricating conditions and
variables, most notably plate chemistry and condition.

With this technology, Hypertherm has introduced a line of laser cutting heads that utilize
the FAST Laser process to deliver up to a 20% increase in cut speed over standard CO2
laser heads on plate steel while also significantly expanding the capacity and quality
range of plate laser cutting systems. These combined benefits produce substantial gains in
productivity and unattended operation potential for dedicated plate lasers (4 to 6 kW) –
whether integrated or retrofitted – while also offering expanded capacity range and cost
performance for shared-duty systems (2 to 3 kW). The Hypertherm LH2100 head offers
two different focal lengths: 7.5 and 10.0 inches; the LH2125 adds a 12.5-inch focal
length option for thicker plate. The Hypertherm LH2125/2100 series is used on laser
systems with 1.5” or 2.0” optics. The Hypertherm LH1575 head offers two different focal
lengths: 5.0 and 7.5 inches for 1.5 inch optics.

Integrated with Hypertherm Automation’s Mariner CNC, on-board FAST Laser process
intelligence coupled to process monitoring optics standard on LH-series cutting heads,
achieves improved overall control of the cutting process with fewer system faults and
reduced operator involvement. Dynamic Pierce Control senses and initiates each cut once
the pierce is complete. These combined capabilities maximize uptime while minimizing
total cycle time.

Note: Refer to Laser Information provided with the FAST Laser head for proper
operation.

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Setups

Laser Cut Types Screen

The Alt soft key at the left edge of the soft keys indicates additional soft keys are
available. This allows for test lifter function to be available.

Test Lifter
Pressing the Test Lifter soft key will command the laser head THC1 lifter to lower to the
plate, sense the plate and retract to the pierce height.

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 Setups

Press the Timing Diagram soft key to view the timing diagram from setups.

Purge Time
Specifies the time delay for cutting gas purge before start of the laser cut motion is
enabled.

New Gas Purge Time

Specifies the Gas Purge Time for switching from one cutting gas to another cutting gas.

Shutter Time
The Shutter Time parameter is used to specify the amount of time to open the shutter
prior to the laser beam on.

Power Ramp Time

The Power Ramp Time parameter is used to specify the amount of time to ramp up the
laser power prior to the laser pierce.

Pierce Time
Specifies the time delay from when laser head completes lowering until motion is
initiated at creep speed for cutting.
When Manual Pierce Control is selected, this is the total pierce time allowed.

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Setups

With Automatic Pierce Control is selected, this time is an additional delay after pierce is
complete.

Pulse On Time
When Automatic Pulse Mode is selected for pierce control the user can select Pulse On
and Off Time to adjust duty cycle response of the sensor pulses from the laser cutting
head.

Pulse Off Time

When Automatic Pulse Mode is selected for pierce control the user can select Pulse On
and Off Time to adjust duty cycle response of the sensor pulses from the laser cutting
head.

Creep Time
Specifies the amount of time after piercing the material that the laser head travels at
Creep Speed for cutting. Creep Speed is determined by a setup parameter in the Speed
Setup Screen and is a percentage of the programmed cut speed. After the Creep Time is
completed, the control accelerates to full cut speed.

Beam Off Time

The Beam Off Time parameter specifies the amount of time the beam output will be
turned off prior to he stop of motion. This feature can be used to tab parts for attachment
to the skeleton.

Postflow Time
Specifies the amount of time that the cutting gas remains on after the cut is complete.

Cut Height
The Cut Height setup parameter is used to select the desired cut distance above the plate.
This will set the initial cut height before the laser cut motion is activated. Cut Height is
derived from the CHS signal and the calibration curve and represents cut distance from
nozzle tip to the plate.

Pierce Height
The Pierce Height setup parameter is used to select the desired Pierce Height above the
plate. This can be entered as a multiplication factor that is calculated times the Cut
Height or an actual Pierce Height distance.

Lens Cut Position

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

Lens Pierce Position

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

Pulse Laser Time

Sets the Laser Pulse Time duration for a one shot beam alignment.

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 Setups

Pulse Laser Power

Sets the Laser Pulse Power for a one shot beam alignment.

Height Control Manual/Automatic

Allows the user to either select a Manual or Automatic Height control for the laser head.

IHS in Manual
The IHS in Manual setup parameter allows the operator to select whether or not to use the
Initial Height Sense feature when operating the Z axis lifter (THC1) in manual mode.

Retract Full/Partial
Selects the retract distance to be set at Full or Partial. In the Full retract mode, the laser
head will retract to the Z-Axis Home position. In Partial retract mode, the laser head will
retract to the set retract distance.

Partial Retract Distance

This setup parameter is used to select the THC 1 Retract Distance when configured for
partial retract mode.

Start IHS Distance

The Start IHS Distance specifies the distance of travel for the THC 1 to move the laser
head at high speed before switching to low speed and beginning Initial Height Sense.
Caution should be taken when selecting this distance so that the laser head does not crash
into the plate.

Preflow During IHS

Selecting ON will activate Preflow gases during the IHS cycle.

Nozzle Contact IHS

This parameter would be set to ON to select the THC 1 to use Contact Sense to detect the
plate during the IHS cycle.

Nozzle Contact During Cut

Nozzle Contact During Cut allows the CNC to detect contact with the plate and generates
a fault if this condition occurs.

Pierce Control Manual/Automatic

Allows the user to select manual or automatic pierce control. Automatic control uses
sensors in the Laser head to detect when the pierce is complete. Manual mode uses a
preset pierce time and preset laser program. Automatic mode dynamically controls laser
duty cycle.

Pierce Mode Pulse/Blast

When Automatic Pierce is selected the user can select to use a definable pulse output or a
single Blast.

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Setups

Pierce Complete
The Automatic Pierce monitors the voltage of sensors in the laser head and compares
them to the value set by this parameter to detect the completion of the pierce.

Next Pulse
Based on sensors in the laser head, the system can determine when the next Laser Pulse is
delivered during Automatic Pierce control. The voltage is derived from the feedback of
the sensors in the laser cutting head.

Cut Chart
A cut chart database allows the user to select factory recommended settings or amend the
database for personalized settings. The Cut Chart information can be saved or loaded via
the hard drive, floppy drive or USB memory stick. The Cut Chart files contain the
factory recommended settings that are available from Hypertherm.

Notes:
• Refer to the FAST Laser operator’s manual for complete information on the operation
and setup of the FAST Laser head.
• The FAST Laser Laser parameters must first be enabled in the password protected
Station Configuration screen to allow use of the Cut Chart Information
• Specific Material, Process Power, Assist Gases, Material Thickness, Focal Length
and Nozzle data fields allow new values to be added. Double click on the field to
enter an new value or press the Plus key “+” to add or “-“ to delete on the keypad.

80
 Setups

Laser Cut Chart Screen

The Cut Chart Database (cut process parameters) transmitted to configure the laser head
are based on the following process variables. All values are user definable.

Material Type
The Material Type, such as Mild Steel, Stainless Steel or Aluminum, may be selected.

Specific Material
This is a user defined value to allow the user to create a custom database based on unique
characteristics of the material type. Double click on the field or press the Plus key “+” to
enter an new material name or “-“ to delete on the keypad.

Process Power
The appropriate process power (Wattage) for the material thickness and material type for
the desired process.

Assist Gas
The appropriate Assist Gas for the desired process.

Material Thickness
The material thickness for the selected material type.

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Setups

Focal Length
Specific Focal Length lens that needs to be installed in the laser head for the desired
process.

Nozzle
Diameter and type of nozzle that needs to be installed for the desired process.

Test Gas
Pressing the Test Gas soft key performs the Test Gas feature of the cutting assist gas
delivery system.

The following parameters are the Cut Process parameters within the database, which are
then available to configure the specific process.

Set Power
The Set Power parameter allows the user set the power (watts) to be used during the cut
process. This value can be less than the process power.

Cut Speed
Specifies the Cut Speed for the selected material process.

Kerf
Specifies the amount of kerf that will be applied to the current part program.

Cut Height
The Cut Height setup parameter is used to select the desired cut distance from the nozzle
tip to the plate. Cut Height is derived from the CHS signal and the calibration curve.

Pierce Height
The Pierce Height setup parameter is used to select the desired Pierce Height. This may
be entered as a multiple factor that is calculated value of the Cut Height or an actual
Pierce Height distance.

Lens Cut Position

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

Lens Pierce Position

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

Resonator On Time
During automated power up this allows a specific time for the resonator to power up.

Purge Time
Specifies the time delay from switching from one cutting gas type to another cutting gas
type.

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 Setups

Pierce Time
Specifies the time delay from when laser head completes lowering until motion is
initiated at creep speed for cutting.

When Manual Pierce Control is selected, this is the total pierce time allowed.
With Automatic Pierce Control is selected, this time is an additional delay after pierce is
complete.

Pulse On Time
When Automatic Pulse Mode is selected for pierce control the user can select Pulse on
time to adjust the pulse.

Pulse Off Time

When Automatic Pulse Mode is selected for pierce control the user can select Pulse on
and off time to adjust the pulse. The Off Time starts when the sensor signal falls below
the next pulse threshold.

Creep Time
Specifies the period after pierce complete that the laser head travels at Creep Speed.
Creep Speed is determined by a setup parameter in the Speeds setup screen and is a
percentage of the programmed cut speed. After Creep Time is complete, the control
accelerates to full cut speed.

Pierce Complete
The Automatic Pierce monitors voltage of sensors in the laser head to detect completion
of the pierce. This is used in conjunction with Pulse On Time, Pulse Off Time and next
pulse.

Next Pulse
Based on sensors in the laser head, the system can determine when the next pulse occurs.
The Next Pulse will be delivered when the voltage drops below the Next Pulse setting.

Start Corner Power

The Start Corner Power allows the user to define a speed where the corner power analog
signal will be used to start to decrease laser power. This is defined as a percentage of cut
speed.

See Corner Power graph, where the example shows this set to 80%.

Minimum Corner Power

This parameter defines the minimum laser resonator power to switch when the cut speed
reduces to zero in a corner. This is defined as a percentage of selected power (watts). See
Corner Power graph, where the example shows 30%.

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Setups

Example of Corner Power Graph

Save Process
Press the Save Process soft key to save the current process settings to the hard drive and
create a custom user database based on the eight process variables selected.

Rest Process
Pressing the Reset Process soft key allows the user to reset the current settings to factory
recommend factory defaults based on the eight process variables selected.

Save Cut Charts

Pressing the Save Cut Charts soft key allows the user to save the current User and
Factory databases to Diskette or USB memory stick. User files are designated with a .usr
file extension and the factory files are designated with a .fac file extension

Load Cut Charts

Pressing the load Cut Charts soft key allows the user to the factory default database files
which are supplied by Hypertherm in a Text file (.txt), user files (.usr) or factory files
(.fac) from Diskette or USB memory stick.

Pulse Laser Time

Sets the Laser Pulse Time duration for a one shot beam alignment.

Pulse Laser Power

Sets the Laser Pulse Power for a one shot beam alignment.

Height Control Manual/Automatic

Allows the user to select a manual or automatic height control for the laser head.

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 Setups

IHS in Manual
The IHS in Manual setup parameter allows the operator to select whether or not to use the
Initial Height Sense feature when operating the Z axis lifter (THC1) in manual mode.

Retract Full/Partial
Selects the retract distance to be set at Full or Partial. In the Full retract mode, the laser
head will retract to the Z-Axis Home position. In Partial retract mode, the laser head will
retract to the set retract distance.

Partial Retract Distance

This setup parameter is used to select the THC Retract Distance when configured for
partial retract mode.

Start IHS Distance

The Start IHS Distance specifies the distance of travel for the THC to move the laser
head at high speed before switching to low speed and beginning Initial Height Sense.
Caution should be taken when selecting this distance so that the laser head does not crash
into the plate.

Preflow During IHS

Select ON to activate Preflow gas during the IHS cycle.

Nozzle Contact IHS

This parameter would be set to ON to select the THC to use Contact Sense to detect the
plate during the IHS cycle.

Nozzle Contact During Cut

Nozzle Contact During Cut allows the CNC to detect contact with the plate and fault.

Pierce Control Manual/Automatic

Allows the user to select manual or automatic pierce control. Automatic control uses
sensors in the Laser head to detect when the pierce is complete.

Pierce Mode Pulse/Blast

When Automatic Pierce is selected the user can select to use a definable pulse output or a
single Blast.

Pierce Complete
The Automatic Pierce monitors voltage of sensors in the laser head to detect completion
of the pierce.

Next Pulse
Based on sensors in the laser head, the system can determine when the next Pulse Pierce
occurs during Automatic Pierce control. The voltage is derived from the feedback of the
sensors.

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Setups

Cut Chart
A cut chart database allows the user to select factory recommended settings or amend the
database for personalized settings. The Cut Chart information can be saved or loaded via
the hard drive, floppy drive or USB memory stick. The Cut Chart files contain the
factory recommended settings that are available from Hypertherm.

Notes:
• Refer to the FAST Laser operator’s manual for complete information on the operation
and setup of the FAST Laser head.
• The FAST Laser Laser parameters must first be enabled in the password protected
Station Configuration screen to allow use of the Cut Chart Information
• Specific Material, Process Power, Assist Gases, Material Thickness, Focal Length
and Nozzle data fields allow new values to be added. Double click on the field to
enter an new value or press the Plus key “+” to add or “-“ to delete on the keypad.

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 Setups

Water Jet

Press the Timing Diagram soft key to view the timing diagram from setups.

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Setups

Purge Time
Specifies the time delay from torch ignition until motion is enabled.

Pierce Time
Specifies the time delay from when cutting tool completes lowering until motion is
initiated at Creep Speed. Used to allow the cutting tool to completely pierce the material
before moving.

Creep Time
Specifies the amount of time after piercing the part that the torch travels at Creep Speed.
Creep Speed is determined by a setup parameter at the Speeds setup screen and is a
percentage of the programmed cut speed. After the Creep Time is completed, the control
accelerates to full cut speed.

Abrasive Off Time

The Abrasive Off delay parameter species the amount of time the abrasive will remain on
at the end of a cut.

Abrasive Charging
When selected, the Abrasive Charging feature will charge or fill the abrasive into the
cutting system for use while cutting.

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 Setups

Watch
The control comes with a unique function for watching critical process related parameters
during cutting. The Watch window allows the operator to customize a certain portion of
the screen to display functions that are critical for your particular cutting operation.
Whether it is Current Speed, Position, I/O status, or torch consumable life, you now have
the flexibility to display the information that you want to see.

As these parameters are turned on or off, the Watch window will be updated with the new
graphical widget. Widget is a GUI programmer’s term for defining icons which
graphically display information.

Several options are available to personalize the Watch window and not all options can be
viewed at one time. The options are grouped into two sizes of widgets or icons. Large
widgets may be placed into the upper position at the top of the Watch window or in the
middle of the Watch window. Small widgets are positioned in the lower left corner of the
Watch Window next to the cut information and clock. The cut information and clock at
the lower right may not be edited.

Selections in the Watch window will change slightly based on the control I/O
configuration and machine option selections that have been enabled.
The Watch positions will allow for the following selections.

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Setups

None
Selecting None leaves the selected position blank.

Input/Output
Allows current state of selected Input, Outputs or Status information to be displayed
during cutting. This can be especially useful in debugging gas control sequencing
problems. To add or delete a desired Input, Output or Status point to the Input/Output list
box, double-click an item or highlight an item and + (add) or – (delete) keys on the alpha-
numeric keypad.

Position
Allows the position for the selected axis to be displayed. Only two axes may be displayed
at the Upper or Middle locations. The Lower location will allow up to four axes to be
displayed.

Following Error
Allows the Following Error to be displayed. Following Error is the distance between the
position the control has calculated and the actual position of the torch. A large Following
Error may indicate that the cut speed selected may be beyond the capability of the cutting
system. Only two axes may be displayed at the Upper or Middle locations. The Lower
location will allow up to four axes to be displayed.

Command Voltage
Allows the user to view directional motion command voltage being sent to the amplifier
for velocity type drives. This displayed voltage also equates to current being commanded
for motion in current type drives. Peak voltage can be displayed for a specified amount
of time.

Temperature
Selecting to add the Temperature information to the Watch window will display the
current temperature inside the control in Fahrenheit or Celsius (selected at the Special
Setups screen).

Note: Specific control hardware is required.

Speedometer
Allows cut speed, maximum machine speed and current machine speed to be graphically
displayed while cutting.

Oxy Fuel Torch Tip

Allows the selected oxy fuel torch tip (1- 12) consumable life to be graphically displayed
while cutting. This is especially useful in helping to determine when the torch tip should
be replaced and keeping track of torch tip data for statistical process control (SPC).

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 Setups

Plasma Torch Tip

Allows the selected plasma torch tip (1- 8) consumable life to be graphically displayed
while cutting. This is especially useful in helping to determine when the torch tip should
be replaced and keeping track of torch tip data for statistical process control (SPC).

Plasma Electrode
Allows the selected plasma electrode (1- 8) consumable life to be graphically displayed
while cutting. This is especially useful in helping to determine when the electrode should
be replaced and keeping track of electrode data for statistical process control (SPC).

Jog Keys
Selecting the jog keys option allows a directional keypad to be added to the watch
window for manual motion directly from the touch screen. The operator can press the
hand ICON in the middle of the navigation pad to enable manual mode. Select the
desired move speed and press the corresponding arrow for manual motion in the desired
direction.

Process Data
The Process Data option allows the user to view up to four selected items for a selected
cut or marking process. Process timers and status items for Oxy Fuel, Plasma, Marker,
Water jet and Laser may be selected. Note: The process data will only be displayed
during the current cut process. Example: Plasma 1 process parameters will only be
displayed in the Watch window at the main cut screen while cutting in Plasma 1 Mode.

Laser Nozzle
Laser Nozzle consumable life to be graphically displayed while cutting. This is
especially useful in helping to determine when the nozzle should be replaced and keeping
track of nozzle data for statistical process control (SPC).

HPR Power Supply

Allows the user to view status for inputs, outputs and gas pressures for the HPR autogas
console. Up to four power supplies may be monitored. This is generally used for
service diagnostics only.

Multiple Watch Windows

Up to ten different Watch windows may be configured on the control for quick selection
and viewing of the Watch icons.

To configure different Watch windows for viewing, first access the Watch setup screen.
Press the number ICON to enter a number or the Left/Right arrows to move up and down
through the selections. The different Watch windows can be selected and viewed during
operation using the same selection process.

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Setups

Example

92
Shape Manager
Shape Library
The CNC contains a built-in Shape Library with more than 68 commonly used shapes.
These shapes are parametric. Parametric shapes are shapes whose size or geometry you
can edit. The shapes in the library are color-coded from easiest (green) to hardest
(black).

To select a simple shape:

1. On the Main screen, press Shape Library
2. Double click a shape.
3. Press OK.
4. If the selection is incorrect, press Cancel and select the shape again.

Keypad operation:
1. Use the arrow keys to navigate to a shape.
2. Press Enter.

The shape is displayed with the default parameters or the parameters from the last time
this shape was edited. For more information on the available shapes, see Files.

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Shape Manager

Text Editor
The text editor screen allows you to write or edit a part program in either ESSI or EIA
format. The current part that is in memory is displayed when this screen opens.

The OK soft key saves changes to the current part in memory. If you want to save the
changes to the hard drive, go to the Files Save to Disk screen.

If you do not want to save any changes that were made, press Cancel on the keyboard.
Changes can be made by pressing on the desired line of code. An alphanumeric keypad
will be displayed to initiate changes.

Show Original Text

Allows you to view and edit the part program in its original format.

Delete Part
Deletes the current part from the Text Editor so that a new part can be constructed.

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Shape Wizard
ShapeWizard® is a proprietary graphical part editor that provides a user-friendly,
graphical interface for editing part programs.

You can view not only the segment that is being edited, but other changes that are made,
as well. You can add EIA RS-274D codes to a part program in the EIA Text window as
ASCII text. If you don’t know EIA RS-274D codes, you can create segments specifying
phrases in your native language.

Manual Line Edit

Press Manual Line Edit to edit a line of text in the EIA Text window. The ASCII text
that you enter must be a valid EIA RS-274D code or an error message will display. The
alphanumeric keypad is displayed for line edits.

Type over a line to erase the highlighted text.

While a text line is highlighted in blue, you can use the Segment Type field and related
fields to change the segment type and insert it into the program.

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As you edit a line of code, the picture of the part in the Preview window is updated. The
corresponding segment is highlighted in red or blue to indicate that it is a cut segment or
a traverse.

Replace Segment
Replaces the segment highlighted in gray in the Text Editor window with the segment
selected from the Segment Type window:

Insert Before Segment

Inserts the segment selected from the Segment Type window to be inserted before the
segment highlighted in gray in the Text Editor window.

Insert After Segment

Inserts the segment selected from the Segment Type window after the segment
highlighted in gray in the Text Editor window.

Remove Segment
Deletes the segment that is highlighted in gray or blue in the EIA Text window from the
part program.

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Teach Trace
The Teach Trace function of the CNC allows parts and remnants to be traced rather than
programmed. The position information from the traced part remains as a part program
that can be saved to disk.

The Teach Trace algorithms present in the CNC can recognize both arcs and lines. This
reduces the overall memory required to store these parts and improves the smoothness of
the cut. The traced part in memory is in EIA format and can be cut, saved or manipulated
using any of the part options.

Teach Trace has two modes, Remnant Trace and Teach Trace. The screen opens in
Remnant Trace mode. Press the Select Teach Trace Mode soft key to use Teach Trace.

Remnant Trace Mode

In Remnant Trace mode, you can trace the outline of a plate remnant and save it as a file
so that it can be used later and nests of parts can be cut from the remnant.

To trace a remnant:
1. On the TeachTrace screen, press the Select Remnant Mode soft key.
2. Jog to the point on the Remnant window where you want the trace to begin. Use the
joystick or jog keys to move the torch over the plate.

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3. Press or click First Point.

4. Jog to the next point and press or click Next Point.
Repeat this step until you have traced all but the final point.
5. When the pointer is over the last point you need to trace, press or click Last Point.
Trace Remnant draws a line between this point and the first point to close the
remnant.
6. Press or click OK to let TeachTrace create the remnant.
TeachTrace connects the last point to the first point automatically and returns to the
Preview Window.
7. Press or click Files then Save to Disk.
8. Select a folder for the new remnant file from the Save to dropdown list.
It is helpful to create a folder named Remnant to hold your remnant files.
9. Enter a file name in the File Name field.
10. Press or click OK.

Teach Trace Mode

The Teach Trace function must be used in conjunction with an optional stand-alone
optical tracing system.

To use the manual function, press Select Manual Mode, which also enables the Change
Move Speed button so you can change the manual move speed. Press the Change Move
Speed button repeatedly to cycle through the programmed manual jog rate settings.

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Start Corner
The Start Corner setup parameter allows the user to select where the taught part will
begin for proper viewing on the screen.

Tracing Pitch
This determines how precisely to learn a part. The Tracing Pitch can be adjusted to trade
off resolution versus size of the taught part. This value does not affect the actual position
resolution of the part.

A good starting point for most tracing systems is 0.01”.

Arc Radial Error

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

Auto Closure Detect

This parameter is used to allow the CNC to detect that it has returned to the starting point.
With this feature ON, the CNC stops the motion of the tracer when the part is complete
allowing a lead-out to be programmed.

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Closure Over/Under Lap

By specifying a positive value for this parameter, the CNC does not stop the tracer until it
has gone past the start point by the amount of this parameter. By specifying a negative
value, the tracer stops as soon as the tracing head position is within this parameter’s
distance of the starting point. This is only available if the Auto Closure Detect is On.

Kerf Direction
Selects the kerf for cut segments.

Traverse/Pierce
Switches between the traverse and cut segments of the part as it is taught.

Select Auto/Manual Mode

Use this button to change trace modes. If you select manual mode, you can also use the
Change Move Speed button to change the trace speed.

Change Move Speed

Press this button to change the trace speed in manual mode.

Select Remnant Mode

Press this button to use remnant mode to create remnants.

Tracing a part
To trace a part while at the Teach Trace screen, select Auto mode, then select traverse or
pierce. You can switch between traverse and pierce during the tracing procedure.
Position the optical sensor near the part drawing and press Start. Use the sensor
positioning controls to direct the sensor towards the part. Once the sensor has located the
part, the tracing system will follow the part outline until completion. When completed,
press OK. The part file can now be cut, saved or edited.

Refer to the instructions provided with your Optical tracing system for further details.

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Nester
Nester is a proprietary part nesting program, which allows the operator to manually group
or nest selected parts together as one part program to conserve raw materials and
maximize machine utilization. This nesting program is designed to maximize the control
features of graphical user interface, simplified keypad operation and advanced
communications software to provide quick, simple and logical programming.

Additionally, an optional Automatic Nesting feature may be enabled to perform true

shape, single station, automatic nesting. With its advanced Graphical User Interface, ease
of use and advanced profile positioning algorithms, this Automatic Nesting feature can
greatly improve the output of your shape cutting operation by reducing overall process
time and increasing plate utilization. Contact your CNC vendor for details on enabling
this Automatic Nesting feature.

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Manual Nesting

Main Screen Layout

The main viewing area is the largest area of the screen and is located in the upper left
corner. The edge of the plate is displayed in dark green. The plate size displayed is based
on plate information that has been selected at the main setup screen.

The upper right corner of the main screen displays the part program list for the nest in
order of cut sequence. In the lower right, part position and orientation information for the
selected part program is displayed and can be manipulated for use as new parts are added.

Add Part
Pressing the Add Part soft key accesses the screen, which allows the user to select a part
program from a selected source.

Remove Part
This soft key is used to remove the selected part from the nest parts list.

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Cut Earlier
Pressing the Cut Earlier soft key will move the selected part program to an earlier
position in the part cut list. The sequence in which the parts are cut changes, but not the
selected part location in the nest.

Cut Later
Pressing the Cut Later soft key will move the selected part program to a later position in
the part cut list. The sequence in which the parts are cut changes, but not the selected
part location in the nest.

View Sheet / View Part

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

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

More information on use of this feature is provided in the Manual cutting section.

Arrow Key (Distance)

The Arrow Key allows the user to select one of five different preset move distances when
the arrow keys are pressed to locate parts in the nest. These five distances are definable
and are selected in the Nester setup screen.

Clear Nest
Clear Nest will delete all the parts located in the nested parts list from temporary
memory.

Setup
Pressing the Setup soft key accesses the Nester setup screen for configuring the variable
parameters when using Nester.

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Nester Setup
The following Setup parameters are used to configure the manual nesting process for use.

Arrow Motion
At this screen, the user can select different move increment dimensions. These
dimensions are used as move distance references when the control arrow keys are pressed
to place parts in position on the plate.

Autoposition
Autoposition is an automated feature of the Nester software to search for the next
available location to place a part that is being added to the nested part list. Autoposition
compares the overall block dimensions of the selected part and searches for the next
available block on the plate that is large enough to accommodate the part being loaded.
Values can be input for the Search Increment and Scrap Clearance parameters that are
used when searching for the next available part location.

Autoposition will not allow parts to be placed on top of other parts or inside other parts.
This feature is enabled or disabled by using the space key at the enable box.

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Using Nester
To begin, first select the plate size requirements for the nest at the Main Setup screen.
This information is used to display the plate size and plate orientation at the main view
screen to place parts on the plate. The plate information is retained with the nested part
program when saved.

Press the Nester soft key from the Shape Manager screen then enter the Nester Setup
Screen to configure the nesting software for use. Press OK to return to the Nester Main
Screen to begin placing parts in the nest.

Adding Parts
At the Nester Main Screen, press the Add Part soft key to add a new part to the nesting
part list. The first screen viewed will allow the user to select a part from the Simple
Shape Library, from a disk or from the host computer via link communications.

After a part has been selected from either location, the user will be prompted to select the
number of pieces desired.

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As new parts are added, they are displayed on the selected plate in preparation for final
placement.

At this screen, the part can be oriented, scaled and moved to final position. This is done
by moving to the Nester Part List and highlighting the file name. Then select the desired
field to manually offset, rotate, mirror and scale the part.

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To position the selected part, use the manual direction keys. The view screen will be
outlined by a bold blue border indicating that the arrow keys are active. Pressing the
arrow keys will allow movement of the part to the desired location on the plate. Each
time the arrow keys are pressed, the selected part will move in the direction of the arrow
by the increment set by the Arrow Key distance soft key. By use of the arrow distance
key, arrow keys and zooming in the view field, exact placement of the desired part may
be obtained.

Additional parts may be added to the nest in the same fashion as described above. To
customize your nest, you may decide to delete parts or add parts to the list and change the
order in which they are cut by use of the soft keys displayed. When finished, press OK to
return to the Main Cut screen and begin cutting the nest. The part nest is currently saved
as a temporary file until another part is loaded.

Saving a Nest
From the Main Cut screen, press the Files soft key then Save to Disk. From here the part
can be saved to a hard disk folder on the CNC, Diskette or USB memory stick. The
nested parts file may be saved as a nest or a part. Saving as a nest using the save as
Nester File feature, will create a larger file which will allow future modification of the
nest through Nester. Nested parts saved as a part file cannot be modified.

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HyperNest – CNC Automatic Nesting Software

Optional HyperNest - CNC feature - This true shape, single station, automatic nesting
package allows quick and simple nesting of profiles on to selected material sizes. With
its advanced Graphical User Interface, ease of use and advanced profile positioning
algorithms, HyperNest - CNC can greatly improve the output of your shape cutting
operation by reducing overall process time and increasing plate utilization.

Main Screen Layout

The main viewing area is the largest area of the screen and is located in the upper left
corner and is used to preview manual nests. During an automatic nest, this area will
remain blank. The plate size used during Automatic nesting is based on plate information
that has been selected at the main setup screen.

The upper right corner of the main screen displays the list of part programs and quantities
of parts to be automatically nested. In the lower right, there locations to save the nested
part program to a folder location and to assign a file name.

Note: This software feature is protected both by a software enable and a hardware key
(dongle) installed on the CNC.

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Automatic Nesting Setup

Pressing the Setup soft key accesses the following setup parameters and can be used to
configure the automatic nesting process for use. Note: If this feature is not available
(grayed out), the feature has not been enabled on your CNC. Contact your CNC vendor
for details on how to enable the Automatic Nesting feature.

Automatic Nesting
Switching the Nesting Parameter to Automatic enables the feature for use.

Part Spacing
The Part Spacing feature sets the spacing between parts during the Automatic Nesting
process.

Plate Edge Spacing

This parameter allows the user to set spacing around the edge of the plate to be used
during the Automatic Nesting process.

Program Origin
The Program Origin (nest start location) may be set to lower left, upper left, bottom left
or bottom right.

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Cut Direction
Cut Direction allows to user to select the direction the parts will be placed in during the
automatic nesting process. Options are: Left or Right, Right to Left, Top to Bottom and
Bottom to Top.

Nest Direction
Select the direction in which nests are placed in the automatic nesting process.

Return to Nest Start

When enabled, the Return to Nest Start feature will insert a traverse segment back to the
start point at the end of the nest.

Use Remnant
If remnants are created and saved for future use, select On to use one of these remnants
for automatic nesting.

Generate and Cut Offcut

Select On to generate offcuts for standard, rectangular nests.
If this feature is enabled, offcuts are created when 30% or more of the sheet remains after
nesting. The offcut is cut after a pause at the end of the nest on the last nested rectangular
sheet.

M65 Auto Reload

Select On to allow new sheets to be reloaded automatically.

When this feature is selected, there is a pause at the end of each sheet until the operator
presses Start to Resume. Then, a new sheet automatically loads and runs. Auto reload
works with standard, rectangular nests only.

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Using HyperNest – CNC

To begin, first select the plate size requirements for the nest at the Main Setup screen.
Press the Nester soft key from the Shape Manager Screen then enter the Setup Screen to
enable the Automatic Nesting software feature and configure the setup parameters for
use. Press OK to return to the Main Screen and begin placing parts in the nest.

Adding Parts
At the Main Screen, press the Add Part soft key to add a new part to the nesting part list.
The Add Part screen will allow the user to select a part from the Simple Shape Library,
from a disk or from the host computer via link communications.

After a part has been selected from the desired location, the user is prompted to select the
number of pieces to be included in the nest.

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After the number of parts is selected, a popup window displays to allow you to select
whether the selected part will be mirrored in the nest, for greater efficiency, or used as a
wildcard part. Wildcard parts “fill in” a sheet on which the nest occupies at least 75% of
the sheet.

As new parts are added, the part file name and quantity are displayed in the parts list
window in the upper right corner of the screen in preparation for final placement during
the Automatic Nesting process.

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Select the desired file location and assign a file name, then press the OK soft key to begin
the automatic nesting process. A progress window will be displayed during the nesting
process.

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Note: The nest process progresses quickly and not all shapes may be visible on screen or
other drawing anomalies may be noted during the nesting process.

In the event that more parts are selected than can fit on one plate, multiple plates or sheets
(nested program) files will be generated and saved in the selected folder with the selected
file name, but a numeric suffix will be added. Example: saving the part file as Nest may
generate multiple part files named NEST1.txt, NEST2.txt, NEST3.txt, etc.

Remove Part
A part may be removed from the part files list by highlighting the selected part in the files
list and pressing the Remove Part soft key prior to executing the nesting.

Note: The software feature on the CNC is protected by a hardware key or dongle. If the
hardware key has been removed from the CNC, the following message will appear when
the Nest Parts soft key has been pressed.

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Nest Summary
Upon completion of the nest, the software will provide a summary of the Automatic
Nesting process.

Statistical analysis of the process is provided for the number of sheets, time to execute
nest, total nest utilization and total number of shapes nested.

Note: Sheets that are generated with the exact same part configuration will be listed as
“Sheet No. # (total #)”.

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Scrolling down will allow you to view an analysis of the parts used and to view the
individual sheets produced and a listing of the net utilization for the specific sheet.

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Press OK to accept the nest and have the first sheet become the current part. Press the
Cancel key to reject the nest and return to the main nesting screen to add or remove parts
from the nest.

Main Screen View of Nest

Note: Parts with open loops or other invalid geometries may not be able to be
automatically nested. It may be possible to manually nest parts which have been rejected
by the Automatic Nesting function.

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

This simple CAD/CAM application lets you move easily from drawing to cutting.

HyperCAD Features
• English or Metric Units
• Part / Sheet viewing capabilities
• Scaling, mirroring or rotating of parts
• Repeating and copying of shapes
• Moving / modifying of lead-ins and lead-outs
• Add-on of chamfers, fillets and notches
• On-screen, full-part cutting simulation
• Built in Help functions

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This feature is offered as a limited use trial version. Contact your CNC vendor for
information on enabling unlimited use of this feature. This package may be used on the
CNC equipped with mouse and PC keyboard or offline on a PC.

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HyperNEST
HyperNEST is a full featured, automatic true shape application designed to allow quick
and simple nesting of profiles onto standard material sizes. The HyperNEST graphical
user interface greatly improves the output of any shape cutting operation.

HyperNEST Features
HyperNEST also lets mechanized end users achieve:
• Multi-torch nesting with a variable number of torches
• Bridging and chain cutting for common line cutting
• Extending consumable life
• “Move, drag and drop” manual interactive nesting
• Viewing and modifying of multiple sheets at the same time
• Multiple nesting scenarios for optimizing plate use and process cutting time
• Use of Wild Card parts to optimize plate utilization
• Automatic off-cut generation
• Built in Help functions

This feature is offered as a limited use trial version. Contact your CNC vendor for
information on enabling unlimited use of this feature. This package may be used on the
CNC equipped with mouse and PC keyboard or offline on a PC.

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

To launch the trial software, select the Evaluation Version.

Example

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Load from Disk
The following screen is used to load a part from a diskette, USB memory stick, or the
hard drive.

Load from
Select the source from which you load a part: diskette, USB memory stick, or a directory
on the hard disk. To add or remove a directory, double-click on the touch screen where
indicated.

Keypad operation: To select a different directory, use the ↑ and ↓ keys on the
keyboard. To add or remove new directory use the + or – key.

Files
Lists the files that are in the directory you selected in the Load from field. Press the
name of the files that you want to load.

Keypad operation: To scroll through different files, use the ↑, ↓, Page Up and Page
Down keys on the keyboard. To remove a file, use the - key on the keyboard. To select
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multiple files to load, highlight the first file selection, then use the ↑ and ↓ keys while
pressing the shift key to highlight the remaining files.
Note: You can only select multiple files if you are loading them from a diskette or USB
memory stick to the hard drive.

File name/Diskette file name

Displays the name of the file you selected. To remove a file, highlight the file name and
double-click on the touch screen where indicated.

Keypad operation: To remove a file using the keyboard, use the – key.

Preview
Check this box to preview the files you selected in the Preview Window.

Load to
Select the destination for the part; either load the part for cutting or save it in a directory
on the hard disk. To add or remove a directory, double-click on the touch screen where
indicated.

Keypad operation: To select a different directory, use the ↑ and ↓ keys on the
keyboard. To add a new directory, use the + key on the keyboard. To remove a
directory, use the - key on the keyboard.
Note: This selection is only available if you are loading the part from the diskette or USB
memory stick.

Hard drive file name

Enter the name for the file that you are loading on the hard drive.
Note: This selection is only available if you are loading the part from the diskette or USB
memory stick.

Resume Last Part

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

Show Certain Files

Allows the operator to search the selected folder for specific part files by using wildcard
searches with both the asterisk (*) and question mark (?).

Keypad operation: To input the asterisk when using a keyboard, press the left shift key
(purple) and the backspace key. To input the question mark, press the right shift key
(blue) and the backspace key.

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Show All Files

Allows the operator to switch from viewing the selected files to viewing all files with the
predetermined file extensions.

After all the parameters are set, press Enter on the keyboard to load the part.
Resume Last Part Features
Rush Job Interrupt
Allows you to pause the current part program and retain the part and current position
information. At the Pause screen, press the Cancel key. A message window offers you
the opportunity to save the part information to use later.

If the user selects YES, the Resume Last Part button will be viewable at the Files Screen.
The user can load and execute another part program and then press the Resume Last Part
soft key to return to the original part and resume cutting.

Automated Power Loss Recovery

Uses the Resume Last Part feature similar to the Rush Job Interrupt. However, the
machine must be homed to ensure proper positioning before it can resume cutting the
part.
You can also use this feature if there is an overtravel, or similar fault.

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Save to Disk
This screen is used to save a part to a diskette, USB memory stick, or the hard drive.

Save to
Select whether you save to the diskette, USB memory or to a directory on the hard disk.
To add or remove a directory, double-click on the touch screen where indicated.

Keypad operation: To select a different directory, use the ↑ and ↓ keys on the
keyboard. To add a new directory, use the + key on the keyboard. To remove a
directory, use the - key on the keyboard.

File name/Diskette file

Enter the file name that you are giving the file you are loading on the disk.
If you select the Save Original Text option, the system will save the part to the disk in its
original programming format.
Note: This selection is not available if you are saving the file to the diskette or USB
memory stick from the hard drive.

Save From
Select whether you save from the current part or from a directory on the hard disk. To
add or remove a directory, double-click on the touch screen where indicated.

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Keypad operation: To select a different directory, use the ↑ and ↓ keys on the
keyboard. To add a new directory, use the + key on the keyboard. To remove a
directory, use the - key on the keyboard.
Note: This selection is only available if saving to the Diskette or USB memory stick from
the hard drive.

Files
Select one or more part files from the list of all the files that are in the Load from
directory that can be loaded from the disk. To remove a file, double-click on the touch
screen where indicated.

Keypad operation: To scroll through different files, use the ↑, ↓, PAGE UP and PAGE
DOWN keys on the keyboard. To remove a file, use the - key on the keyboard. To select
multiple files, highlight the first file selection, then use the ↑ and ↓ keys while pressing
the shift key to highlight the remaining files.
Note: This selection and Multiple file selection are only available if you are saving files
to the diskette or USB memory stick from the hard drive.

Hard drive file name

Enter the name that you are giving to the file if you are loading it on the hard drive.
Note: This selection is only available if you are saving files to the diskette or USB
memory stick from the hard drive.

Preview
Check this box to preview the file that is selected in the Files listbox.

Keypad operation: To check or uncheck the box, press the SPACE key on the keyboard
when the Preview box has the focus.
Note: This selection is only available if you are saving files to the diskette or USB
memory stick from the hard drive.

After you have made all your selections and entries, press OK to save the part.

Save Log to Disk

This feature is enabled when Key Logging is selected in setups.
The Key Logging feature is used as a diagnostic tool to record key presses that are made
at the control during operation. When this feature is enabled, all key presses and
application faults are saved in a daily log file that can be sent to the control manufacturer
for evaluation.

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Download from Host

The following screen is where you download a part from a host computer. After all the
parameters below are set, press Enter on the keyboard to start the download.

Download from
Selects the directory on the host computer from which you want to download a part. To
add or remove a directory, double-click on the touch screen where indicated.

Keypad operation: To select a different directory, use the ↑ and ↓ keys on the
keyboard. To add or remove new directory use the + or – key.

Files
Lists the files in the download from directory that can be downloaded from the host
computer.

Keypad operation: To scroll through different files, use the ↑, ↓, PAGE UP and PAGE
DOWN keys on the keyboard. To remove a file, use the - key on the keyboard. To select
multiple files to download, highlight the first file selection, then use the ↑ and ↓ keys
while pressing the shift key to highlight the remaining files.

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Remote file name

The name of the remote file that will be downloaded from the host computer.

Preview
Check this box to preview the file that you selected in the Files list box. To check or
uncheck the box, press the SPACE key on the keyboard when the Preview box has the
focus.

Download to
Selects you want to download the part -- to the current part in memory or to a directory
on the local hard disk. If you select one of the local directories, the Local file name field
displays.

Keypad operation: To select a different directory, use the ↑ and ↓ keys on the
keyboard. To add a new directory, use the + key on the keyboard. To remove a
directory, use the - key on the keyboard.

Local file name

The user-defined file name assigned to the file that is being downloading to the hard
drive.

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Upload to Host
Use this screen to upload a part to a host computer. After all the parameters are set, press
Enter on the keyboard to start the upload.

Upload to
Select the directory on the host computer to which you want to upload a file. To add or
remove a directory, double-click on the touch screen where indicated.

Keypad operation: To select a different directory, use the ↑ and ↓ keys on the
keyboard. To add a new directory, use the + key on the keyboard. To remove a
directory, use the - key on the keyboard.

Remote file name

Enter the name of the file that you are uploading to the host computer.

Upload from
Select whether you upload the current part in memory or from a directory on the local
hard disk. If you select one of the local directories, the Files, Local file name and
Preview fields display. To add or remove a directory, double-click on the touch screen
where indicated.

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Keypad operation: To select a different directory, use the ↑ and ↓ keys on the
keyboard. To add a new directory, use the + key on the keyboard. To remove a
directory, use the - key on the keyboard.
Note: This selection is only available if you are saving a file to the diskette or USB
memory stick from the hard drive.

Files
Lists all the files in the upload from directory that can be uploaded to the host computer.
To remove a file, double-click on the touch screen where indicated.

Keypad operation: To scroll through different files, use the ↑, ↓, Page Up and Page
Down keys on the keyboard. To remove a file, use the - key on the keyboard. To select
multiple files to upload, highlight the first file selection, then use the ↑ and ↓ keys while
pressing the shift key to highlight the remaining files.

Local file name

The name of the local file that will be uploaded to the host computer.

Preview
If you check this box, you can preview the file you selected in the Preview window.

Keypad operation: To check or uncheck the box, press the SPACE key on the keyboard
when the Preview box has the focus.

Loading Invalid Files

While loading the desired part file, the control will check the part for proper geometry
and other errors. If an error is detected, a message is displayed:

If the system attempts to load the part, the control highlights the invalid line of code from
the text editor.
For example, in the following sample code, the line of code “XXXXXXXX” is invalid
and has been circled for easy detection. Correct the file using the text editor. After the
invalid code is corrected, the control will attempt to translate the part file and will
indicate additional invalid codes.

132
 Files

133
Files

134
Library Shapes
Double-click on a shape to edit it.

Library Shape Setup

On the screen for the shape you select, enter the correct dimensions to create the part you
require. There is a small Help icon in the lower right hand corner of the display to
indicate which parameter the control is looking for. The current parameter is highlighted
with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

135
Library Shapes

Rectangle

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

136
 Library Shapes

Base Width
Enter the width of the base of the part.

Height
Enter the height of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Note: the Rectangle simple shape has the ability to select the location for the lead-in and
lead-out by pressing the Space key. Press the Space key to move the lead-in and lead-out
to the next available location.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

Lead Type
Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

137
Library Shapes

Circle

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

138
 Library Shapes

Circle Diameter
Enter the diameter of the part.

Lead-In Radius

Overburn Length
Parts that contain a circular element user overburn. Overburn specifies the arc length that
the torch will travel past the circle closure point. The dimension entered is the chord
length of the overburn-arc.

In some cases it is desirable to have an underburn length. For these conditions, enter a
negative number for the overburn length.

Lead Out Radius

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

Lead Type
Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

139
Library Shapes

Triangle

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

140
 Library Shapes

BaseWidth
Enter the width of the base of the part.

Left Side Angle

Enter the number of degrees for the angle on the left side of the part.

Right Side Angle

Enter the number of degrees for the angle on the right side of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

141
Library Shapes

L-Bracket

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

142
 Library Shapes

Base Width
Enter the width of the base of the part.

Top Width
Enter the width of the top of the part.

Overall Height
Enter the height of the part from the base to the top.

Side Height
Enter the height of the shortest side of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

143
Library Shapes

Trapezoid

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

144
 Library Shapes

Base Width
Enter the width of the base of the part.

Height
Enter the height of the part.

Left Side Angle

Enter the number of degrees for the left side angle of the part.

Right Side Angle

Enter the number of degrees for the right side angle of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

145
Library Shapes

Slant Rectangle

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

146
 Library Shapes

Base Width
Enter the width of the base of the part.

Top Width
Enter the width of the top of the part.

Overall Height
Enter the height of the part from the base to the top.

Side Height
Enter the height of the shortest side of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

147
Library Shapes

Gambrel Rectangle

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

148
 Library Shapes

Base Width
Enter the width of the base of the part.

Left Slant Width

Enter the width (measured horizontally) of the left, slanted side of the part.

Right Slant Width

Enter the width (measured horizontally) of the right, slanted side of the part.

Overall Height
Enter the height of the part from the base to the top.

Side Height
Enter the height of the sides of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

149
Library Shapes

Roofed Rectangle

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

150
 Library Shapes

Base Width
Enter the width of the base of the part.

Left Slant Width

Enter the width (measured horizontally) of the left, slanted side of the part.

Overall Height
Enter the height of the part from the base to the point at the top.

Side Height
Enter the height of the sides of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

151
Library Shapes

4-Sided Polygon

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

152
 Library Shapes

Base Width
Enter the width of the base of the part.

Left Slant Width

Enter the width (measured horizontally) of the left, slanted side of the part.

Overall Height
Enter the height of the part from the base to the point at the top.

Side Height
Enter the height of the sides of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

153
Library Shapes

5-Sided Polygon

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

154
 Library Shapes

Overall Width
Enter the width of the part.

Left Slant Width

Enter the width of the slant (measured horizontally) of the left side of the part.

Right Slant Width

Enter the width of the slant (measured horizontally) of the right side of the part.

Overall Height
Enter the height of the part, from base to top.

Side Height
Enter the height of the right side of the part.

Lead In Radius
Enter the radius of the lead-in arc.

Lead Out Radius

Enter the radius of the lead-out arc.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

Lead Type
Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

155
Library Shapes

Oval

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

156
 Library Shapes

Width
Enter the width of the part.

Height
Enter the height of the part.

Lead In Radius
Enter the radius of the lead-in arc.

Overburn Length
Parts that contain a circular element user overburn. Overburn specifies the arc length that
the torch will travel past the circle closure point. The dimension entered is the chord
length of the overburn-arc.

In some cases it is desirable to have an underburn length. For these conditions, enter a
negative number for the overburn length.

Lead Out Radius

Enter the radius of the lead-out arc.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

Lead Type
Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

157
Library Shapes

Circle with Flat Side

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

158
 Library Shapes

Circle Diameter
Enter the length of the diameter of the part.

Center to Flat Side

Enter the distance from the center to the flat side of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

159
Library Shapes

Circle Slice

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

160
 Library Shapes

Circle Radius
Enter the radius (straight side) of the part.

Slice Angle
Enter the number of degrees of the angle of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

161
Library Shapes

Straight Slots

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

162
 Library Shapes

Slot Width
Enter the width of the slots.

Slot Height
Enter the height of the slots.

Number of Slots
Enter the number of slots in the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

163
Library Shapes

Angled Slots

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

164
 Library Shapes

Slot Width
Enter the width of the slots.

Slot Height
Enter the height of the slots.

Slot Angle
Enter the number of degrees for the angles at the end of each slot.

Number of Slots
Enter the number of slots in the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

165
Library Shapes

Horizontal Rip

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

166
 Library Shapes

Length
Enter the length of the horizontal rip.

167
Library Shapes

Vertical Rip

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

168
 Library Shapes

Length
Enter the length of the vertical rip.

169
Library Shapes

Flange

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

170
 Library Shapes

Flange Outer Diameter

Enter the diameter of the outer edge of the part.

Flange Inner Diameter

Enter the diameter of the inner edge of the part.

Lead In Radius
Enter the radius of the lead-in arc.

Overburn Length
Parts that contain a circular element user overburn. Overburn specifies the arc length that
the torch will travel past the circle closure point. The dimension entered is the chord
length of the overburn-arc.

In some cases it is desirable to have an underburn length. For these conditions, enter a
negative number for the overburn length.

Lead Out Radius

Enter the radius of the lead-out arc.

Lead Type
Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

171
Library Shapes

Circle with Rectangular Hole

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

172
 Library Shapes

Circle Diameter
Enter the diameter of the outer circle.

Hole Width
Enter the width of the rectangular hole.

Hole Height
Enter the height of the rectangular hole.

Lead In Radius
Enter the radius of the lead-in arc.

Overburn Length
Parts that contain a circular element user overburn. Overburn specifies the arc length that
the torch will travel past the circle closure point. The dimension entered is the chord
length of the overburn-arc.

In some cases it is desirable to have an underburn length. For these conditions, enter a
negative number for the overburn length.

Lead Out Radius

Enter the radius of the lead-out arc.

Lead Type
Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

173
Library Shapes

Gusset

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

174
 Library Shapes

Base Width
Enter the width of the base of the part.

Height
Enter the height of the part.

Clearance Radius
Enter the length of the radius of the clearance curve.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

175
Library Shapes

8-Sided

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

176
 Library Shapes

Left Slant Width

Enter the width of the side that slants to the left.

Base Width
Enter the width of the base of the part.

Right Slant Width

Enter the width of the side that slants to the right.

Top Slant Height

Enter the height of the slanted sides on the top of the part.

Side Height
Enter the length of each side.

Bottom Slant Height

Enter the height of the slanted sides on the bottom of the part.

Lead In Radius
Enter the radius of the lead-in arc.

Lead Out Radius

Enter the radius of the lead-out arc.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

Lead Type
Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

177
Library Shapes

Rectangle with Convex Corners

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

178
 Library Shapes

Base Width
Enter the width of the base of the part.

Height
Enter the height of the part.

Corner Radius
Enter the length of the radius of the curve in the convex corners.

Convex Corners
Enter the number of convex corners on the part.

Lead In Radius
Enter the radius of the lead-in arc.

Lead Out Radius

Enter the radius of the lead-out arc.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

Lead Type
Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

179
Library Shapes

Rectangle with Concave Corners

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

180
 Library Shapes

Base Width
Enter the width of the base of the part.

Height
Enter the height of the part.

Corner Radius
Enter the length of the radius of the curve in the concave corners.

Convex Corners
Enter the number of convex corners for the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

181
Library Shapes

L-Bracket with Elbow Radii

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

182
 Library Shapes

Base Width
Enter the width of the base of the part.

Top Width
Enter the width of the top of the part.

Overall Height
Enter the height of the part, from base to top.

Side Height
Enter the height of the right side of the part.

Inside Elbow Radius

Enter the radius of the inside curve of the part.

Outside Elbow Radius

Enter the radius of the outer curve of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

Lead Type
Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

183
Library Shapes

Slant L-Bracket with Elbow Radii

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

184
 Library Shapes

Base Width
Enter the width of the base of the part.

Top Width
Enter the width of the top of the part.

Overall Height
Enter the height of the part from base to top.

Side Height
Enter the height of the short side of the part.

Inside Elbow Radius

Enter the radius of the inside curve of the part.

Outside Elbow Radius

Enter the radius of the outer curve of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

Lead Type
Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

185
Library Shapes

Trapezoid with Convex Corners

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

186
 Library Shapes

Base Width
Enter the width of the base of the part.

Height
Enter the height of the part.

Left Side Angle

Enter the number of degrees for the angle on the left side of the part.

Right Side Angle

Enter the number of degrees for the angle on the right side of the part.

Corner Radius
Enter the radius of the curve in the convex corners of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

187
Library Shapes

Flange Slice

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

188
 Library Shapes

Flange Outer Radius

Enter the radius of the outside curved edge of the part.

Flange Inner Radius

Enter the radius of the inside curved edge of the part.

Slice Angle
Enter the angle of the straight sides of the part

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

189
Library Shapes

Elbow

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

190
 Library Shapes

Elbow Outer Radius

Enter the radius of the outer edge of the part.

Elbow Inner Radius

Enter the radius of the inner edge of the part.

Elbow Angle
Enter the number of degrees of the angle formed by the straight edges of the part.

End Length
Enter the length of the ends of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

191
Library Shapes

Flange Repair Ring

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

192
 Library Shapes

Flange Outer Diameter

Enter the length of the diameter of the outer, circular edge of the part.

Flange Inner Diameter

Enter the length of the diameter of the inner hole within the part.

Lead In Radius
Enter the radius of the lead-in arc.

Overburn Length
Parts that contain a circular element user overburn. Overburn specifies the arc length that
the torch will travel past the circle closure point. The dimension entered is the chord
length of the overburn-arc.

In some cases it is desirable to have an underburn length. For these conditions, enter a
negative number for the overburn length.

Lead Out Radius

Enter the radius of the lead-out arc.

Lead Type
Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

193
Library Shapes

Rectangle with Rectangular Hole

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

194
 Library Shapes

Base Width
Enter the width of the base of the part.

Overall Height
Enter the height of the part from base to top.

Hole Width
Enter the width of the hole within the part.

Hole Height
Enter the height of the hole within the part.

Side to Hole
Enter the distance between the left edges of the part and the hole within it.

Top to Hole
Enter the distance between the top of the part and the top of the hole within it.

Lead-In/Lead-Out
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Hole Lead Type

Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

195
Library Shapes

Rectangle with Circular Hole

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

196
 Library Shapes

Base Width
Enter the width of the base of the part.

Overall Height
Enter the height of the part from base to top.

Hole Diameter
Enter the diameter of the hole within the part.

Side to Hole
Enter the distance from the left side of the part to the center of the hole within it.

Top to Hole
Enter the distance from the top of the part to the center of the hole within it.

Lead-In/Lead-Out
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Overburn Length
Parts that contain a circular element user overburn. Overburn specifies the arc length that
the torch will travel past the circle closure point. The dimension entered is the chord
length of the overburn-arc.

In some cases it is desirable to have an underburn length. For these conditions, enter a
negative number for the overburn length.

Hole Lead Type

Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

197
Library Shapes

Rectangle with Circular Hole and Convex Corners

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

198
 Library Shapes

Base Width
Enter the width of the base of the part.

Overall Height
Enter the height of the part from the base to the top.

Hole Diameter
Enter the diameter of the hole within the part.

Side to Hole
Enter the distance between the left side of the part and the center of the hole within it.

Top to Hole
Enter the distance between the top of the part and the center of the hole within it.

Corner Radius
Enter the length of the radius of the convex corners.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Overburn Length
Parts that contain a circular element user overburn. Overburn specifies the arc length that
the torch will travel past the circle closure point. The dimension entered is the chord
length of the overburn-arc.

In some cases it is desirable to have an underburn length. For these conditions, enter a
negative number for the overburn length.

Hole Lead Type

Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

199
Library Shapes

Rectangle with Tab

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

200
 Library Shapes

Tab to Left Side

Enter the distance between the left side of the part and the left side of the tab.

Tab Width
Enter the width of the tab.

Tab to Right Side

Enter the distance between the right side of the part and the right side of the tab.

Tab Height
Enter the height of the tab.

Overall Heigth
Enter the height of the part from the base to the top of the tab.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

201
Library Shapes

Rectangle with Convex Tab

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

202
 Library Shapes

Tab to Left Side

Enter the distance between the left side of the part and the left side of the tab.

Tab Width
Enter the width of the tab.

Tab to Right Side

Enter the distance between the right side of the part and the right side of the tab.

Tab Height
Enter the height of the tab.

Overall Heigth
Enter the height of the part from the base to the top of the tab.

Convex Diameter
Enter the diameter of the convex curve of the tab.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

203
Library Shapes

Rectangle with Notch

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

204
 Library Shapes

Notch to Left Side

Enter the distance between the left sides of the part and the notch.

Notch Width
Enter the width of the notch.

Notch to Right Side

Enter the distance between the right sides of the notch and the part.

Notch Height
Enter the height of the notch.

Overall Height
Enter the height of the part from base to top.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

205
Library Shapes

Rectangle with Slant Notch

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

206
 Library Shapes

Notch to Left Side

Enter the distance between the left sides of the part and the notch.

Left Slant Width

Enter the width of the left slant in the notch.

Notch Width
Enter the width of the notch.

Right Slant Width

Enter the width of the right slant in the notch.

Notch to Right Side

Enter the distance between the right sides of the notch and the part.

Notch Height
Enter the height of the notch.

Overall Height
Enter the height of the part from base to top.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

207
Library Shapes

Rectangle with Radius Notch

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

208
 Library Shapes

Radius to Left Side

Enter the distance between the left sides of the part and the radius.

Radius Diameter
Enter the diameter of the radius.

Radius to Right Side

Enter the distance between the right sides of the part and the radius.

Height
Enter the height of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

209
Library Shapes

Convex Rectangle

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

210
 Library Shapes

Base Width
Enter the width of the base of the part.

Side Height
Enter the height of the rectangular portion of the part.

Convex Diameter
Enter the diameter of the convex portion of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

211
Library Shapes

Concave Rectangle

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

212
 Library Shapes

Base Width
Enter the width of the base of the part.

Center Height
Enter the height of the part between the base and the lowest point of the concave side.

Concave Diameter
Enter the diameter of the concave portion of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

213
Library Shapes

Triangle with Concave Side

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

214
 Library Shapes

Base Width
Enter the width of the base of the part.

Height
Enter the height of the part.

Concave Radius
Enter the length of the radius of the concave portion of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

215
Library Shapes

Polygon with Concave Side

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

216
 Library Shapes

Base Width
Enter the width of the base of the part.

Overall Height
Enter the height of the part from the base to the top.

Side Height
Enter the height of the right side of the part.

Concave Radius
Enter the radius of the concave portion of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

217
Library Shapes

Slant Rectangle with Radius

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

218
 Library Shapes

Base Width
Enter the width of the base of the part.

Top Width
Enter the width of the top of the part.

Overall Height
Enter the height of the part from the base to the top.

Side Height
Enter the height of the right side of the part. The height of the side must be less than the
overall height of the part.

Clearance Radius
Enter the length of the radius of the clearance curve.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

219
Library Shapes

Slant Rectangle with Circular Hole

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

220
 Library Shapes

Base Width
Enter the width of the base of the part.

Top Width
Enter the width of the top of the part.

Overall Height
Enter the height of the part from the base to the top.

Side Height
Enter the height of the right side of the part. The height of the side must be less than the
overall height of the part.

Hole Diameter
Enter the diameter of the hole within the part.

Side to Hole
Enter the distance from the left side of the part to the center of the circle within it.

Top to Hole
Enter the distance from the top of the part to the center of the circle within it.

Lead In Radius
Enter the radius of the lead-in arc.

Overburn Length
Parts that contain a circular element user overburn. Overburn specifies the arc length that
the torch will travel past the circle closure point. The dimension entered is the chord
length of the overburn-arc.

In some cases it is desirable to have an underburn length. For these conditions, enter a
negative number for the overburn length.

Lead Out Radius

Enter the radius of the lead-out arc.

221
Library Shapes

Slant Rectangle with Beveled Corners

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

222
 Library Shapes

Base Width
Enter the width of the base of the part.

Top Width
Enter the width of the top of the part.

Overall Height
Enter the height of the part from the base to the top.

Side Height
Enter the height of the right side of the part. The height of this side must be less than the
height of the left side.

Corner Selection
Use the dropdown list to select a corner of the part. Use the remaining fields to specify
the style of that corner. Repeat your selections for up to three corners.

Corner Type
Use the dropdown list to select a square or bevel corner.

If you select a bevel corner, use the Corner Width and Corner Height fields to enter the
dimensions of the bevel.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

223
Library Shapes

Cross

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

224
 Library Shapes

Left Width
Enter the width of the left side of the part.

Center Width
Enter the width of the center of the part.

Right Width
Enter the width of the right side of the part.

Top Height
Enter the height of the top of the part.

Center Height
Enter the height of the central portion of the part.

Bottom Height
Enter the height of the bottom portion of the part

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

225
Library Shapes

Cross with Circular Hole and Concave Inside Corners

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

226
 Library Shapes

Left Width
Enter the width of the left side of the part.

Center Width
Enter the width of the center of the part.

Right Width
Enter the width of the right side of the part.

Top Height
Enter the height of the top of the part.

Center Height
Enter the height of the central portion of the part.

Bottom Height
Enter the height of the bottom portion of the part

Hole Diameter
Enter the length of the diameter of the hole within the part.

Inside Corner Radius

Enter the length of the radius of the curve on the inside of the corner.

Lead In Radius
Enter the radius of the lead-in arc.

Lead Out Radius

Enter the radius of the lead-out arc.

227
Library Shapes

4 Sided Convex Rectangle

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

228
 Library Shapes

Base Width
Enter the width of the rectangular base of the part.

Base Height
Enter the height of the rectangular portion of the part.

Left Convex Radius

Enter the length of the radius of the left convex side of the part.

Right Convex Radius

Enter the length of the radius of the right convex side of the part.

Top Convex Radius

Enter the length of the radius of the top convex side of the part.

Bottom Convex Radius

Enter the length of the radius of the right convex side of the part.

Corner Size
Enter the length and height of the corners of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

229
Library Shapes

4 Sided Concave Rectangle

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

230
 Library Shapes

Base Width
Enter the width of the base of the part.

Base Height
Enter the height of the part from the base to the top.

Left Concave Radius

Enter the length of the radius of the left concave side of the part.

Right Concave Radius

Enter the length of the radius of the right concave side of the part.

Top Concave Radius

Enter the length of the radius of the top concave side of the part.

Bottom Concave Radius

Enter the length of the radius of the bottom concave side of the part.

Corner Size
Enter the length and height of the corners of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

231
Library Shapes

Pipe Mount

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

232
 Library Shapes

Left End Width

Enter the distance between the left side and the center of the left pipe.

Distance Between Pipes

Enter the distance between the center of the pipes.

Right End Width

Enter the distance between the right side and the center of the right pipe.

Height
Enter the height of the part.

Pipe Radius
Enter the radius (measured vertically) of the pipes.

Number of Pipes
Enter the number of pipes in the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

233
Library Shapes

Bolt Hole Circle

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

234
 Library Shapes

Circle Diameter
Enter the length of the diameter of the part.

Bolt Hole Diameter

Enter the length of the diameter of the bolt holes.

Bolt Hole Offset

Enter the distance between the centers of the bolt holes .

Number of Bolt Holes

Enter the number of bolt holes within the part.

Lead In Radius
Enter the radius of the lead-in arc.

Overburn Length
Parts that contain a circular element user overburn. Overburn specifies the arc length that
the torch will travel past the circle closure point. The dimension entered is the chord
length of the overburn-arc.

In some cases it is desirable to have an underburn length. For these conditions, enter a
negative number for the overburn length.

Lead Out Radius

Enter the radius of the lead-out arc.

Lead Type
Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

235
Library Shapes

Bolt Hole Flange

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

236
 Library Shapes

Flange Outer Diameter

Enter the length of the diameter of the outer edge of the part.

Flange Inner Diameter

Enter the length of the diameter of the circle at the center of the part.

Bolt Hole Diameter

Enter the length of the diameter of the bolt holes.

Bolt Hole Offset

Enter the distance between the centers of the bolt holes .

Number of Bolt Holes

Enter the number of bolt holes within the part.

Lead In Radius
Enter the radius of the lead-in arc.

Overburn Length
Parts that contain a circular element user overburn. Overburn specifies the arc length that
the torch will travel past the circle closure point. The dimension entered is the chord
length of the overburn-arc.

In some cases it is desirable to have an underburn length. For these conditions, enter a
negative number for the overburn length.

Lead Out Radius

Enter the radius of the lead-out arc.

Lead Type
Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

237
Library Shapes

Bolt Hole Rectangle

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

238
 Library Shapes

Base Width
Enter the width of the base of the part.

Overall Height
Enter the height of the part from the base to the top.

Bolt Hole Diameter

Enter the length of the diameter of the bolt holes.

Bolt Hole Offset Width

Enter the distance between the center of the bolt holes and the side of the part.

Bolt Hole Offset Height

Enter the distance between the center of the bolt holes and the top or bottom of the part.

Lead In

Overburn Length
Parts that contain a circular element user overburn. Overburn specifies the arc length that
the torch will travel past the circle closure point. The dimension entered is the chord
length of the overburn-arc.

In some cases it is desirable to have an underburn length. For these conditions, enter a
negative number for the overburn length.

Lead Out

Bolt Hole Lead Type

Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

239
Library Shapes

Bolt Hole Rectangle with Convex Corners

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

240
 Library Shapes

Base Width
Enter the width of the base of the part.

Overall Hieght
Enter the height of the part from the base to the top.

Corner Radius
Enter the length of the radius of the convex corners.

Bolt Hole Diameter

Enter the length of the diameter of the bolt holes.

Bolt Hole Offset Width

Enter the distance between the center of the bolt holes and the side of the part.

Bolt Hole Offset Height

Enter the distance between the center of the bolt holes and the top or bottom of the part.

Lead In Radius
Enter the radius of the lead-in arc.

Overburn Length
Parts that contain a circular element user overburn. Overburn specifies the arc length that
the torch will travel past the circle closure point. The dimension entered is the chord
length of the overburn-arc.

In some cases it is desirable to have an underburn length. For these conditions, enter a
negative number for the overburn length.

Lead Out Radius

Enter the radius of the lead-out arc.

Lead Type
Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

241
Library Shapes

Bolt Hole Rectangle with Center Hole

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

242
 Library Shapes

Base Width
Enter the width of the base of the part.

Overall Height
Enter the height of the part from the base to the top.

Center Diameter
Enter the length of the diameter of the central hole.

Bolt Hole Diameter

Enter the length of the diameter of the bolt holes.

Bolt Hole Offset Width

Enter the distance between the center of the bolt holes and the side of the part.

Bolt Hole Offset Height

Enter the distance between the center of the bolt holes and the top or bottom of the part.

Lead-In/Lead-Out
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Overburn Length
Parts that contain a circular element user overburn. Overburn specifies the arc length that
the torch will travel past the circle closure point. The dimension entered is the chord
length of the overburn-arc.

In some cases it is desirable to have an underburn length. For these conditions, enter a
negative number for the overburn length.

Hole Lead Type

Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

243
Library Shapes

Bolt Hole Rectangle with Center Hole and Convex Corners

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

244
 Library Shapes

Base Width
Enter the width of the base of the part.

Overall Height
Enter the height of the part from the base to the top.

Corner Radius
Enter the radius of the convex corners.

Center Diameter
Enter the diameter of the central hole.

Bolt Hole Diameter

Enter the diameter of the bolt holes.

Bolt Hole Offset Width

Enter the distance between the center of the bolt holes and the side of the part.

Bolt Hole Offset Height

Enter the distance between the center of the bolt holes and the top or bottom of the part.

Lead In Radius
Enter the radius of the lead-in arc.

Overburn Length
Parts that contain a circular element user overburn. Overburn specifies the arc length that
the torch will travel past the circle closure point. The dimension entered is the chord
length of the overburn-arc.

In some cases it is desirable to have an underburn length. For these conditions, enter a
negative number for the overburn length.

Lead Out Radius

Enter the radius of the lead-out arc.

245
Library Shapes

Rounded L-Bracket

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

246
 Library Shapes

Base Width
Enter the width of the base of the part.

Top Width
Enter the width of the top of the part.

Overall Height
Enter the height of the part from the base to the top.

Side Height
Enter the height of the right side.

End Radius
Enter the length of the radius of the curve at the corners of the part.

Elbow Radius
Enter the length of the radius of the curve at the elbow of the part.

Lead In Radius
Enter the radius of the lead-in arc.

Lead Out Radius

Enter the radius of the lead-out arc.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

Lead Type
Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

247
Library Shapes

Horseshoe

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

248
 Library Shapes

Outside Diameter
Enter the diameter of the outside curved portion of the part.

Inside Diameter
Enter the diameter of the inside curved portion of the part.

Side Height
Enter the height of the straight sides of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Part Type
Indicate whether you want to cut the part as a separate piece or a hole in a larger part.
Chain cut options are available for simple shapes that have external cut paths.

249
Library Shapes

Convex Roof Trapezoid with Hole

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

250
 Library Shapes

Convex Diameter
Enter the diameter of the convex portion of the part.

Hole Diameter
Enter the diameter of the hole within the part.

Left Side to Hole

Enter the distance between the left corner of the base to the center of the circle.

Right Side to Hole

Enter the distance between the right corner of the base to the center of the circle.

Bottom to Hole
Enter the distance between the base and the center of the circle.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Overburn Length
Parts that contain a circular element user overburn. Overburn specifies the arc length that
the torch will travel past the circle closure point. The dimension entered is the chord
length of the overburn-arc.

In some cases it is desirable to have an underburn length. For these conditions, enter a
negative number for the overburn length.

Hole Lead Type

Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

251
Library Shapes

Convex Roof Polygon with Hole

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

252
 Library Shapes

Convex Diameter
Enter the diameter of the convex portion of the part.

Hole Diameter
Enter the diameter of the hole within the part.

Left Side to Hole

Enter the distance between the left corner of the base to the center of the circle.

Right Side to Hole

Enter the distance between the right corner of the base to the center of the circle.

Bottom to Hole
Enter the distance between the base and the center of the circle.

Side Height
Enter the height of the straight sides of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

Overburn Length
Parts that contain a circular element user overburn. Overburn specifies the arc length that
the torch will travel past the circle closure point. The dimension entered is the chord
length of the overburn-arc.

In some cases it is desirable to have an underburn length. For these conditions, enter a
negative number for the overburn length.

Hole Lead Type

Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

253
Library Shapes

Convex Roof Polygon with Oval Hole and Concave Bottom

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

254
 Library Shapes

Convex Diameter
Enter the diameter of the convex portion of the part.

Hole Width
Enter the width of the hole within the part.

Hole Height
Enter the height of the hole within the part.

Left Side to Hole

Enter the distance between the left corner of the base to the center of the hole.

Right Side to Hole

Enter the distance between the right corner of the base to the center of the hole.

Bottom to Hole
Enter the distance between the base and the center of the hole.

Side Height
Enter the height of the straight sides of the part.

Bottom Radius
Enter the radius of the curve on the bottom of the part.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

255
Library Shapes

Pulley Cover

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

256
 Library Shapes

Left Height
Enter the diameter of the outside, left edge.

Right Height
Enter the diameter of the outside, right edge.

Left Hole Diameter

Enter the diameter of the left hole within the part.

Right Hole Diameter

Enter the diameter of the right hole within the part.

Hole Offset
Enter the distance between the centers of the two holes.

Lead In Radius
Enter the radius of the lead-in arc.

Overburn Length
Parts that contain a circular element user overburn. Overburn specifies the arc length that
the torch will travel past the circle closure point. The dimension entered is the chord
length of the overburn-arc.

In some cases it is desirable to have an underburn length. For these conditions, enter a
negative number for the overburn length.

Lead Out Radius

Enter the radius of the lead-out arc.

Lead Type
Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

257
Library Shapes

Paddle Blind

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

258
 Library Shapes

Left Height
Enter the diameter of the outside, left edge.

Center Height
Enter the height of the center of the part.

Right Height
Enter the diameter of the outside, right edge.

Left Hole Diameter

Enter the diameter of the left hole within the part.

Right Hole Diameter

Enter the diameter of the right hole within the part.

Hole Offset
Enter the distance between the centers of the two holes.

Lead In Radius
Enter the radius of the lead-in arc.

Overburn Length
Parts that contain a circular element user overburn. Overburn specifies the arc length that
the torch will travel past the circle closure point. The dimension entered is the chord
length of the overburn-arc.

In some cases it is desirable to have an underburn length. For these conditions, enter a
negative number for the overburn length.

Lead Out Radius

Enter the radius of the lead-out arc.

Lead Type
Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

259
Library Shapes

Water Pump Gasket

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

260
 Library Shapes

Side Heights
Enter the diameter of the outside edges of the sides of the part.

Center Height
Enter the diameter of the outside, center edge of the part.

Outside Hole diameters

Enter the diameters of the outside holes within the part.

Center Hole Diameter

Enter the diameter of the center hole.

Corner Radius
Enter the radius of the curve in the corners of the part.

Outside Hole Offset

Enter the distance between the centers of the outside holes.

Lead In Radius
Enter the radius of the lead-in arc.

Overburn
Parts that contain a circular element user overburn. Overburn specifies the arc length that
the torch will travel past the circle closure point. The dimension entered is the chord
length of the overburn-arc.

In some cases it is desirable to have an underburn length. For these conditions, enter a
negative number for the overburn length.

Lead Out Radius

Enter the radius of the lead-out arc.

Lead Type
Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

261
Library Shapes

Frame

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

262
 Library Shapes

Base Width
Enter the width of the base of the part.

Height
Enter the height of the part.

Left Thickness
Enter the distance between the inner and outer edges on the left side of the part.

Top Thickness
Enter the distance between the inner and outer edges on the top of the part.

Right Thickness
Enter the distance between the inner and outer edges on the right side of the part.

Bottom Thickness
Enter the distance between the inner and outer edges on the bottom of the part.

Corner Selection
Use the dropdown list to select a corner of the part. Use the remaining fields to specify
the style of that corner. Repeat your selections for up to three corners.

Corner Type
Use the dropdown list to select a square, bevel, or round corner.
• If you select a bevel corner, use the Corner Width and Corner Height fields to enter
the dimensions of the bevel.
• If you select a round corner, use the Corner Radius field to enter the radius of the
corner.

Lead-In/Lead-Out Length
Enter the appropriate value to ensure proper piercing (lead-in) and gas bleed-off (lead-
out) to obtain optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the
ShapeWizard and then saving the new shape to disk.

263
Library Shapes

Pulley

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

264
 Library Shapes

Outer Diameter
Enter the diameter of the outside edge of the part.

Inner Diameter
Enter the diameter of the inside edge of the part.

Hub Diameter
Enter the diameter of the hub in the center of the part.

Spoke Width
Enter the width of the spokes of the part.

Corner Radius
Enter the radius of the curve in the corners of the part.

Number of Spokes
Enter the number of spokes in the part.

Lead In Radius
Enter the radius of the lead-in arc.

Overburn Length
Parts that contain a circular element user overburn. Overburn specifies the arc length that
the torch will travel past the circle closure point. The dimension entered is the chord
length of the overburn-arc.

In some cases it is desirable to have an underburn length. For these conditions, enter a
negative number for the overburn length.

Lead Out Radius

Enter the radius of the lead-out arc.

Lead Type
Depending on the shape you select, the style of the lead in/ lead out can be selected as
radius, lock or straight line. The lock style lead-in creates greater stability for the part
and is only available if the part type is set to piece. Lead-in selection is only available if
the part type is set to piece or hole.

Note: Some shapes offer drop down fields to increase options with additional parameters.

265
Library Shapes

Sprocket

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

266
 Library Shapes

Outside Diameter
Enter the diameter of the outside edges of the teeth on the sprocket.

Root Diameter
Enter the diameter of the part at the root of the curves between the teeth of the sprocket.

Hole Diameter
Enter the diameter of the hole in the center of the part.

Roller Diameter
Enter the diameter of the roller that defines the curve at the corners of the roots of the
tooth.

Rollers between Teeth

Enter the number of rollers that fit between the root corners of the teeth.

Number of Teeth
Enter the number of teeth on the sprocket.

Tooth Angle
Enter the number of degrees of the angle of the straight side of the tooth.

Tooth Corner Radius

Enter the radius of the curve at the corner of the teeth.

Lead In Radius
Enter the radius of the lead-in arc.

Lead Out Radius

Enter the radius of the lead-out arc.

267
Library Shapes

Text

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

268
 Library Shapes

Character Height
Enter the height of the characters in the text.

Text
Use the radio buttons to select whether the text will be cut or marked.

If you select Marked, use the dropdown lists to select the marker and the offset.

Text
Enter the text you want to cut or mark.

269
Library Shapes

Test Pattern

Library Shape Setup

Enter the correct dimensions to create the part you require. There is a small Help icon in
the lower right hand corner of the display to indicate which parameter the control is
looking for. The current parameter is highlighted with a yellow arrow.

While you are entering parameters, the control is performing some general checks for
proper geometries. If the control finds a set of parameters that conflict, a warning
message is displayed and the parameters in conflict are highlighted in red.

Note: The system does not check for all incorrect geometries and it is possible to enter a
part that does not make geometric sense.

As you enter dimensional parameters, the control automatically draws the new shape with
the values you enter. This is extremely useful in providing a visual check of the shape
that has been entered.

Base
Enter the width of the base of the part.

270
Part Options
There are a number of options available under the Part Options soft key. These options
can be used to customize the current part loaded into working memory. All options will
display the effects of the changes in the Preview Window.

Scale Factor
Allows the operator to scale the current part in memory by a programmed factor. After a
new scale factor has been entered, the part is redrawn and its overall dimensions shown.
The scale factor must be greater than zero.

Rotate Angle
Allows the operator to rotate the current part in memory by a programmed value. After a
new rotate angle has been entered, the new part is displayed in the Preview window. The
rotate angle can be any positive or negative angle.

271
Part Options

Mirror X/Mirror Y
These checkboxes make the X or Y dimensions negative. The result is a mirror image of
the current part in memory.
For keypad operation, press the Next or Enter key to toggle to the X or Y field. When the
cursor is on the field, press the Space key to enter a checkmark in the current highlighted
field.

Kerf
Press the Kerf soft key to show the kerf path in light blue. This helps you see the Kerf
path before cutting. Press the button again to turn the Kerf part graphics off.

272
 Part Options

Repeat
The control has three built-in automatic repeat types: Straight, Staggered, and Nested.

Straight Repeat

Repeat Type
Allows the user to select which type of the three repeats to use: Straight, Staggered or
Nested.

Start Corner
Allows the user to select which corner of the plate from which to start the shape repeat.

Number of Rows
Program the number of rows to cut.

Number of Columns
Program the number of columns.

X Pattern Offset/Y Pattern Offset

This control automatically calculates the pattern offset based on the dimension of the
current part in memory.

273
Part Options

Scrap Clearance
Allows the user to insert scrap clearance between parts in the grid pattern. The same
value is used for X and Y dimensions.

Staggered Repeat

X Nest Distance/Y Nest Distance

The control automatically calculates the nest offset based on the dimension of the current
part in memory. This parameter is only available for the Nested type of repeat.

274
 Part Options

Nested Repeat

Pattern Offsets
This is an automated feature that calculates the minimum spacing required between
repeated parts. The spacing is based on the size of the part (including lead-in and lead-
out), the kerf value and scrap clearance. This calculated spacing is not always optimum
but allows the part to be repeated without overlapping.

You can use this pre-calculated value or select new values manually. If you enter new
pattern offset values, the control automatically draws the new group pattern with the new
values.

Nest Distance
This is an automated feature that calculates the minimum spacing required between
nested parts. The spacing is based on the size of the part (including lead-in and lead-out),
the kerf value and scrap clearance. This calculated spacing is not always optimum but
allows the part to be repeated without overlapping.

You can choose to use this pre-calculated value or select new values manually. As you
enter new offset values, the control automatically draws the new nested pattern with the
new values.

Tip: If you change Nest Distance values manually, start with a simple nest (1 column x 1
row) and perform adjustments based on the display. As the nest distance values are
adjusted, the pattern displayed on screen is updated. When the Nest Distance is what you
want, increase the nest size to a 2-column, 2-row nest. Then the X and Y pattern offsets
can be adjusted in the same fashion. When the desired nest spacing has been reached,
increase the nest size as needed to the maximum size that the plate allows.

275
Part Options

Align
This screen allows you to:
• Launch the Align wizard.
• Align the current part to one of the four corners of the plate. This is common with
parts that have an internal pierce point such as a flange.
• Accommodate skewed plates when aligning the part. This is commonly used with a
nest of parts that has a small margin of error for placement of the nest on the plate.

Align Wizard
The Align wizard automates the sequence of operations to enter coordinates for a skewed
plate on the table and to align parts to a skewed or aligned plate.

The Align wizard opens automatically from the Align screen or you can press the Align
Wizard soft key on the Align window.

As you work with the Align wizard, it keeps track of your progress and displays it at the
bottom of the wizard window in the progress bar.

You can choose to use the torch or a laser pointer to align the plate. If you choose the
laser pointer, you must have a marker offset value of at least 1 entered for Marker Offset
10, 11, or 12 on the Setups screen.

276
 Part Options

Manual Part Alignment

To align a part manually on the plate:
1. Set parameters that are needed to align your part in the upper right corner of the
screen.
2. Move the torch to the first corner location (Corner to Align with) using the jog keys.
3. Press At Corner.
4. If you are aligning a part, go to step 7.
5. Move the torch to a point along the edge of the plate toward the selected Skew
Reference.
6. Press At Skew Point.
7. Press OK. The machine will move to the start point for the part and return to the
Main screen and be ready for cutting.

Corner to Align with

Selects the corner of the plate to align the part in.

Scrap Clearance
This is the amount of clearance between the edge of the plate and the part the control will
add in when moving to the start point of the part.

277
Part Options

Skew Adjustment
This determines if the control will adjust for plate skew when performing the align
function.

Skew Reference
This is the skew reference corner which you will move towards and mark a point along
the edge. This is only available if Skew Adjustment is On.

At Corner
Press this soft key when at the corner of the plate you want to align the part in.

At Skew Point
Press this soft key when at the edge of the plate for skew adjustment. This is only
available if Skew Adjustment is On.

Automatic Plate Alignment (APA)

The Automatic Plate Alignment (APA) feature detects the edges of a rectangular plate
and calculates the degree of skew to align a part on the plate. Two types of APA
sequences are available:

• Five-point alignment is the default type of APA and detects plate alignment, skew,
and size.
• Three-point alignment detects plate alignment and skew.

Notes about APA:

• The APA sensors must be assigned in I/O setups. The logic states must be set so that
the input is active when the sensor is over the plate.
• The sensor moves fast to the outward edge of the plate until the sensor detects the
edge and switches to OFF. For accuracy, motion reverses until the sensor is activated
again and switches to ON. See Sensing Sequence.
• If User Defined is selected as the Manual Offset value on the Manual Options screen,
an X/Y tool offset value from the Setup screen is required to compensate for the
distance between the master torch and the APA sensor.
• Scrap clearance, if required, is entered on the Align screen. In addition, Corner to
Align With on the Align screen sets the start corner location of the program.
• If your machine requires homing, this function should be performed before APA.
• Some sensors may detect the table slats as an extension of the plate. If this is a
problem in your application, configure 2 sensors. The first sensor to detect the edge
of the plate (switch to OFF) is used for all plate detection at that location.
• An appropriate X/Y offset for the two sensors is recommended to minimize the
potential that booth sensors would the slats as an extension of the plate. The distance
between the first and second sensor is programmed in tool offset #11 on the Setup
screen.
• Sensing radius should be programmed according to the radius of the sensor. If dual
sensors are used, the radius applies to both sensors.

278
 Part Options

• You can insert program codes into the part program to automatically configure 3-part
APA for that part. See Part Code.

Sensing Sequence
1. The sensor moves off the plate at
high speed (status = OFF). 1
2. The sensor returns to the plate at 2
medium speed (status = ON). 3
3. The sensor moves off the plate at
slow speed (status = OFF). The
edge of the plate is detected and
recorded.

Five-Point Alignment
5-point alignment uses 5 reference points to calculate skew and plate size. The CNC
commands the Sensor PHC to move around the plate in search of the edge at 5 points.
After the 5 reference points have been detected, the CNC positions the torch in the
correct location to start the part program with the calculated skew.

To start 5-point alignment:

1. Position the Plate Sensor above the plate manually. The Auto Plate Align Sensor
Input should be ACTIVE.
2. Select Part Options > Align. Verify that the correct corner has been selected. Edit
parameters for Skew alignment.
3. Press the Automatic Plate Align soft key on the Part Options screen.

The sensor moves across the plate to detect the reference edges of the plate. Each
position is recorded as one of the reference points. Motion continues until all 5 points are
detected.

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Part Options

After the sensor detects all 5 reference points, the CNC positions the sensor or the torch
at the starting point of the part program.

The values for Scrap Clearance and Start Corner on the Align screen contribute to the
calculation of the final position for the alignment and the start point of the part program.
The APA function also enters the values for the dimensions of the plate in the appropriate
fields in the Setup screen.

The part program can be executed automatically at the end of the alignment if Auto Start
after APA is enabled on the process Setup screen or it can wait for the start of the cycle.

Three Point Alignment

During a 3-point alignment, the CNC commands motion of the sensor around the plate
and searches for the edges of the plate at 3 reference points After the sensor detects the 3
reference points, the CNC positions the sensor or the torch at the starting point of the part
program with the calculated alignment and skew.

Program Code
To configure APA within a part program, you must add EIA program codes to the
beginning for the part program. The parameters remain in effect until they are changed
or the CNC is restarted.

Three point alignment distance and speeds can be defined with the following EIA format
program code:

G66D100B300C30

• G66 = 3-point alignment command

• Dvalue = Distance between two plate edge reference points
• Bvalue = Rapid feed rate for distance (D) motion

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 Part Options

• Cvalue = Slow feed rate for the distance to the edge

Motion Path
The following drawing shows a typical edge detection sequence for APA with the
following selections on the Align screen:
• Corner to Align: Lower left
• Skew Point: Upper left

Change the values for these fields to specify a different starting point and sequence.

3 2

Distance D

4
1 Start

To start the 3-point alignment:

1. Load a part program with the appropriate program codes included at the beginning of
the program. See Program Code.
2. Position the plate sensor above the plate manually. The Auto Plate Align Sensor
Input should be ACTIVE.
3. Select Part Options > Align. Verify that the correct corner has been selected. Edit
parameters for Skew alignment.
4. Press Auto Plate Alignment.

The sensor moves across the plate to detect the reference edges of the plate. Each
position is recorded as one of the reference points. Motion continues until all 3 points are
detected.

After the sensor detects all 3 reference points, the CNC positions the sensor or the torch
at the starting point of the part program.

The values for Scrap Clearance and Start Corner on the Align screen contribute to the
calculation of the final position for the alignment and the start point of the part program.

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Part Options

The APA function also enters the values for the dimensions of the plate in the appropriate
fields in the Setup screen.

The part program can be executed automatically at the end of the alignment, or it can
wait for the start of the cycle, as specified in Program Code selection list on the Setup
screen.

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Cut Operations
CutPro Wizard
The CutPro wizard automates the sequence of choices and selections that you must make
before you begin cutting parts. If you have parts, nests, and cutting processes stored on
your system, you can use the CutPro wizard to simplify cutting operations.

The CutPro wizard also helps you to align parts and handle plate skew with the Align
wizard. For more information on the Align wizard, see the Part Options chapter.

The CutPro wizard opens automatically from the Main screen or you can press the
CutPro Wizard soft key on the Main screen. As you work with the CutPro wizard, it
keeps track of your progress and displays it at the bottom of the wizard window in the
progress bar.

Cutting in Manual Mode

After you verify that the cut mode, cut speed and Kerf values are set correctly, press the
Start key on the Main or Manual window to cut a part. The following window is
displayed:
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Cut Operations

To cut the part, verify that the Cut Mode is set to the selected cut type and that the Kerf
and Cut Speed settings are correct, then press the Start key on the front panel. This starts
cutting in the selected Cut Mode.

To preview the path, press the Change Cut Mode soft key until Trial appears in the Cut
Mode window. Press the Start key to have the cutting device follow the cut path without
cutting. Motion is performed at the programmed speed.

Press the Stop key on the front panel to stop a cut. The machine decelerates to a smooth
stop along the cut path. If the cutting process was on when you pressed the Stop key, it is
de-activated according to the programmed cut logic.

During a cut, the Watch window displays information about the part being cut, such as
the current cut speed, current axes positions and path position.
In sheet view, the control automatically scrolls to keep the cut location centered within
the view screen. This feature is useful during normal cutting to zoom in and follow the
cut-path.

View Sheet is useful when proper plate size values have been entered in Cutting setups
and when the machine has been homed. If you attempt to view large parts with a fully
zoomed screen, the part may not be fully drawn on the screen before the next view

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 Cut Operations

location displays and the screen may flash. Zoom out to correct this and view a larger
area.

Speed Increase
Increases the current cut speed by 3%.

Speed Decrease
Decreases the current cut speed by 3%.
Note: Double click the speed field to enter a new speed value.
Keyboard operation: To change the current cut speed while cutting a part, press the
Enter key once to highlight the current cut speed, enter the new cut speed, and press Enter
again.

Repeats
If a Shape Repeat option has been enabled, press the Repeats soft key to see the number
of rows and columns remaining to be cut. The Repeats soft key operates with the Extend
soft key which is only active during initiation of the cut sequence.

Cut Delay Timers

Cut Delay Timers define the timing logic for the cut and are available for both Oxy-fuel
and plasma at the Cut Types setup screen. In cut mode, the control displays the preset
delays as they are executed in the lower right corner of the screen. For certain delay
times, such as Preheat and Pierce, a countdown timer shows the preset time and time
remaining. An example of the Preheat Timer is illustrated below:

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Cut Operations

The Preheat times, Total, Completed and Remaining, are shown to a tenth of a second.

When you activate the Cut Sense input, the Preheat delay time cycle ends. The time at
the point of activation becomes the new Preheat time for subsequent cuts. Three soft
keys are also displayed which can be used to modify the Preheat cycle in progress.

Press the Start key twice to bypass the Preheat and Pierce Time Delays and begin the cut
in the Oxy Fuel cut mode.

The function of these keys is explained below:

Extend
Extends the Preheat timer until it is stopped with either the Set-Now or Release soft key.

Set Now
Ends the selected delay timer and saves the new set time. Use the Set Now soft key with
the Extend soft key to modify the preset Preheat time.

Release
Ends the selected delay timer, but does not modify the original delay time.

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Multitasking
Multitasking allows you to load and configure a new part program while another part
program is cutting. This feature is only available in advanced operation mode.

To begin, press the multitasking soft key. The current part program displays in the lower
right corner of the Preview Window. The new program displays in the main view area.

Press the multitasking soft key to switch between programs.

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Pause
If the cut process fails, the CNC has full-featured recovery capabilities.
The Cut Loss Recovery features of the CNC are available from the Pause screen which
displays when the operator presses Stop or if cut sense is lost.

Press the Cancel key while the Pause screen is displayed to cancel the current part.

Return to Start
Allows the operator to return to the initial starting point of the part. Note: If the Return
to Start function is used after a cut loss, all information about the current position of the
cutting device on the path is lost.

Backup and Forward on Path

Use these two soft keys to move backward and forward along the cut path at the selected
move speed to locate the pierce restart point. Press the Start key to resume the cut at the
programmed cut speed. In addition to all segments of a standard part, the Backup and
Forward on Path functions allow full movement through all sections of Shape Repeat
part, as well.

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Pause

Like the Manual Mode functions, Backup and Forward on Path use the currently selected
move speed. The different speeds allow moving rapidly along the path, or precisely
positioning the cutting device.

When a cut loss occurs, the initial backup and forward speed is the one that was used last.
To toggle between the move speeds, press the Change Move Speed soft key in the Pause
window. The corresponding speed is displayed in the Move Speed window.

Move to Pierce/Mark
Press the Move to Pierce/Mark soft key to move directly to any pierce point.

Enter the information for the pierce point and press Enter. The cutting device moves
directly to the selected pierce point.

Change Cut Mode

Alternates the restart mode between Cut and Trial. This allows the operator to move
through the part partially as a trial cut and partially as an actual cut.

Change Move Speed

Cycles through the four move speeds that are available. The four move speeds are the
Maximum Machine Speed, High Jog Speed, Medium Jog Speed and Low Jog Speed from
the Speeds setups.

Change Consumable
Opens the Change Consumable screen.

On-Path Restart
To restart the cut at the pierce point that you selected using On-Path Backup, press the
START key. The cut speed and the cut mode are the same as they were before the motion
was paused unless the values have been edited in the Watch window.

While the Pause Window is displays, the manual arrow keys are fully functional so you
can move the cutting device. This allows you to move the machine in any direction (not
necessarily along the path) to inspect the partially cut piece. Once the cutting device is
moved off the cut path, the Off-path Pause Window displays.

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 Pause

The differences between the On-path Pause Window and the Off-path Pause window are
outlined below.

Return to Path
Press the Return to Path soft key in the Off-path Pause window to return the cutting
device to the point on the cut path from which it was jogged away. This feature is useful
for inspecting or replacing components after cut loss and then returning to the cut loss
point. When the cutting device is back on the cut path, the On-path Pause Window is
restored and cutting can resume.

Move Part
Moves the entire part on the plate. The point along the cut path to which the cutting
device moves becomes the current position of the cutting device. The On-path Pause
window displays again because the cutting device is on path.

Off-Path Restart
Press the Start key from the Off-path Pause window, to construct a lead-in from the off-
path point back to the original part.

In a cut loss situation, the operator can use the Backup on Path key in the On-path Pause
window menu to position the cutting device on the cut path where the cut was lost. The

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Pause

operator can then use the manual arrow keys to jog the cutting device off path to a
suitable pierce point.

Press Start at this point to cut a new lead-in from the off-path pierce point to the point
along the path from which the cutting device was jogged away. When the cutting device
is back on path, it continues along the path to cut the remainder of the part.

Rush Job Interrupt

Allows the user to pause the current part program and retain the part and current position
information. On the Pause screen, press the Cancel key. A prompt displays on screen to
allow the user the option to save the part information for later use.

If you select Yes, the Resume Last Part button displays on the Files Screen. You can
load and execute another part program and then return to the original part using the
Resume Last Part soft key. The part program and position resumes.

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 Pause

Change Consumable
This screen tracks consumable life data for statistical analysis. In addition, the feature
can prompt the operator that a consumable has reached its expected life by using an
output from the control to activate an indicator such as an indicator lamp or audible
alarm. This feature allows the operator to change the consumable and avoid a
consumable failure that can affect cut quality or damage the torch.

Note: This Change Consumable feature can only track consumable life data and offer
features related to that data. The control cannot detect consumable condition or failures.

Overview
If the New Torch Tip or New Electrode soft key is pressed every time a torch tip or
electrode is changed, the last information for the corresponding consumable will be
added to a database. This database shows the date a consumable was changed and how
long it lasted in minutes, pierces, inches and millimeters.

To reset the current consumable value, press the New Tip/New Electrode button. Select
the torch tip or electrode to be updated. The value of the tracking information is reset to
zero and starts counting up as you cut in the selected mode. The “Installed on” date for
the selected consumable is updated and the current values for the selected consumable are
recorded, with the date, in a database that can be saved to disk.

The database is saved in CSV (comma separated value) format on the CNC and can be
downloaded for use with standard database software programs for productivity and cost
analysis. In addition, this data may also be viewed in the Watch Window during cutting.

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Pause

The consumable information that is updated (Oxy torch 1-12 / Plasma torch 1-8) is
determined by the “Station Select 1-20” inputs.

In the previous example, Plasma Torch #1 torch tip has a limit of 5000 minutes of
operation. After 5000 minutes, the Change Consumable output becomes active and is
indicated with a lamp or audible alarm. The intent is to set the limits at an expected life
value of the consumable so that the operator is reminded to change the consumable when
it has reached its expected life.

The data collected on the consumable life automatically updates to the new highest value.
In the previous example, the new maximum value could extend above 5000 minutes
when the new value is reached so the value would increase to 5001 and continue. This
auto update feature can be disabled in the password protected Special Setups screen.

Minutes
The estimated life in time that the torch tip or electrode lasts. This value increases to the
maximum life achieved or a maximum value can be entered.

Pierces
The estimated life in pierces that the torch tip or electrode lasts. This value increases to
the maximum life achieved or a maximum value can be entered.

Inches/millimeters
The estimated life in distance that the torch tip or electrode lasts. This value increases to
the maximum life achieved or a maximum value can be entered.

Minutes per Pierce

Piercing causes additional wear on the consumables. This parameter allows the user to
enter a value which is added to the overall minutes value for each pierce, providing a
more accurate representation of overall consumable wear.
Arc Errors
Actual Arc Errors can be tracked using the Arc Error Input to the control from the Plasma
supply. The power supply indicates an Arc Error when the Plasma Arc did not achieve a
long-life ramp down. The Arc Error input to the control is through the HD4070 serial
communication or through the discrete Arc Error input.

Volts per Minute

The Volts per Minute parameter allows the user to enter a value that is used to change the
cut Arc Voltage, based on the number of minutes that have elapsed while cutting in
Plasma mode. This value adjusts the Voltage offset value.

Note: This feature is only available for systems configured with the Sensor THC.

Last Torch Tip Installed

Displays the date and time when the selected tip was installed.

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 Pause

Last Electrode Installed

Displays the date and time when the selected electrode was installed.

New Torch Tip

Press the New Torch Tip soft key to select which Torch Tip has been replaced and to
update the database.

New Electrode
Press the New Electrode soft key to select which Electrode has been replaced and to
update the database.

Setups
Press the Setups soft key to access the control setups and adjust the cutting process.

Reset Database
Resets the values in the database on the control and clears the torch tip or electrode
information after uploading or saving the database.

Upload Database
Uploads the current database to a host computer running our link.

Save Database
Saves the current database to the diskette or USB memory stick.

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Pause

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Manual
The manual key is indicated by the hand icon.

Press the manual key on the screen to view the following screen. The directional jog
keys are active when they are green.

Whenever the manual keys are active, the cursor icon in the graphics display window is
the shape of a hand.

From the Manual window, the machine can be moved in one of eight directions using the
arrow keys. The dual-purpose arrow keys are press on/release off. The cutting device
moves while you hold the key down. When the key is released, the cutting device comes
to a smooth stop.

If the latched manual key feature is enabled in the control setups, press the manual key a
second time to allow motion to continue without holding down the arrow key. This

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Manual

feature is available for the manual direction keys in the Manual, Align and Pause screens.
When this feature is activated, the dialog “Latched Manual Keys On” will be displayed in
red at the bottom right corner of the part window. Motion can be paused by use of the
Stop, Cancel or an arrow key. The latched manual key feature can be turned off by
pressing the manual key again.

Return to Start
Whenever the Manual window is opened, the transverse and rail positions at that point
are saved. After rip cutting or other manual operations, it may be necessary to return to
this "start" position. Press the Return to Start soft key to generate motion in the transverse
and rail axes from the machine’s current position to the position that was saved when the
Manual window opened.

Move Distance
When Move Only is displayed in the Manual Mode window, the second soft key from the
left changes to Move Distance. The Move Distance soft key allows you to perform
moves over exact distances. After you press Move Distance, the control prompts you for
traverse and rail distance values for the machine’s motion. Enter the appropriate values
and press ENTER. The cutting device moves the distance you entered in a straight line
without executing any cut logic.

Values are entered the same way as described in the previous Cut Distance paragraphs.
As with any automatic motion, you may press STOP on the front panel at any time to
bring the machine smoothly to a stop before the programmed motion is complete.

Cut Distance
When Rip Cut mode is selected in the Manual Mode window, the second soft key from
the left changes to Cut Distance. This soft key allows you to make rip cuts of an exact
length. After you press Cut Distance, the control prompts you for traverse and rail
distance values for machine motion. Enter the appropriate values and press ENTER.
After the cutting device executes the cut logic sequence, it moves the distance you
entered in a straight line.

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 Manual

If you enter incorrect values, press the CANCEL key at any time. After motion has
begun, press STOP on the front panel to bring the machine smoothly to a stop before the
programmed motion is complete.
Rip Cut mode is useful for making a cut along a specified linear path. Motion stops and
cutting action ceases when the new position is reached or when the STOP key is pressed.
If you do not know the exact distance, enter a distance longer than needed in the right
direction, and then press STOP to end the cut.

Manual Options
Press the Manual Options soft key to access the Manual Options screen.

Home Axes
Press the Home Axes soft key to access the Homes Axes screen.

View Sheet/View Part

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

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Manual

After the display zooms out, you can zoom in again by pressing the + key, which adds
horizontal and vertical scroll bars. Press the - key to zoom out again.

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 Manual

While the scroll bars are displayed, you can hold down the scroll bar and move it to
adjust the view of the machine horizontally and vertically. This mode is useful in normal
cutting to closely follow the cut path while in zoom.

While cutting in sheet view, the control automatically scrolls to keep the cut location
centered within the view screen. This feature is useful in normal cutting to follow the
cut-path while zoomed in.

View Sheet is more useful when proper plate size values have been entered in cutting
setups and when the machine has already been homed. If you are viewing large parts
being cut with the display fully zoomed, the system may not be able to draw the part on
screen before it has to move to the next view location. In this case, the view screen may
flash but you can correct this by zooming out to a larger view area.

Change Manual Mode

This soft key alternates the control Manual Mode between Move Only and Rip Cut.

If you press this soft key the second soft key from the left to changes function from Move
Distance to Cut Distance. Rip Cutting is described in more detail below.

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Manual

Change Move Speed

This soft key toggles through the four Move Speeds: maximum machine speed, high jog
speed, medium jog speed and low jog speed from the Speeds setups.

Zero Positions
Press this soft key to return all axes positions to 0 (zero).

Rip Cutting
When the Manual Mode window displays Rip Cut, the arrow keys can then be used to
begin a cut sequence and machine motion in the chosen direction.

To initiate a Rip Cut:

1. Verify that the correct cut-mode (Oxy or Plasma) has been selected.
2. Verify that the proper cut speed is displayed in the Cut Speed window (editable in
Rip Cut mode).
3. Press the arrow key corresponding to the desired start direction for the cut.
The cutting sequence proceeds even after the key is released; however, machine
motion is generated only as long as an arrow key is held down, unless the latched
manual key feature has been enabled.
4. Use the arrow keys to change direction.
5. Press Stop, Cancel, or Manual to stop the operation of the cutting device.

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 Manual

Manual Options

Raise Torch
Raises the cutting torch while the soft key is pressed or until the Torch Up sense input is
activated.

Lower Torch
Lowers the cutting torch while the soft key is pressed or until the torch down sense input
is activated. If the torch down output has been enabled to stay on during the cut in
plasma setups, press the Lower Torch soft key to keep the torch in the down position
until the Lower Torch soft key is depressed a second time.

Manual Offset
Manual Offset is useful for cutting tables that have a laser alignment tool attached and
allows you to use your laser alignment tool for aligning a part to a plate. The offset will
stay in place until it is turned off from this screen or a part is cut in either oxy-fuel or
plasma cut mode.
You can select the following offsets:
• User Defined – Uses the selected X / Y Offset distance.
• Laser pointer to Plasma 1 – Offset 10

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Manual

• Laser pointer to Plasma 2 – Offset 11

• Laser pointer to Oxy Fuel – Offset 12

Adjust Dual Gantry Skew

Allows you to realign the Dual Gantry Axis manually using the directional manual jog
(arrow ↑ and ↓) keys.

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 Manual

Home Axes
From the Home screen, each axis or all axes can be "homed". In addition, the transverse
and rail axes can be sent to one of four programmed alternate home positions.

The home feature sets a known, absolute physical position location on the cutting table
that is used for referencing future manual “Go to Home” and other motion commands.
This is generally performed through activation of a home switch positioned on the
appropriate axis giving it a known physical location.

When the homing command is entered at the control, the control moves the axis toward
the home switches at the fast home speed until the switches have been activated. After
the switches have been activated, motion stops and the axis moves in the opposite
direction off switch at the slow home speed. The moment that the switch is deactivated,
the position is recorded at the control and provides an absolute reference point for future
motion commands.

Transverse
Press the Transverse soft key to initiate the automated homing procedure. This procedure
generally produces machine motion in the transverse axis, depending on the homing
parameters set in the Setups.

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Manual

Rail
Press the Rail soft key to initiate the automated homing procedure. This procedure
generally produces machine motion in the Rail axis, depending on the homing parameters
set in the Setups.

CBH
Press the CBH soft key to initiate the automated homing procedure. This procedure
generally produces machine motion in the CBH axis, depending on the homing
parameters set in the Setups.

THC
Press the THC soft key to initiate the automated homing procedure for the Sensor THC.
This procedure generally produces machine motion in the THC axis, depending on the
homing parameters set in the Setups.

Tilt
Press the Tilt soft key to initiate the automated homing procedure for the Tilt Axis.

Rotate
Press the Rotate soft key to initiate the automated homing procedure for the Rotate Axis.
Note: If Tilt and Rotate Axes are enabled, the following window will appear and allow
access to the Tilt/ Rotate or other axes.

Select Yes to access Homing for the Tilt and Rotate Axes. Select No to access the
Homing functions for the other axes,

All
Press the All soft key to initiate the automated homing procedure. This procedure
generally produces machine motion in one or more axes, depending on the homing
parameters set in the Setups.

Go To Home Position
Press one of the four Go To Home Position soft keys to move the transverse and rail axes
to the predefined position set in the corresponding edit window. The Go To Positions are
absolute and require that an automated home procedure already be executed.

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Diagnostics
Control Information
This screen displays the current software versions and hardware configuration of the
control. You must provide this information if you contact the factory for support. A
typical control information screen is shown below.

Hardware
The Hardware section shows the current hardware configuration which includes the
Processor Type, Processor Speed, Memory Installed, Hard Drive Size, Hard Drive Free
Space and Motion Control Card revision.

Software Versions
The Software Versions section shows the current version of the Control’s Operating
System, Operator Interface (software version), Virtual Device Driver and the Motion
Control Card software.

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Diagnostics

Control Information
The control Information section displays the Hardware Key number, the control model
number, serial number, control I/O type, axes enabled and I/O enabled.

Software Modules
The Software Modules information displays the optional software features which have
been loaded or have been enabled for use, such as DXF Translator, McAfee VirusScan
Software, or NJWIN font Viewer.

Voltage
System Voltages at the motherboard are displayed for motherboards equipped with this
monitoring feature.

Temperature
Temperature at the motherboard is displayed for motherboards equipped with this
monitoring feature.

Fans
Fan speeds at the motherboard are displayed for motherboards equipped with this
monitoring feature.

Limited Version
The Limited Version information is displayed if the control is operating on a trial version
of the software. The version of software is available for 90 days and can enabled for
permanent use with a password available from the control vendor.

THC Revision
The current Command THC Interface and Real Time Revision Levels are displayed at the
Control Information screen when enabled.

System Diagnostics
Press the System Diagnostics soft key to access the touch screen calibration utility for
tuning touch screen response.

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 Diagnostics

I/O
Inputs
This test continuously monitors and displays the state of all of the optically-isolated
discrete inputs in the control. The current state of each input, On or Off, is displayed next
to the input name.

You can change the name of inputs that are displayed with a white background. To
change the input name, use the Previous/Next arrow key to highlight the input and type
the new input name. The input can be connected to the control and used as commanded
in the part program. For example, the EIA W7 S1 code pauses the program and waits for
input 7 to become active.

A password is required to view this screen.

Note: The number and name of the inputs depends on the control software and hardware
configurations.

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Diagnostics

Outputs
This test allows the activation of all optically-isolated discrete outputs in the control. To
change the state of an output, select it with the PREV and NEXT keys and press the
SPACE key. The current state of each output, On or Off, is displayed next to the output
name. Below is an output screen with all of the outputs Off.

Warning: When you activate the control’s outputs manually, the machine, torch and
marker can move and the cutting device can activate.

You can change the name of outputs that are displayed with a white background. To
change the output name, use the Previous/Next arrow key to highlight an output and type
the new output name. The output can be connected to the control and used as
commanded in the part program. For example, the EIA M22 and M23 code will turn on
and off output 12.

Note: The number and name of the outputs depends on the control software and
hardware configurations.

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 Diagnostics

Expanded I/O

For controls equpped with more than 64 I/O, a series of selection softkeys are available to
access the required inputs, ouputs and analog I/O.

Note: The optional USB Front Panel I/O is not accessible from the I/O Diagnostics
screen. Functionality for the USB Front Panel can be tested through the Keyboard
Diagnostics.

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Diagnostics

Analog Input Diagnostics

Note: The appearance of the View screen depends on the type of Analog Input Card that
is installed.

Inputs
The Analog Input Card required to operate the optional Joy Stick and Speed Pots is
equipped with six low voltage inputs that are optically isolated and can operate at 24 –
120 VAC/DC. The first four inputs are used for the optional joystick feature. Inputs five
and six are used to support THC One and THC Two Nozzle Contact Sense respectively.
The Input Logic for these inputs is normally open.

Analog Inputs
The Analog Input values shown in the upper right hand of the screen are the voltages
coming into the analog card. Analog Inputs 1 and 2 are used for THC 1 and 2. Analog
inputs 3 and 4 are used for optional external speed pots.

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 Diagnostics

Serial Port
This diagnostic screen allows you to test the control serial ports. To perform the test,
install the appropriate jumper or jumpers. If the serial port you are testing is configured
for RS-232, jump pin 2 to pin 3. If you are testing a serial port that is configured for RS-
422, jump pin 2 to pin 3 and pin 4 to pin 7. Select the appropriate serial port to test and
press the Test Port soft key to initiate the test.

If the serial port is functioning properly, the text in the Send window will appear in the
Received window. If the serial port is not functioning properly, a Communications Time
Out message will appear below the Received window. If the serial port test fails, the
control may be defective and the factory should be consulted for further instructions.
Below is a serial port test screen with a successful test.

Port
Select the port that you want to test.

Test
Select a single or continuous signal to send for testing.

Send window
Contains the text that will be transmitted during the serial port test.

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Diagnostics

Received window
Displays the text that is received during the serial port test. If the test is successful, the
text in the Send and Received windows is the same.

Test Port
The soft key that initiates the serial port test on the selected port.

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 Diagnostics

Drives and Motors

The Drives and Motors diagnostic screen allows a technician to send a direct signal to the
drive amplifiers for testing, without enabling the servo loop.

Warning! Use extreme caution when you send direct signals to the drive amplifiers.
Unexpected motion on the cutting table can occur.

Select OK on the warning window:

Enter the machine password to view the Drives and Motors screen:

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Diagnostics

Pulse Type
Select the kind of pulse, single or repeated, that is sent to the drive amplifier. If you
select a repeated pulse, the signal continues until the Test soft key for that axis is pressed
again.

Pulse Direction
Selects the direction of the pulse; positive, negative or alternating, that is sent to the drive
amplifier.

Pulse Magnitude
Sets the voltage of the signal that is sent to the drive amplifier.

Pulse Duration
Sets the amount of time for each segment of the signal that is sent to the drive amplifier.

Test Transverse/Rail/Dual Gantry/CBH

The Test buttons send the selected output signal to the appropriate drive amplifier. If a
repeating signal has been selected, any combination of available test buttons can be used
for the test. The output signal is sent to the drive amplifier until the output soft key has
been pressed a second time to end the test.

Test All
Sends the selected output signal to all drive amplifiers.

Speed
The Speed window displays the current speed for each axis.

Note: When more than four axes are selected, the user must select which group of axes
will be tested on the Drives and Motors Diagnostic screen:

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 Diagnostics

SERCOS Drives and Motors

The SERCOS Interface allows the user to expand the number of axes available for use.
Motion commands are sent to the drives is over a serial link using diagnostic software
provided by the Drive vendor.

Warning! Use extreme caution when you send direct signals to the drive amplifiers.
Unexpected motion on the cutting table can occur.

Press Yes on the following warning message window:

When the Drive and Motors Diagnostics screen displays, the appropriate drive
communications software is launched for the drive that you selected. Refer to
information supplied by the drive vendor on how to use the drive setup software for the
drive that you selected. The following sections provide some examples of drive setup
and tuning software.

Note: Screen resolution may temporarily change during the use of these utilities.

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Diagnostics

DriveTop from Indramat

318
 Diagnostics

PacSci 800Tools from Pacific Scientific

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Diagnostics

Error Messages
The control displays error messages when programming, machine, or internal errors are
detected. A list of the common error messages are explained below in the following
sections.

SERCOS Errors
A number of different errors can be posted from the SERCOS Interface for both motor
and I/O performance. The error messages are specific to the drive and I/O modules in
use. Refer to information supplied by the drive and I/O hardware supplier for the
appropriate actions.

SERCOS Ring Not Running

This error indicates that communication with the SERCOS ring has been lost. Generally,
this is caused by a fault condition on the ring. Check SERCOS hardware and cycle
power.

No Part Loaded
This message displays if the control does not contain a valid part program in memory. To
clear this error message, load a valid part program from either the Shape Library, hard
drive, diskette USB memory, or from a host system.

Part Larger than Plate

This message displays if the part program that has been loaded is larger than the plate
size information in Setups. The operator can ignore the message and continue the cut or
return to Setups to correct the plate size.

Kerf too Large, Arc/Line has Disappeared. Abort Cut?

This message displays if the kerf size selected is too large and will affect the shape of the
part. The operator can continue to cut the part, abort the cut to review the kerf that was
selected, or abort the cut to review the part program for errors. If the operator chooses to
continue cutting the part program that prompted this error, unexpected results can result.

Cut Sense Lost

This message displays if the Arc ON Feedback setup parameter is enabled and the Cut
Sense input is deactivated by the plasma unit while cutting. When this condition occurs,
the control displays the Pause screen. The operator can then use the Cut Recovery
feature to finish cutting the piece.

Communications Time Out

This message displays if the host system does not respond within the time set in the Link
Time Out field for either a Host Upload or Download.

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 Diagnostics

To correct this problem:

• Increase the Link Time Out setup parameter.
• Check the communications setup parameters on the host system and the control.

Host Not Responding

This message displays if communication to the Host system is lost after initial
communication has been established.

To correct this problem:

• Re-establish communications to the host by exiting and re-entering the Upload or
Download to Host screens.
• Review the communications setup parameters on the Host system and the control.

Scale Factor must be between .001 and 1000

This message displays if a value less than .001 or greater than 1000 is entered for a
Scaling Factor.

To correct this problem, enter a value between .001 and 1000 for the Scaling Factor.

Radius at Arc Beginning and Radius at Arc End are not within the Arc
Radial Error Tolerance
This message displays if the radius beginning-arc and the radius-ending arc of a part
program are not within the Arc Radial Error setup parameter in the Main Setup screen.

To correct this problem:

• Increase the Arc Radial Error Tolerance setup parameter.
• Correct the part program itself.

Transverse Position Error Exceeded

This message displays if the current Transverse position error exceeds the Servo Error
Tolerance Setup parameter in the machine setups screen. This message also displays if
the position feedback loops are not operating properly, or the machine is being
commanded to move or accelerate faster than it is able.

Generally, this error is displayed if the setting for Incremental or Absolute EIA I and J
codes is set to the wrong state for the active part program. To correct this problem:

• Increase the Servo Error Tolerance Setup parameter in the machine setups screen.
• Re-tune the system.
• Decrease the Maximum machine speed setup or acceleration rate setup parameters.

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Diagnostics

Rail Position Error Exceeded

This message displays if the current Rail position error exceeds the Servo Error
Tolerance Setup parameter in the machine setups screen. It can also appear if the position
feedback loops are not operating properly or if the machine is being commanded to move
or accelerate faster than it is able.

This error generally indicates a servo drive or motor problem. To correct this problem:
• Check for fault indications on the servo drives.
• Increase the Servo Error Tolerance Setup parameter in the machine setups screen.
• Re-tune the system.
• Decrease the maximum machine speed setup or acceleration rate setup parameters.

Dual Gantry Position Error Exceeded

This message displays if the current Dual Gantry position error exceeds the Servo Error
Tolerance Setup parameter in the machine setups screen. It also may appear if the
position feedback loops are not operating properly or the machine is being commanded to
move or accelerate faster than it is able.

This error generally indicates a servo drive or motor problem. To correct this problem:

• Check for fault indications on the servo drives.

• Increase the Servo Error Tolerance Setup parameter in the machine setups screen.
• Re-tune the system.
• Decrease the Maximum machine speed setup or the acceleration rate setup
parameters.

Transverse Positive Hardware Overtravel Reached

This message displays if the control detects a positive limit switch in the Transverse axis.
This can also occur if the limit switch input is set for the wrong polarity or the limit
switch wiring is not properly connected.

This error generally indicates a servo drive or motor problem. First check for fault
indications on the servo drives. If the Transverse axis tripped the positive limit switch,
use Manual mode to jog the Transverse axis away from the limit switch.

Rail Positive Hardware Overtravel Reached

This message displays if the control detects a positive limit switch in the Rail axis. This
can also occur if the limit switch input is set for the wrong polarity or the limit switch
wiring is not properly connected.

If the Rail axis tripped the positive limit switch, use Manual mode to jog the Rail axis
away from the limit switch.

Transverse Negative Hardware Overtravel Reached

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 Diagnostics

This message displays if the control detects a negative limit switch in the Transverse axis.
This can also occur if the limit switch input is set for the wrong polarity or the limit
switch wiring is not properly connected.

If the Transverse axis tripped the negative limit switch, use Manual mode to jog the
Transverse axis away from the limit switch.

Rail Negative Hardware Overtravel Reached

This message displays if the control detects a negative limit switch in the Rail axis. This
can also occur if the limit switch input is set for the wrong polarity or the limit switch
wiring is not properly connected.

If the Rail axis tripped the negative limit switch, use Manual mode to jog the Rail axis
away from the limit switch.

Transverse Positive Software Overtravel Reached

This message displays if the Transverse axis position is greater than the Maximum Travel
Limit setup parameter for the Transverse axis.

If this occurs, use Manual mode to jog the Transverse axis to a position within the Travel
Limit setup parameters.

Rail Positive Software Overtravel Reached

This message displays if the Rail axis position is greater than the Maximum Travel Limit
setup parameter for the Rail axis.

If this occurs, use Manual mode to jog the Rail axis to a position within the Travel Limit
setup parameters.

Transverse Negative Software Overtravel Reached

This message displays if the Transverse axis position is less than the Minimum Travel
Limit setup parameter for the Transverse axis.

If this occurs, use Manual mode to jog the Transverse axis to a position within the Travel
Limit setup parameters.

Rail Negative Software Overtravel Reached

This message displays if the Rail axis position is less than the Minimum Travel Limit
setup parameter for the Rail axis.

If this occurs, use Manual mode to jog the Rail axis to a position within the Travel Limit
setup parameters.

Dual Gantry Skew Error Exceeded

This message displays when the control has detected a position error fault between the
two drive axes on the dual gantry. It also may appear if the position feedback loops are

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Diagnostics

not operating properly, or the machine is being commanded to move or accelerate faster
than it is capable.

To correct this problem:

• Increase the Skew Error Tolerance Setup parameter in the machine setups screen.
• Re-tune the system.
• Decrease the maximum machine speed or the acceleration rate setup parameters.

Need Station Selection

This message displays if the input for a station or process has not been activated.
Example: When cutting in Plasma mode, a Plasma 1 or Plasma 2 input may be required
to execute the selected Plasma cut process.

Buffer Time Out

This message displays if there is an instance where the motion buffer is full and cannot
record the data being saved. This error allows the operator to stop the motion, back up on
path to the last pierce and start over without a position error. This error should be
reported to the control vendor.

CNC Time Out

This is a general error that may appear if there is an instance when any buffer is full and
cannot record the data being saved. This error allows the operator to stop the motion,
back up on path to the last pierce and start over. This error should be reported to the
control vendor.

Unable to Find HASP

The HASP is a hardware protection key (dongle) that enables the software. If the HASP
is not installed, the control will not work. If this message appears and the hardware key
is in place, contact your control vendor for assistance.

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 Diagnostics

Norton Ghost Utility

If a disaster occurs and prevents the control from operating, the Norton Ghost™ Utility is
available on specified controls to replace core system files and re-enable operation of the
control. Norton Ghost must be installed on the control hard drive with an appropriate
ghost image file.

The Norton Ghost Utility works by allowing you to retrieve an image file from the drive
D: partition of the hard drive to replace all data on drive C: The Ghost Image can be a
factory default or custom user created image files.

Note: All current information on Drive C: will be lost. You should create a unique user
image after table configuration which includes all the important table settings.

This feature may be executed from the System Tools screen or through use of a Ghost
image utility. This tool is available from the control supplier and transmitted over the
Internet.

• Create Utility from E-mail -- To create a Norton Ghost tool utility from the
compressed software sent via the Internet:
• USP Memory --Instructions to download USB format tools and files are available to
create a bootable USB device. Specific batch files to run the utility are included.
• Diskette -- The file sent by the Internet will be an auto-executable file which will
place the required files onto a diskette to be used at the control.

To copy the executable file to a diskette:

1. Place a blank diskette into your PC.
2. Double click on the recovery EXE file.
A message box displays.
3. Click on the “Create Floppy” button to copy the files.
The EXE will copy the new files to the floppy disk to take to the control.

Create a Ghost Recovery File

To create a Custom Image File:
1. Place the Norton Diskette or USB memory device into the control.
2. Turn the control on. Norton Ghost displays:

Starting PC DOS.......
.
.
.
Select 1 to make a New Backup Image or 2 to restore
existing [1,2]

3. Press 1 to create a new back up image.

You can create up to three custom images. They are created as “newest” to “oldest”

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Diagnostics

image and are automatically assigned. The “original” ghost image is the factory
default and cannot be over written.
Back up begins automatically:

--------------Backing Up Drive, Please Wait ---------------

The following Message appears when the backup is complete:

---- Back Up Complete, Please Remove Disk and Reboot -----

4. Remove the diskette or USB memory device.

5. Turn the control off and then on.
You may need to reload table setups and software updates if the image is not current.

Retrieve an Image File

To retrieve an image file:

1. Place the Norton Diskette or USB memory device into the control.
2. Turn the control on.
Norton Ghost displays:

Starting PC DOS.......
.
.
.
Select 1 to make a New Backup Image or 2 to restore
existing [1,2]

3. Press 2 to retrieve the back up image.

You can create up to three custom images. They are created as newest to oldest
image. The original ghost image is the factory default. The next message allows the
user to select which version to use when restoring:

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 Diagnostics

1. Newest.gho
2. Older.gho
3. Oldest.gho
4. Original.gho

Select the Number of the Image to restore from the

choices above [1,2,3.4 ]

4. Press the number for the image that you want to retrieve.

--------------------Restoring, Please Wait ----------------

Norton Ghost launches and displays messages to indicate the progress of the restore. The
following message displays when the restore is complete:

--------------------End Restoring, Please Remove Disk and Reboot -----------------------

Remove the diskette or USB memory device. Turn the control Off and then On. Table
setups and software updates may need to be reloaded if the image is not current.

327
Diagnostics

328
Password Setups
The following setup screens are only available with the supervisory passwords. This
prevents unauthorized personnel from entering these screens.

Warning! Only trained service personnel should have access to these passwords.
Incorrect settings can cause machine damage.

The 2865 password allows you to view the machine, speeds, link and axes setups without
making changes. This password is useful for verifying setups without the danger of
accidentally changing them or revealing the supervisory password to an unauthorized
user.

Note: After the CNC is installed on the cutting table or setup parameters are
changed, save the current setup file to both the hard drive and a floppy disk for future
reference.

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Password Setups

Machine

X Axis Orientation
Specifies the X axis as the transverse or rail axis. The default setting is Transverse. This
parameter should be set before cutting the part.

Up Direction
Defines the machine motion when the ↑ arrow key is pressed during manual mode.

Right Direction
Defines the machine motion when the → arrow key is pressed during manual mode.

Dual Gantry Installed

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

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

X and Y Motor/Encoder
Select Swapped to swap the X and Y Axis encoder signals internally. This feature
simplifies the installation of systems with alternative wiring configurations.

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 Password Setups

Auto Torch Spacing

Select Yes to enable the automatic torch spacing feature. This feature uses embedded
part program codes and dedicated outputs to control individual torch stations to set
spacing and clamping of direct and mirrored cutting. Refer to the Auto Torch Spacing
information for additional information.

Tilt Rotator Installed

Enables use of the Tilt Rotator feature. Tilt Rotator is a unique rotational 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 the length of the line
segment.

Dual-Tilt Rotator Installed

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

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.

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

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Password Setups

Dual Tilting Rotator Mode

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

Key Press Logging

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

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

THCs Installed
Defines the total number of Sensor THC axes assigned for operation at the control.

THC Installed On 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: Refer to the Station Configuration and Sensor THC sections of this guide for
additional information on the setup and use of the Sensor THC.

Ignore Torch Collision During IHS

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

Command THCs Installed

Enables the Command THC serial link. For more information on this feature, refer to the
Command THC section of this guide. Shown in Type P mode only.

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 Password Setups

SERCOS
The SERCOS interface requires configuration to establish communications for motion
and 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 300

The 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
SSCD

Yaskawa
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 Reco
or 1 Beckhoff node. No more than one Reco or Beckhoff I/O node can be enabled.

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Password Setups

Drive Type
Select the manufacturer of the SERCOS style drive. This makes the proper operation and
tuning parameters and software available.

Update Rate
Select the motion and I/O update rate for the SERCOS ring. One millisecond is
recommended but the actual value depends on the capabilities of the hardware being
used.

Baud Rate
Select the communication rate for the SERCOS ring. This is determined by the type of
drive and I/O being used.

Light Level
Adjust the intensity of the light pulses used on the fiber optic ring. This feature
compensates for diminished signal due to issues such as ring distance.

Drive I/O
Select the I/O options that are supported on the drive amplifier; None, Overtravel and
Home Switches, or All I/O.

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 Password Setups

Note: The drive I/O populates the general purpose I/O (both analog and digital) in order
from the lowest SERCOS drive axis to the highest SERCOS drive axis. All I/O is the
default setting for the SMCC interface.

RECO/Beckoff I/O at Address 50

Select Yes if the Indramat RECO or Bechkoff I/O module is being used 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 (both analog and digital)
following all drive I/O.

HPR/4070 at address 60
Select Yes if the optional SERCOS interface for HPR/4070 is being used.

HTA I/O at Address 70

Select Yes if the optional Hypertherm SERCOS interface card is being used.

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Password Setups

Speeds
The Speeds setup screen is where you set the machine speeds for the operating modes.

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 for these speeds. When a
speed range that is lower than the maximum speed is entered, a new range at the
maximum machine speed setting is created. You can set a maximum of 5 speed ranges.

To reduce the number of Speed To ranges, enter the maximum speed in the highest range
and the additional range fields will be removed from the screen.

Acceleration Rate
Determine both the acceleration and deceleration rate for all motion.

All mechanical systems have different acceleration and deceleration rates to move the
cutting device smoothly. The higher the acceleration rate, the quicker the machine will
get up to speed. The lower the acceleration rate the smoother the machine will position
the cutting device.

336
 Password Setups

Enter a value in milliGs for the desired acceleration rate. One milliG is approximately
0.384 inches per second2. A recommended, initial value for this field is 10 mGs.
Fast Stop Deceleration Rate
This parameter is activated by the Fast Stop or Torch Collision Input and specifies in
milliGs how quickly the system will stop when the Fast Stop Input is active. Generally,
this value is much higher than the acceleration rate.

One milliG is approximately 0.384 inches per second2.

Maximum Machine Speed

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

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

Maximum Contouring Rate (IPM) =

60 seconds Θ 1 Inch Θ 100,000 edges

minute User edges second

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

Limited Machine Speed

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

High Jog Speed

Defines the high speed for manual motion.

Medium Jog Speed

Defines the medium speed for manual motion.

Low Jog Speed

Defines the low speed for manual motion.

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Password Setups

Minimum Corner Speed

Defines the minimum speed to use when negotiating corners. The CNC has centripetal
velocity and acceleration contouring algorithms which provide optimal cut quality for
most cut operations. In some situations, a minimum corner speed prevents over-burning
at corners. In normal operations, this parameter should be set to zero.

Fast Home Speed

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

Slow Home Speed

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

Creep Speed Percentage

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

Plasma Hi/Lo Speed Percentage

Specifies the percentage of the Cut Speed at which the CNC activates the Torch Height
Disable output. The plasma system uses this output to switch from low to high current or
to disable the height control.

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

Plasma Distance To Corner

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

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

Plasma Distance From Corner

Specifies the distance after turning a corner at which the plasma system should enable the
Automated Height Sensor. Distance from Corner is active whenever the speed drops
below the Plasma Hi/Lo Percentage, or segments intersect at an angle greater than the
tangent angle.

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

For additional details on how the Torch Height Disable feature of this CNC operates,
please refer to the Cutting Section of this guide.

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 Password Setups

CBH Speed Setups

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

CBH Acceleration Rate

Specifies the acceleration rate for smooth and stable movement of the contoured bevel
head. The higher the acceleration rate, the quicker the CBH will get up to speed. The
lower the acceleration rate, the smoother the machine will position the cutting device.
Values are entered in revolutions/second2.

Maximum CBH Speed

Specifies the maximum speed for the CBH rotation in revolutions/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 Setups

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

THC Acceleration Rate

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

Maximum THC Speed

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

THC Jog Speed

Specifies the THC jog speed.

THC Home/Fast IHS Speed

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

THC Slow IHS Speed

Specifies the speed that is used to retract the torch after the plate has been sensed. The
torch retracts at this speed until contact sense is lost. This determines the exact distance
to the plate regardless of any flexing of the plate. A very low speed is recommended for
optimal accuracy.

The following Speeds setup parameters are available when Tilt Rotator has been enabled.

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Password Setups

Rotate Acceleration Rate

Specifies the acceleration rate for smooth and stable movement of the contoured bevel
head. The higher the acceleration rate, the quicker the Rotate Axis gets up to speed. The
lower the acceleration rate, the smoother the machine will position the cutting device.
Values are entered in revolutions/second2.

Maximum Rotate Speed

Specifies the maximum speed for the Rotate Axis rotation in revolutions/minute.

Rotate High Jog Speed

Specifies the high speed for the rotate axis jog.

Rotate Low Jog Speed

Specifies the low speed for the rotate axis jog.

Tilt Acceleration Rate

Specifies the acceleration rate for smooth and stable movement of the contoured bevel
head. The higher the acceleration rate, the quicker the tilt axis gets up to speed. The
lower the acceleration rate, the smoother the machine positions the cutting device. Values
are entered in revolutions/second2.

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 Password Setups

Maximum Tilt Speed

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

Tilt High Jog Speed

Specifies the high speed for tilt axis jog.

Tilt Low Jog Speed

Specifies the low speed for tilt axis jog.

Torch Height Disable

The Torch Height Disable feature is used to activate the Torch Height Disable output and
freeze, or disable, the automatic adjustment of the automated torch height control system
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 following
parameters:
• 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 is
implemented. The definition of a corner is based on the tangent angle in the special
password screen and the value of the Plasma Hi/Lo speed.

Tangent Angle
Specifies the degree of the tangent angle for motion control. Segments within a part that
intersect at angles greater than the selected tangent angle will decelerate to zero or the
minimum corner speed.

Segments within a part that intersect at angles less than or equal to the selected tangent
angle do not decelerate unless the next segment is a speed-limited arc.

Plasma Hi/Lo Speed Percentage

Specifies the percentage of the cut speed below which the CNC will activate the Torch
Height Disable output. The plasma system can use this output to switch from low to high
current or to disable the height control.

Plasma Distance To Corner

Specifies the distance before turning a corner at which the plasma system should switch
from low current to high current or disable the Automated Height Sensor. Distance to
Corner is active when the speed drops below the Plasma Hi/Lo Percentage, or when
segments intersect at an angle greater than the tangent angle.

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Password Setups

Plasma Distance From Corner

Specifies the distance after turning a corner at which the plasma system should enable the
Automated Height Sensor. Distance from Corner is active whenever the speed drops
below the Plasma Hi/Lo Percentage, or segments intersect at an angle greater than the
tangent angle.

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

Plasma Hi/Lo Percentage Value 90%

Distance to Corner Value .5 inches
Distance from Corner Value .5 inches
Tangent Angle Value 20 Degrees

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

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Ports
The CNC comes standard with two RS-232C serial ports, which can be converted to an
RS-422 configuration. For more information about how to change the serial ports to the
RS-422 configuration, refer to Serial Port Connections. This port has been specially
designed with opto-isolation and filtering to minimize EMI/RFI noise problems that are
common in many cutting operations. Parameters are enabled and disabled 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 to
communicate with a host computer. Information on how to access the Phoenix software
is provided later in this section.

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

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

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Port Designation
Specifies which serial port is configured for link use with the following remote
communication settings. Select Link, Messaging, HD4070, FineLine or Command THC
(type”V” controls).

Baud Rate
Specifies the baud rate for the remote communication link. The available baud rates are
shown. The CNC also incorporates a unique compression utility that allows the effective
baud rate to be doubled. For example, for links configured to run at 9600 baud, the
effective rate is 19.2K baud.

Note: For serial messaging communication speeds from 1200 baud to 115200 baud are
available. See Serial Messaging in the Program Code section for more information.

Parity
Specifies the parity for the remote communication link.

Data Bits
Specifies the number of data bits the remote link is using. This value is 8 for the link
software included with the control.

Time Out Delay

Specifies the amount of time the CNC waits before it displays a communications error if
it is not be able to establish a link with a remote device.

Transmit Delay
Specifies the amount of delay the CNC inserts between each character that is transmitted
over the serial port. Some communication links require a small delay to avoid missing
characters that have been sent to them. This parameter should normally be set to 0.

The following parameters allow the user to create a custom communication link on the
CNC by entering the ASCII code equivalent to the character or symbol used by the host
computer for dialog start. For example: The ASCII Decimal Code 33 is equal to the !
symbol.

Rewind
This field is only enabled when Link File Dump Mode has been enabled. Enter the
ASCII code equivalent to the character or symbol used by the host computer for tape
rewind at the host tape drive system. Enter 0 to eliminate the rewind command.

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

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

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

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

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

End of Transmission
Enter the ASCII code equivalent to the character or symbol used by the host computer for
dialog acknowledge.

Using Phoenix Link

Select Yes if you are using the Phoenix Communication link program that is supplied on
the control. The CNC automatically enters the appropriate ASCII codes to the
communication link dialog parameters listed previously.

Show Host File Names

Select whether File Names are shown on the Download from Host screen. This is a time-
saving feature for operators who have very large part folders at the host computer and
know the exact file name of the part program they want to load. The Using Phoenix Link
parameter must be set to ON to enable this feature.

File Dump Mode

Select On to configure the link communication protocol to communicate with link
programs that operate in File Dump Mode. This allows the CNC to accept part programs
as a single uninterrupted stream of information as with a tape reader style link.

Allow M65 Auto Reload

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

Auto Home before Auto Reload

Automatically homes the machine before the next auto reload (EIA M65 code), either
serial link, USB memory or from diskette, is executed

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ESSI Program Termination

This parameter allows the operator to tell the CNC which ESSI code (0,63, 64 99, / or =)
is used as machine stop.

Download Updates
Allows the operator to download CNC software updates through the link communication
to the host PC. To use this feature, the “Using Phoenix Link” parameter must be set to
YES. The new update file must be placed in the same folder location as the Link
software. When the Update Software soft key is pressed on the Special Password screen,
the CNC searches for the new software update through the link rather than the floppy
drive.

Use Multi Drop

Allows the CNC to work with the Phoenix Link software multi-drop feature. The multi-
drop feature allows the Phoenix Link software to communicate with multiple controls to
one communications port at the host PC. Up to eight controls can be supported with the
multi-drop feature.

Note: The “Using Phoenix Link” parameter must be set to Yes to enable this feature. In
addition, specific hardware (serial communication board Rev C or higher) may be
required to support this feature. Please contact your CNC supplier for more details.

Address
Defines the CNC identification address for the multi-drop communication feature. The
Phoenix Link software uses this address at the host PC to know which CNC it is
communicating with.

Control Monitoring
Allows the user to view CNC status at the host PC. Status for file name, position, cut
mode and cut information is displayed. This feature is only available with the Phoenix
Link communication software. Refer to the Phoenix Link section for additional
information.

The following additional parameters are available when Serial Messaging has been
enabled. See Serial Messaging in the Program Code section of this guide for more
information.

Flow control
Select None, Xon/Xoff or Hardware.

During Jog on Path

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

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

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Note: The Message Type 21 is not executed for Backup on Path.

Retry on Time Out

Select the number of times the system automatically retries Message Type 22. After the
system tries to send the message this many times it displays “Message Error” to indicate
that the external device does not respond.

Time Out
This value is used for Message Type 22 if there is no time-out value used in the
command string of the program code. Refer to the Delay Time / Time Out information
for more information.

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I/O
Press the I/O soft key to configure the inputs and outputs for the shape cutting table.

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Expanded I/O
Available when more than 64 I/O have been selected. A drop-down box is available to
assign I/O in the higher I/O ranges.

Note: When the optional USB front panel is used, the top 128 I/O are assigned to USB
I/O to support the front panel

Input Logic
The CNC comes standard with up to 32 discrete inputs. Used as a mask to determine
whether an input is treated as a normally open or closed contact. Entering a numerical
value here sets all the Inputs to a predefined set of logic states for all of the inputs.

With Input Logic set to zero (0), an active input is displayed with a green lamp in the
input diagnostic screen.

Logic Selection Box

Determines whether the logic state for each input is normally open or closed. To select
the logic state for an input, select the desired input and press the space key.

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Input Selection
Defines which inputs are used by the CNC and their physical location on the CNC
interface. All controls are shipped with the default selection of inputs and interface
locations for the selected control interface (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 Decel value or the Fault Ramp time that has been
selected for the individual axis.

Inputs Inverted
Defines which inputs are used by the CNC and their physical location on the CNC
interface. All controls are shipped with the default selection of inputs and interface
locations for the selected control interface (I/O) configuration.

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

Initial Feedback Delay

Allows the initial feedback from the drive system to be held off after initial power up.
This allows the drive system to become fully enabled before it enables the position loop.

Fume Extraction Delay

Enter the number of seconds after the end of a cut part program that the fume exhaust
remains on.

Speed Pot and Joystick Overview

Through the use of single-ended inputs to an optional analog input card installed in the
control, your CNC can be configured to support an external joystick or two speed
potentiometers.

Note: These features are not available for all CNC types and optional CNC hardware
may be required.

• The external joystick is used as a directional command signal when it is in manual

motion.
• The optional speed potentiometer can be used to adjust the current motion speed.
• These features must first be enabled at the password-protected I/O screen.

Joystick Installed
Select Yes to enable the optional external joystick. This parameter is not available for all
CNC types and optional CNC hardware is required.

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Speed Pot Installed

Select Yes to enable the optional external speed potentiometer. This parameter is not
available for all CNC types and optional CNC hardware is required.

Plasma Override %
Sets the minimum and maximum range for adjustment of the plasma speed potentiometer
based on a percentage of the set cut speed. The speed potentiometer feature must be
enabled to use this parameter.

Oxy Fuel Override %

Sets the minimum and maximum range for adjustment of the oxy fuel speed
potentiometer based on a percentage of the set cut speed. The speed potentiometer
feature must be enabled.

Trial Override %
Sets the minimum and maximum range for adjustment of the trial speed potentiometer
based on a percentage of the set trial speed. The speed potentiometer feature must be
enabled.

Speed Pot Installed On

Assigns speed potentiometer inputs to the desired Analog Input if a dedicated speed
potentiometer input is not available on the analog input card.

Analog Offset 1- 12
Corrects for any imbalance or zeroes the incoming analog voltage to the analog input
card

Note: To calibrate the analog inputs, jumper the two pins specific to the input together
and view the incoming voltage on the Diagnostics Analog I/O screen. The incoming
voltage should be 0. If any voltage is displayed at the diagnostic screen, an offset voltage
equal to the incoming voltage being read can be entered here to make the incoming
voltage 0. Refer to the installation instructions later in this section for more details.

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Input Definitions

Input Definition
Spare Activated through the part program. If a spare input is located
in the part program, the CNC pauses the process until the input
state is detected. The spare inputs can be implemented with
specific EIA “O” and “M” codes that indicate the input number
and function. Refer to Appendix A for a complete description
of these commands.

Torch Up Sense Indicates that the torch is in the full up position.

Torch Down Sense Indicates that the torch is in the full down position.

Preheat Sense Indicates that the preheat input from the torch is active.

Cut Sense Indicates that the plasma arc has transferred to the work piece.
If the Arc On Feedback setup parameter is ON, machine
motion begins at the activation of this input. Type “M” and
“P” controls.

Tracer on Path Used with the Teach Trace feature and indicates that the
tracing system has detected the template line.

Drive Disabled Causes the CNC to stop all motion and generate a fault
message. Position information is lost.

Remote Pause Stops all CNC motion and displays the Pause screen. No
motion is allowed until this input is deactivated.

Remote Start Begins the selected program cycle as if the Start button on the
CNC had been pressed.

Program Inhibit Forces the CNC to command the motion output to a zero (0)
speed. This is generally used as a dwell to pause motion
during a tool change or as a pause from a PLC interface.

Raise/ Lower Torch Operates multiple Sensor THCs when multiple Sensor THCs
are commanded by the CNC as separate axes. The Torch Raise
and Torch Lower commands can be issued with soft keys or
through these external inputs to the control. Type V control.

Station Select Input Indicates which Sensor THCs is active when multiple Sensor
THCs are commanded by the CNC as separate axes. Also
tracks consumable data for the specified plasma or oxy torch.

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Stations 1-8 are 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. If the X axis Use Home Limit Switch parameter is set
to YES and a homing function is performed, the X axis moves
in the specified home direction at the fast home speed until the
input is activated. The X axis then decelerates to a stop and
moves in the opposite direction at the slow home speed until
the switch is deactivated. After the switch is deactivated, the X
axis decelerates to a stop or, if the Use Marker Pulse parameter
is set to YES, continues until the encoder marker pulse is
detected.

Y Home Switch Indicates that the machine has traveled to its Y axis home
position. If the Y axis Use Home Limit Switch parameter is set
to Yes and a homing function is performed, the Y axis moves
in the specified home direction at the fast home speed until the
input is activated. The Y axis then decelerates to a stop and
moves in the opposite direction at the slow home speed until
the switch is deactivated. After the switch is deactivated, the Y
axis decelerates to a stop or, if the Use Marker Pulse parameter
is set to Yes, continues until the encoder 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 a homing function is performed, the Z axis moves
in the specified home direction at the fast home speed until the
input is activated. The Z axis then decelerates to a stop and
moves in the opposite direction at the slow home speed until
the switch is deactivated. After the switch is deactivated, the Z
axis decelerates to a stop or, if the Use Marker Pulse parameter
is set to Yes, continues until the encoder marker pulse is
detected.

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

X Overtravel Switch Indicates that the machine has traveled into its full positive
travel of a X axis. If hardware overtravels are enabled and this
input is activated, the CNC stops all motion and generates a

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fault message. Motion is not re-enabled until the switch is

deactivated.

Limit Switch Indicates that the machine has traveled into its full positive
travel of an axis. If hardware over travels are enabled and this
input is activated, the CNC stops all motion and generates a
fault message. Motion is not re-enabled until the switch is
deactivated. (Type “M” configuration only)

Ready to Fire PS 1-4 Ensures that all HD4070 power supplies have completed each
individual Initial Height Sense and are ready for use. The torch
ignition is held off by the Hold Ignition Input to the power
supply from the control. This input is exclusive to the HD4070
multiple power supply configuration.

Raise /Lower 4070 1-2 Used as a manual raise/lower command to the selected
HD4070 integrated THC through the CNC serial power supply
communication link. This input is exclusive to the HD4070
multiple power supply configuration.

X +Overtravel Switch Indicates that the machine has traveled to its full positive travel
on the X axis. If hardware over travels are enabled and this
input is activated, the CNC stops all motion, generates a fault
message and only allows manual motion in the X axis negative
direction.

X –Overtravel Switch Indicates that the machine has traveled to its full negative
travel on the X axis. If hardware overtravels are enabled and
this input is activated, the CNC stops all motion, generates a
fault message and only allows manual motion in the X axis
positive direction.

Y +Overtravel Switch Indicates that the machine has traveled to its full positive travel
on the Y axis. If hardware overtravels are enabled and this
input is activated, the CNC stops all motion, generates a fault
message and only allows manual motion in the Y axis negative
direction.

Y –Overtravel Switch Indicates that the machine has traveled to its full negative
travel on the Y axis. If hardware overtravels are enabled and
this input is activated, the CNC stops all motion, generates a
fault message and only allows manual motion in the Y axis
positive direction.

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Power Supply OK Used for the optional Automated Process Controller (APC). It
confirms a ready condition from the plasma power supply
before beginning the cut process.

Fast Stop Used as an urgent stop input command to the control. When
the Fast Stop input becomes active, the CNC decelerates
motion using a special Fast Stop Decel parameter, and forces
the operator to the Pause Screen. One second after the input
becomes active, the Drive Enable output from the CNC turns
off and disables motion. Position information and I/O points
are maintained while the input is active. This allows the
operator to recover the last position after the input has been
cleared.
Note: The Fast Stop Decel parameter is located on the
password protected Speeds setup screen.

Torch Collision Used on torch systems with breakaway mounts. If a torch

makes contact with the plate or an obstacle that causes the
breakaway mount to release, an input for the mount is sent to
the CNC indicating that a torch collision has occurred. The
operator is forced to the Pause screen. While the input is
active, the Cut output is turned off and manual motion is
enabled, allowing the operator to raise, lower and move the
torch position to clear the fault.
Note: Position information, motion command, and I/O points
are maintained and allow the operator to return to the cut path
and resume cutting. This feature uses the Fast Stop
Deceleration rate. Manual raise inputs can be used.

Joystick (Direction) Command manual motion (up, down, left, and right) when
using an external joystick.

Fume Extraction Sense If selected, this input confirms that an external Fume
Extraction system on the cutting table is operational before
beginning the cut. An option to override is displayed if the
input has not been satisfied at the time of the cut.

Cut/Mark Sense 1& 2 Verifies that the plasma torch or marker tool has established
the arc for the selected process. This indicates to the CNC
that motion can begin. (Type “V” controls).

THC Cut Sense Verifies that the plasma torch or marker tool has established
the arc for the selected Sensor THC and indicates to the CNC
that motion can begin. (Type “V” controls).

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Plasma Select 1 & 2 Select which Plasma process logic is used by the control.
These inputs are generally run by external switches. (Type
“V” controls).

Marker Select 1 & 2 Select which Marker process logic is used by the control.
These inputs are generally run by external switches. (Type
“V” controls).

Sensor THC Enable Indicates which Sensor THCs are active when multiple Sensor
THCs are commanded by the CNC as separate axes. This
input is now supported by the Station Select input.

THC Homing to Limit The THC Enable Input is used during Sensor THC Homing as
the Current Limit input if the Home to Hard Stop Current
Limited option is selected.

Nozzle Contact Sense Used during Sensor THC IHS to detect the location of the cut
surface. This input is returned to the CNC through the
external voltage divider card.

THC Homing to Switch The Nozzle Contact Sense Input is used during Sensor THC
Homing as the Home Switch input, if the Home to Switch
option is selected.

THC Automatic Used as an external input to switch the Sensor THC between
automatic and manual operation.

Speed Limit Input Limits the machine speed for safety during machine testing
and maintenance. When this input is active, motion is limited
to the user-defined Limited Machine Speed selected in the
password protected Speeds screen

Tilt +/– Overtravel Switch Indicates that the machine has traveled to its full positive
travel in the Tilt axis. If hardware overtravels are enabled and
this input is activated, the CNC stops all motion, generates a
fault message and only allows manual motion in the Tilt axis
opposite direction. The Tilt Overtravel Input is also used for
homing the tilt axis.

Tilt +/– Used for manual jog commands for the tilt axis.

Tilt Home Feature Uses the Tilt Overtravel Switch input to indicate that the
machine has traveled to its tilt axis home position. When the
Tilt axis is homed, it moves in the specified home direction at
the Fast Home Speed until the input is activated. The tilt axis
decelerates to a stop and moves in the opposite direction at the

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Slow Home Speed until the switch is deactivated. See also Tilt
Overtravel Switch.

Rotate +/– Used for manual jog commands for the rotate axis.

Rotate Home Switch Indicates that the machine has traveled to its rotate axis home
position. When the rotate axis is homed, it moves in the
specified home direction at the Fast Home Speed until the
input is activated. The rotate axis decelerates to a stop, moves
in the opposite direction at the Slow Home Speed until the
switch is deactivated.

Pierce Complete Used for the laser cut process to confirm that the pierce is
complete.

Gas Control Read Comp. Used as part of the HD3070 Automatic Gas Console
communication to confirm that communication is complete.

Gas Control Error Used as part of the HD3070 Automatic Gas Console
communications to indicate an error from the Auto Gas
Console.

Enable Oxy Fuel 1-12 Used for tracking consumable data for the specified oxy torch.
This input is now supported by the Station Select input.

Enable Plasma 1-8 Used for tracking consumable data for the specified plasma
torch. This input is supported by the Station Select input.

Arc Error Counter 1-8 Used as part of consumable data tracking, this input triggers a
counter on the Change Consumable Screen. A Plasma Enable
Input must be mapped to enable this input.

Test Lifter Performs a test IHS function with a Sensor THC.

Output Logic
The CNC comes standard with up to 32 discrete outputs. The Output Logic parameter is
used as a mask to determine whether or not the output is to be treated as a normally open
contact or as a normally closed contact.

Logic Selection Box

The Logic Selection Box allows the user to select the Logic state for each input to be
either normally open or normally closed. The logic state for the inputs can be switched by
selecting the desired Output and pressing the space key.

Output Selection
The Output Selection box feature is used to define which inputs will be used by the
control, and their physical location on the control interface. All controls are shipped with

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Password Setups

the default selection of Outputs and interface locations for the selected control Interface
(I/O) configuration.

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Output Definitions

Output Description
Spare Activated through the part program. If a spare output is
located in the part program, the CNC turns on the output as
directed. The Spare outputs can be implemented with
specific EIA “W” and “M” codes that indicate the output
number and function. Refer to Appendix A for a complete
description of these commands.

Torch Up Raises the cutting torch. It is activated for the “Primary

Torch Up Time” and the “Pierce Torch Up Time” in oxy
fuel mode. It is activated for the “Torch Up Time” in
plasma mode.

Torch Down Lowers the cutting torch. It is activated for the “Primary
Torch Down Time” and the “Pierce Torch Down Time” in
oxy fuel mode. It is activated for the “Torch Down Time”
in plasma mode.

Ignition Control Turns on the igniters in oxy fuel mode or ignites the plasma
system in plasma mode.

Torch Height Disable

/Dual Grid Control Disables the automatic torch height controller in plasma
mode. It is activated whenever the current axis position is
within the “Plasma Distance To Corner” or the “Plasma
Distance From Corner” parameters while cutting a part. It
is also active whenever the current cutting speed drops
below the result of (Programmed Cut Speed x (Plasma
High/Lo Speed/100)).

This output also reduces the plasma current in a switchable

current plasma system when the machine speed is less than
the Plasma Hi/Lo speed percentage.

Reduce Current Used with the HD4070 to switch the plasma to low current
mode.

CNC/Tracer Controls a CNC relay. The CNC relay determines whether

the control, tracing system, or joystick is commanding the
amplifiers. This output is always active unless the CNC is
off, in Teach Trace mode, or is disabled.

Marker / Marker Enable Activates an external marking device. It can only be

activated by the appropriate “M” code in the part program.

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Refer to Appendix A for a complete description of

appropriate “M” code commands.

Cut Control Enables the cutting oxygen in oxy fuel mode or starts the
plasma system in plasma mode. This output can also be
used to activate a marking device.

Low Preheat Control Enables the low preheat gas when cutting in oxy fuel mode.
It is activated for the “Low Preheat Time” when initiating a
cut.

Preheat Control Enables the high preheat gas when cutting in oxy fuel
mode. It is activated for the “High Preheat Time” when
initiating a cut.

Key Press Indicator Activated whenever a key is pressed on the control.

Motion Indicator Activated whenever the CNC is commanding machine

motion.

Plasma Select Activated whenever the CNC is in the Plasma cutting

mode.

Bleed Off Gas Used by the oxy fuel cut logic to send an output to the oxy
torch to purge gases at the end of a cut. This output is on
for the duration of the Bleed Off time selected in setups.

Pierce Control Used by the plasma and oxy fuel cut logic to send an output
to the torch during the pierce. This output is on for the
duration of the Pierce Time selected in setups.

Turn ON / Off Supply Used by the Optional APC to turn on or off the plasma
supply through the control.

N2 Select Used by the Optional APC to enable the use of nitrogen

while cutting.

Drive Enable Used to enable the drives during normal functions and to
disable the drives during fault conditions.

Fume Extraction Control Enables fume extraction and the Initial Feedback Delay and
Fume Extraction Delay fields.

Shutter Open Used exclusively with the laser cut logic to open the laser
shutter for use.

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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.

Abrasive Control Used exclusively with water jet cut logic and activates the
abrasive control, adding abrasive to the cut stream while
cutting, or for charging the abrasive prior to cutting.

Plasma Enables Used for external logic. The appropriate output(s) is on

during plasma cutting, based on the Plasma Select inputs.

Marker Enables Used for external logic. The appropriate output(s) is on

during marking, based on the Marker Select inputs.

Nozzle Contact Enable Active during Sensor THC IHS. This input is tied back to
the CNC through the external voltage divider card. This
output can also be used to switch an external drive system
to low output mode (if equipped) during IHS for stall force
plate sensing.

Hold Ignition Is part of the Sensor THC operation to hold ignition of the
external Plasma Supply. This output can be tied back to the
CNC through the external voltage divider card or direct to
the power supply depending on 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

communications to select the appropriate valves for
operation.

Gas Control Write Used as part of the HD3070 automatic gas console
communications to configure the unit for operation.

Remote Test Operate Used as part of the HD3070 automatic gas console
communications to initiate the remote test.

Remote Test Preflow Used as part of the HD3070 automatic gas console
communications to test operation of preflow gases.

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Remote Air Plasma Used as part of the HD3070 automatic gas console
communications to signal the Air Plasma output.

Remote H35/ N2 Plasma Used as part of the HD3070 automatic gas console
communications to signal the H35/N2 output.

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

communications to signal the O2 Output.

Change Consumable Activates when a consumable data value on the Change

Consumable Screen has reached its preset maximum.
Generally, this output is tied to an external indicator light
or audible alarm to prompt the system operator to change
the appropriate consumable. The affected consumable data
must be reset on the Change Consumable Screen to clear
the output.

Current Set BCD Sets the current at the plasma power supply or marker
supply. These outputs are tied to the BCD inputs.
Combinations of the current values are 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 Enable and Cut Control outputs.
All the noted options are available and can be configured
on the Marker Setup screen for the desired process timing
and operational results.

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

Station Enable 1-20 Activates any function specific to a torch station and are
controlled through 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 are configured
with oxy fuel or other types of fuel. However, plasma can
only be configured on stations 1-8.

Station Lock 1-19 Are part of the Automated Torch Spacing feature. The
station lock locks the unused torch station to the gantry or
beam when the torch is not in use.

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Station Clamp 1-19 Used as part of the Automated Torch Spacing feature. The
Station Clamp is used to clamp the selected torch station to
the transverse axis for standard cutting.

Station Mirror 1-19 Used as part of the Automated Torch Spacing feature. The
station mirror 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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Axes – Transverse or Rail

The following screen is identical for both the traverse and rail setup screens.

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

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

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

Proportional Gain
Proportional gain correlates to elastic stiffness in the control loop. Increase the
proportional gain to increase the static stiffness, but decrease the response of the servo
loop.

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Under a proportional loop control, the drive system applies a restoring torque to the
motor in proportion to the position error of the axis.

If proportional gain too high, the system and axis become unstable. During cutting, the
torch can overshoot the path. This is also called a “hot” control loop.

If proportional gain too low, the system response is not precise. This can be seen in the
test pattern when the outside corners become rounded 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 shape cutting machines, this parameter should be set to zero (0).

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

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

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

Use of the internal velocity loop with a current loop amplifier can result in higher static
stiffness, smoother machine motion, and less overshoot.

Servo Error Tolerance

Allows the user to program the amount of servo loop following error to be allowed prior
to display an error message. The parameter is limited to a maximum value of five inches.

Encoder Counts per inch

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

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For example: The resolution of a 4X – 1000 line encoder counts both edges (lines) of
channel A and channel B to equal 4 counts per line multiplied by the 1000 lines per
revolution would equal 4000 counts per revolution. If the encoder revolutions per inch to
travel are 1:1, we would have 4000 encoder counts per inch of travel.

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

Fault Ramp Time

This parameter sets the motion deceleration time after a fault occurs. At the end of “Fault
Ramp Time, The drives will be disabled.

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

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

Encoder Polarity
This parameter allows changing of the encoder input polarity to establish proper counting
for positive machine motion without any wiring changes.

Encoder Decode Mode

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

Use Hardware Overtravels

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

Backlash Compensation
The Backlash Compensation parameter is used to offset or compensate for any backlash
in the mechanics of the drive system.

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

The Home feature is used to set a known absolute physical position location on the
cutting table that is used for referencing future manual “Go to Home” and other motion

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commands. This is generally performed through activation of a home switch positioned

on the appropriate axis giving it a known physical location.

When the Homing command is entered at the control, the CNC will move the axis
towards the Home Switches at the Fast Home Speed until the switches have been
activated. Once the switches have been activated, motion stops and then the axis moves
in the opposite direction off switch at the Slow Home Speed. The moment that the
switch is deactivated, the position is recorded at the control, providing an absolute
reference point for future motion commands.

Absolute Home Position

Defines the position of the axis when the Home Limit Switch or Marker Pulse is detected.

Home Offset Distance

Allows the user to set an offset distance from the Home Limit Switch.

Home Switch Normally

If a Home Limit Switch is used, the user is prompted for switch polarity.

Home Direction
Determines which direction the axes will travel during phase one of the homing
sequence.

Use Marker Pulse

When enabled, the absolute home position will be assigned at the instant the marker pulse
is detected. It is recommended that the Marker Pulse be used for optimal homing
repeatability.

Use Software Travel Limits

The CNC is capable of running with software Overtravel limit switches based on
position. When enabled, this feature allows the user to select the fault logic of fault or
Fast Decel when active. Fault operates as hardware switches with immediate fault. Fast
Decel uses the fast Decel value to ramp down motion.

Maximum Travel Limit

If Software Overtravels are enabled, the user is prompted for the maximum travel of the
cutting machine.

Minimum Travel Limit

If Software Overtravels are enabled, the user is prompted for the minimum travel of the
cutting machine.

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Axes -- SERCOS
The SERCOS Interface controls the position loop from the amplifier. As a result, limited
information for motion is required in the CNC setups. Tuning is performed through
serial port diagnostic software available at the Drives & Motors Diagnostic screen.

The following is a listing of the unique SERCOS parameters. Note: parameters will
apply to all SERCOS axes.

SERCOS Drive Address

Each Drive Axes is automatically assigned a Drive Address at the CNC. The appropriate
drive amplifier will be coded with the matching Drive Address to provide control motion
to the correct amplifier / motor on the SERCOS ring.

Note: The drives may be physically located in any order on the ring.

Emulated Encoder Counts/ motor rev

This parameter allows the user to adjust the number of counts per motor rev that the drive
generates over the SERCOS ring, to adjust resolution. This parameter is available for Pac
Sci drives only. Other drive types allow the emulated Counts /motor rev parameter to be
set up in the drive tuning software.

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Axes -- Dual Gantry

The following setup screen is available if the CNC is configured for a Dual Gantry Axis.

The Dual Gantry Axis is commanded as a separate axis on the control that mirrors the
output of the main Rail Axis. Additionally, performance of the Dual Gantry Axis is
compared to the main Rail Axis and additional output command is given to keep the axis
in position.

The definitions for the setup parameters are the same as for the Transverse/Rail Axes.
However, the number of selections are reduced as features for overtravels and homing do
not apply.

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

Note: These speed parameters are directly tied to the Speed To field for the acceleration
rates previously noted on the Speeds setup screen. Changing these speed parameters will
replace the Speed To values entered at the Speeds setup screen.

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Proportional Gain
Proportional Gain correlates to Elastic Stiffness in the control loop. Increasing the
proportional gain increases the static stiffness, but decreases response of the servo loop.

Under proportional loop control the drive system will apply a restoring torque to the
motor in proportion the position error of the axis.

With a Proportional Gain too high, the system will be unstable which will result in
overshoots, and a generally “nervous” and shaky axis. This is also referred to as a “hot”
control loop.

With a proportional gain too low, the system will respond in a loose or sloppy manner.
This can be seen in the test pattern when the outside corners become rounded and the
circle segments do not all meet in the center.

Integral Gain
Integral Gain improves the positioning accuracy of the control loop. Integral gain can be
used to compensate for static friction or gravity. Excessive Integral Gain can result in
system instability.

For most shape cutting machines this parameter should be set to zero (0).

Derivative Gain
Derivative Gain helps to dampen out sudden changes in velocity. The higher the
derivative gain, the slower the response time to the control loop.

For most velocity loop drives this parameter will be set to zero (0).

Feedforward Gain
Feedforward Gain can be used to drive the following error to zero during machine
motion. In all digital control loops there is a finite amount of error that is introduced by
the velocity command. Increasing Feedforward Gain can reduce this introduced error.

Velocity Gain
When using a current loop amplifier, the internal velocity loop in the CNC can be used to
provide dampening without an external tachometer.

Using the internal velocity loop with a current loop amplifier can result in higher static
stiffness, smoother machine motion, and less overshoot.

Skew Error Tolerance

If the Dual Gantry Axis is installed, the user will be prompted for Skew Error Tolerance.
This is the amount of position error allowed between the master and slave gantry drive
axes prior to an error message being displayed.

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Encoder Counts per inch

Enter a value that is the number of encoder edges per inch of machine travel. It is
possible to enter fractional encoder units and the CNC will keep track of these fractions
automatically. Encoder Counts per inch are equal to the resolution of the encoder,
multiplied by the encoder revolutions per inch (based on the machine drive gearing).

For example, the resolution of a 4X – 1000 line encoder counts both edges (lines) of
channel A and channel B to equal 4 counts per line multiplied by the 1000 lines per
revolution would equal 4000 counts per revolution. If the encoder revolutions per inch to
travel is 1:1, we would have 4000 encoder counts per inch of travel.

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

Note: This value should match the value used for the Rail for proper operation.

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

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

Encoder Polarity
This parameter allows changing of the encoder input polarity to establish proper counting
for positive machine motion without any wiring changes.

Encoder Decode Mode

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

Use Home Limit Switch

Selecting “Yes” will enable the Home feature for the Dual Gantry Axis. Note: The Z
Home Switch must first be defined and mapped to an input location in the I/O screen to
enable this feature.

Switch Offset Distance

The Switch Offset Distance is used to specify any physical position offset between the
Dual Gantry and Rail Home Switch positions. This allows the CNC to very accurately
position the two axes for operation and remove any skew of the gantry.

Backlash Compensation
The Backlash Compensation parameter is used to offset or compensate for any backlash
in the mechanics of the drive system.

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Axes -- CBH
The following setup screen is available if the CNC is configured for a Contour Bevel
Head.

The definitions for the setup parameters are the same as for the Transverse/Rail Axes,
with the exception of Absolute Home Angle and Home Offset Angle. These two setup
parameters serve the same basic function as previously described but are measured in
degrees of rotation rather than inches or millimeters. However, the number of selections
are reduced as these parameters are not used with a Contour Bevel Head.

Proportional Gain
Proportional Gain correlates to Elastic Stiffness in the control loop. Increasing the
proportional gain increases the static stiffness, but decreases response of the servo loop.

Under proportional loop control, the drive system will apply a restoring torque to the
motor in proportion the position error of the axis.

With a Proportional Gain too high, the system will be unstable which will result in
overshoots and a generally “nervous” and shaky axis. This is also referred to as a “hot”
control loop.

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 Password Setups

With a proportional gain too low, the system will respond in a loose or sloppy manner.
This can be seen in the test pattern when the outside corners become rounded and the
circle segments do not all meet in the center.

Integral Gain
Integral Gain improves the positioning accuracy of the control loop. Integral Gain can be
used to compensate for static friction or gravity. Excessive Integral Gain can result in
system instability.

For most shape cutting machines, this parameter should be set to zero (0).

Derivative Gain
Derivative Gain helps to dampen out sudden changes in velocity. The higher the
Derivative Gain, the slower the response time to the control loop.

For most velocity loop drives, this parameter will be set to zero (0).

Feedforward Gain
Feedforward Gain can be used to drive the following error to zero during machine
motion. In all digital control loops there is a finite amount of error that is introduced by
the velocity command. Increasing Feedforward Gain can reduce this introduced error.

Velocity Gain
When using a current loop amplifier, the internal velocity loop in the CNC can be used to
provide dampening without an external tachometer.

Using the internal velocity loop with a current loop amplifier can result in higher static
stiffness, smoother machine motion, and less overshoot.

Servo Error Tolerance

Allows the user to program the amount of servo loop Following Error to be allowed prior
to display an error message. The parameter is limited to a maximum value of 90 degrees.

Encoder Counts per rev

Enter a value that is the number of encoder edges per revolution of the Contour Bevel
Head axis. It is possible to enter fractional encoder units and the CNC will keep track of
these fractions automatically. Encoder Counts per rev are equal to the resolution of the
encoder multiplied by the encoder revolutions per rev.

For example: The Resolution of a 4X – 1000 line encoder counts both edges (lines) of
channel A and channel B to equal 4 counts per line time multiplied by the 1000 lines per
revolution would equal 4000 counts per revolution.

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

Drive Type

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

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

Encoder Polarity
This parameter allows changing of the encoder input polarity to establish proper counting
for positive machine motion without any wiring changes.

Encoder Decode Mode

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

Follower Initially
This parameter is used to determine if the CBH axis will be On when the CNC is first
powered up.

Auto Home At Power Up

Determines if the Contour Bevel Head will automatically go into the homing routine
upon powering up the control.

Absolute Home Angle

Defines the position of the axis when the home limit switch or marker pulse is detected.

Home Offset Angle

Allows the user to set an offset angle from the home limit switch.

Use Home Limit Switch

Tells the CNC to look for a home limit switch during phase one of the homing sequence.

Home Direction
Determines which direction the axes will travel during phase one of the homing
sequence.

Use Marker Pulse

When enabled, the absolute home position will be assigned at the instant the marker pulse
is detected. It is recommended that the marker pulse be used for optimal homing
repeatability.

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Axes -- Rotate

Absolute Home Angle

Defines the position of the axis when the home limit switch or marker pulse is detected.

Home Offset Angle

Allows the user to set an offset angle from the home limit switch.

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Password Setups

Axes -- Tilt

Absolute Home Angle

Defines the position of the axis when the home limit switch or marker pulse is detected.

Home Offset Angle

Allows the user to set an offset angle from the home limit switch.

Note: Homing to a limit switch uses the Tilt Overtravel Switch (+/ –) input.

Homing with Overtravel Switch

The Home with overtravel switch parameter is used to activate use of the Home feature
and uses the Overtravel Switch as its reference.

The Home feature is used to set a known absolute physical position location for the tilt
axis.

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 Password Setups

Axes -- Transverse 2
The transverse 2 axis is only available when a second bevel head has been enabled.

Minimum Torch Spacing

Sets the minimum distance that is allowed between the transverse 1 and transverse 2
axes.

Mirrored Marker Offsets

Allows preset tool offsets to be performed as mirrored motion for the transverse 2 axis.

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Password Setups

Station Configuration
This password protected screen for the Voyager III and Mariner controls is used to
configure a plasma, marker or laser torch station for use. This provides a single location
to assign the tool, process, and lifter selections for the station. You can configure up to
eight stations for the plasma 1 & 2 and marker 1 & 2 process selections.

The “4532” password allows you to view the Station configuration screen and verify
setups but does not allow changes.

You can also use this station configuration screen to enable the serial link for the
Command THC, as well as serial communication for the HD4070 and HPR130 plasma
systems.

You can use codes within a part program to select the stations that are used. These
station codes enable a THC station and are used in conjunction with the process selection
codes to configure the cut or mark process.

When a station selection code is executed through program codes, the corresponding
station select output is active.

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 Password Setups

Stations 1-4 or 5-8

The Stations 1-4 or Stations 5-8 soft keys access the corresponding stations for
configuration.

Reset
Resets or clears all station setup parameters to None.

Part Program Support

Enable a station for use. Place station and process selection codes before the cut or mark.

Station Selects
You can select or cancel stations (lifters or THCs) using an EIA-274D program code with
the following format.

Code Description
M19 Tvalue Cancel all station selections
M37 Tvalue Select station 1-20 (Tvalue)
M38 Tvalue Cancel station 1-20 (Tvalue)

You can override these station selection program codes by selecting THC inputs to the
control. The feature to override the part program must be enabled at the Cutting Setup
screen.

Process Selects
Make process selections with an EIA-274D program code in the following format:

Example: M36 Tvalue

M Code

Valve Identity
T1 = Plasma Process 1
T2 = Plasma Process 2
T3 = Marker Process 1
T4 = Marker Process 2
T5 = Laser Process

Station Configuration Variables

The following options are available for station configuration:

Lifter
None
Sensor THC
Command THC (with serial link)
HD4070 integrated THC 1 or 2 (used only with the HD4070 power supply)
Other (any standalone lifter station)

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Power Supplies
None HD4070 Torch 1or 2 Powermax series
Max100/ 100D HT4001 FineLine 100
Max200 HT4100 FineLine 200
HT2000 HT4400 Other (any other plasma system)
HD3070 HPR130

Marker
None
ArcWriter
FineLine 100 & 200
HD4070 Torch 1or 2
HPR130
Other (any standalone marker)

Laser
Rofin RF 40 & 50
Rofin DC 35
Rofin TR 60
Other

Set the Station Select Override feature in Cutting Setups to Disabled to override station
selections with manual inputs.

Set the Process Select Override feature in Cutting Setups to Disabled to override process
selections with manual inputs.

Overview

1. Press the Stations 1-4 or Station 5-8 soft key to access a station.
2. Select the appropriate lifter station from the list of available lifter types.
3. Select the appropriate tool (plasma power supply or marker tool) the station from the
list of available tools in the Plasma and Marker Process fields. The tool selection
should reflect the actual tools in use for that individual lifter. The Station can be
configured so that all four plasma and marker processes operate on one station or are
distributed throughout all 8 stations.
4. If necessary, use the Reset soft key to reset or clear all station setup parameters
setting the values to None.

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The selections you make for the four processes, THC designations, and certain power
supplies can limit the overall configuration.

For example, if you selected a Sensor THC for Station 1 and a MAX200 for plasma
process 1, you cannot select another power supply type for plasma process 1. However,
you can select a MAX200 for plasma process 1 at other stations if you select a Sensor
THC.

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Password Setups

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 Password Setups

Support for Command THC

Selecting a Command THC as the lifter for a process enables the serial link to be
assigned for a single Command THC.

Note: The actual serial port must be assigned on the Ports setup screen. This also
configures the selected Plasma or Marker Cut Types screen to display the Command
THC features. If a Command THC has been selected for a station but does not use the
serial communication to the control, the lifter type should be set to Other.

Refer to the Command THC section for additional information on the operation of the
Command THC.

Support for HD4070

The HD4070 feature establishes the Serial Link HD4070 Power Supply communication
link and configures the selected Plasma or Marker Cut Types screen to display the
HD4070 features. A single HD4070 must be assigned to Stations 1 and 2. A second,
multi-dropped HD4070 can be assigned on stations 3 and 4.

Each HD4070 can use two integrated Command THCs. These are controlled by the
HD4070 and have designated station locations.

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Password Setups

In the previous example, you can see that the Cutting and Marking with the HD4070
Integrated Torch 1 is limited to Plasma 1 and Maker 1 on Station 1. Additionally, the
cutting and marking with HD4070 Integrated Torch 2 is limited to Plasma 2 and Maker 2
on Station 2. These stations can be configured for Cut or Mark or both. A second multi-
dropped HD4070 can also be assigned on stations 3 and 4.

Support for FineLine 100 / 200

You can configure serial communications to the Inner Logic FineLine 100 and FineLine
200 for use with selected THCs.

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 Password Setups

Special

Date
Enter the current date.

Time
Enter the current time. This is the time that is displayed on the main screen.

Display Time
Select whether the display time is shown in either AM/PM format or 24-hour clock
format.

Mouse Pointer
Select On to use an external mouse or touch screen.

Keyboard
Select Not Installed to use the on-screen keypad. Select Installed to use an external
keyboard.

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Password Setups

User Level
Select the user experience level. The level you select determines view screens and the
features that are available. For example, the intermediate level provides a larger preview
area and an ALT soft key to access additional screens.

Motion Cursor
Select the style of the Motion Cursor.

File Extensions
Enter the file extensions of the part files that will be accepted at the control.

Adding Folders
Select whether the CNC operator can add folders from the parts directory on the CNC or
the host computer.

Deleting Folders
Select whether the CNC operator can delete folders from the parts directory on the CNC
or the host computer.

Deleting Files
Select whether the CNC operator can delete folders from the parts directory on the CNC
or the host computer.

Mapping Drives
Select whether the CNC operator can map to external drives from the CNC through the
optional network.

Configuring Watch
Select whether the CNC operator can change the items in the Watch Window.

Adding Processes
Select whether the user can add new processes to the laser cut charts when enabled.

Removing Processes
Select whether the user can remove processes to the laser cut charts when enabled.

Force Simulation
Select On to put the CNC into simulation mode. This mode disables motion but
maintains CNC operation and I/O feedback.

Temperature
Select whether the internal CNC temperature is displayed in Fahrenheit or Celsius in the
Watch Window.

Note: This setting is not available on all CNC types and optional CNC hardware is
required.

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 Password Setups

Tools Installed
Selects or limits the cut modes available to the CNC operator.

Message Enables
The following pull down box is used to enable and disable system messages. To change
the status of a message, highlight the selected message and press the Space key.

Ready to Start Cutting Message

When enabled, the Ready Message feature will display a ready message when the Start
button is pressed.

Kerf Too Large Warning Message

Disables the Kerf Too Large warning message. This message notifies the user that a
conflict between the cut paths and the current Kerf value for a part has been detected and
that some detail could be lost when the part is cut.

Homing Must Be Performed Message

Prompts the operator to home the selected axis before motion begins. The selected axis
must have homing enabled on the axes setup screen.

Values Have been Changed Message

Displays as a confirmation when changes to values on the current configuration screen
are detected. This ensures that changes are not made in error when exiting the screen.

Home Torch Height Control Message

Prompts the operator to home the Sensor THC axis at power up and before motion
begins.

Ready to Final Align Message

Appears as part of the skew alignment function and displays just before final motion to
position the tool begins.

Part Larger than Plate Message

Displays when the dimensions of the part that have been loaded exceed the selected plate
dimensions.

Cut Chart Data Has Changed Message

Displays as a confirmation when changes to the values on the current Cut Chart screen
are detected. This ensures that changes are not made in error when exiting the screen.

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Password Setups

Save Part for Rush Job

Enables or disables the Resume Part prompt for Rush Job Interrupt.

Automatic Align Wizard

Enables or disables the automatic availability of the alignment wizard on the Align
screen.

Automatic Cut Wizard

Enables or disables the automatic availability of the Cut Pro wizard on the Main screen.
If availability of the wizard is enabled, it appears 10 seconds after the Main screen is
opened.

Start Cut from Cut Wizard

Allows or prevents cutting to start directly from the Cut Pro Wizard. If this is disabled,
the operator must use the Start button on the console to begin the cut.

Latched Manual Keys

Enables or disables the Latched Manual Key feature which allows the manual motion
keys to remain on with a single key press.

Auto Drop Down

When this option is enabled, all options are displayed in a drop-down list.

Zero Positions
Determines whether the CNC operator has the ability to zero positions. When disabled,
the zero positions soft key is grayed out and is unavailable to the operator.

Auto Size App.

Changes the size of the application software to full screen display (when it is enabled) or
the standard size of 640x480.

Language
Allows the user to select the language that is displayed on the CNC from the available
languages stored on the control. Languages can be added to the CNC by performing the
standard software update with a language-specific update file. Some languages also
require the installation of a font viewer to properly display characters. To change to a
different language, select the desired language and press the OK soft key. You must
restart the CNC for the new language to be displayed.

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 Password Setups

Tangent Angle
Sets the degree of the tangent angle for motion control. Segments within a part that
intersect at angles greater than the selected tangent angle decelerate to zero or to the
minimum corner speed. Segments within a part that intersect at angles less than or equal
to the selected tangent angle, do not decelerate unless the next segment is a speed-limited
arc.

Password
Allows the user to enter a new password for machine setups. Numbers or letters can be
used.

Special Password
Allows the user to enter a new password for special setups. Numbers or letters can be
used.

Station Configuration Password

Allows the user to enter a new password for Station Configuration setups. Numbers or
letters can be used.

Auto Update Max Consumable Life

If this feature is enabled, it tracks the consumable life values beyond the user-defined set
point and assigns that maximum value as the new set point. If this feature is disabled, the
user-defined set point for maximum consumable life is not updated.

Machine Position Resets

If this setting is enabled, it resets the absolute machine position when the Zero Positions
soft key is pressed. Only the current incremental motion (part) position is reset to zero.
Position information based on homing is not lost.

Arc Speed Limit Check

Allows the user to turn off the Speed Limit Check that is performed by SoftMotion for
arcs larger than 10”. This compensates for abrupt motion commands caused by non-
tangent line arc segments and smoothes out motion.

HD3070 Auto Gas

When enabled, this setting allows the CNC to communicate with the auto gas console for
the HD3070 and gives access to the related setup parameters.

Front Panel
Defines the use of an optional 12-station or 6-station operator console.

Save Setups
Press the Save Setups button to save the current CNC setting to the floppy disk or hard
drive. A window displays to select the drive and enter a file name.

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Password Setups

Note: After installation of the CNC on the cutting table or if any setup parameters
are changed, it is important to save the current setup file to both the hard drive and floppy
disk for future reference.

Load Setups
Press Load Setups to load the selected control setting from the floppy drive or hard drive
on to the control. A window displays where you can select the drive and enter the file
name.

Update Software
Press the Update Software button to update the CNC operating software from a floppy
disk.

Update Help
Press the Update Help button to update the CNC help files from a floppy disk.

System Tools
Press the System Tools button to access core Windows features for system performance.
Features include Update Registry, Scan Hard Disk, Defrag Hard Disk and Format Disk.
System Tools also accesses features for virus scanning and adding special fonts for some
languages.

Restore Last Version

Restores the CNC to the previous version of system software.

Make Link Disk

The CNC is shipped with proprietary communication link software for communication
with a host computer. Press this soft key to transfer the link software to a floppy disk so
it can be loaded onto a host computer. A text file is included with the software to instruct
the user on setup and use of the link.

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System Tools – Windows XP

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

Note: A reminder is posted on the screen when entering the Systems Tools that a mouse
and keyboard are required for proper operation. The mouse and keyboard should be
connected to the CNC before entering the System Tools.

System Tools

Automated Backup
Select the frequency of the automatic reminder for the backup of information on the main
hard drive. At the selected time, the system displays a prompt to back up the system when
you turn it on.

Table Manufacturer Information

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

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Backup Hard Drive

Press the Backup Hard Drive soft key to save the contents of the main hard drive to a
specified location on the CNC hard drive or mapped location using the Norton Ghost
Utility.

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

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Scan Hard Disk

Press the Scan Hard Disk soft key to scan the hard drive for viruses or disk errors using
Norton antivirus software.

Select Yes to scan the hard drive for viruses using Norton anti-virus software.

Select No to scan the hard drive for errors and correct them using the Windows XP
CHKDSK (check disk) utility. This task should be performed approximately every three
months depending on the number of files loaded to and removed from the control.

The Check Disk (CHKDSK) function cannot operate while the CNC software is in
operation. You will be prompted to press “Y” (for yes) to check the disk the next time
that the CNC boots up.

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Antivirus
The AntiVirus feature allows you to search files that are loaded on the CNC for known
viruses. Contact your CNC vendor to obtain the anti-virus software for your control.

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Defragment Hard Disk

Scans the CNC hard disk for file locations and rearranges them for optimum
performance. This task should be performed approximately every three months.

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Format Floppy Disk

Formats a floppy disk if the CNC has difficulty reading a floppy disk formatted by a
computer.

Important: Formatting the diskette will remove any files that are stored on the diskette.

Reset Setups
Deletes the current setup file and reloads default values. A new setup file can then be
loaded on the CNC through the Special Password screen.

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

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Network Tools
Network tools allow the CNC to be incorporated directly into an office PC Network for
part allocation. This feature is available on the control’s Windows XP operating system
and 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 XP

operating system and should only be performed by qualified personnel.

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

To Map the CNC for loading files

Enables the Mapped Network Drive feature on the special password screen. On the Files
screen, double click on the load from file location or press the + key then enter a drive
location.

The control automatically logs on to the system at boot up.

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Phoenix Link
Overview
The Phoenix Link communication software is communication software on the CNC for
transmission of part and consumable database files between the CNC and the host
computer. The program uses a 2X compression feature that allows the communication
system to operate at speeds up to 230 K baud.

Phoenix Link
When the Phoenix Link communication software is operating, the following window
displays at the host computer for configuration. After the software is running, the
window can be minimized.

Port
Allows you to select the communication port on the host computer.

Baud
Allows you to select the baud rate for communication on the host computer. The
minimum baud rate is 9600 bps; the maximum baud rate is 115,200 bps.

Folder
Allows you to change the path of the Master folder (in the Parts folder). Subfolders and
the part files within this folder are viewed at the CNC.

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Files
Allows you to indicate which file extensions are acceptable for part program files that are
downloaded by the link software and viewed at the CNC.

Settings
Allows you to configure the link to allow the Auto Reload (M65) feature to be enabled
and recognized during communication. In addition, you can also select and configure
communication with multiple CNCs using Multi-Drop.

Test
Tests the operation of the communication port. To test, simply connect the send and
receive signals on the selected communication port by inserting a paper clip and click on
the port to test. The status of the test is displayed in the lower left corner of the window.

Help
Displays the current version of the link software.

Files
The Files setup parameter allows you to indicate which file extensions are acceptable for
part program files that are downloaded by the link software and viewed at the CNC.

After a file has been saved on the CNC, it is assigned the .txt file extension.

Important: Take care when downloading files. Part programs with the same name, but
different file extensions, are overwritten during multiple file downloads. A warning is
displayed at the control before a file is overwritten.

The list of acceptable part program types is listed in the lower half of the of the Files
option box. A checkmark (√) before the file extension indicates which selected file type
will be displayed at the control. Note that the checkmark (√) in the file extension listing
also indicates the file extension that is placed on a part program when uploading a file to
the host.

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The following options are available to define what part programs can be viewed at the
control.

Show All Files

Allows all file types in the selected parts folder to be viewed at the control. A checkmark
(√) before this feature indicates that it has been enabled.

Show Extension in Name

Allows the user to view the file extension as part of the file name at the CNC. For the
file name Job123.CNC, the control displays Job123_CNC in the filename location of the
download screen. The control displays Job 123 if this feature is not enabled. This
feature is helpful if multiple files that have the same file name but different file
extensions are being used. A checkmark (√) before this feature indicates that it has been
enabled.

Add to Files
Allows the user to add to the list of acceptable part program types to be viewed at the
CNC. Up to four file types (extensions) can be added to the default .txt extension. A
checkmark (√) before a file extension indicates which file extension will be added to any
part file that is uploaded to the host.

Remove from Files

Allows the user to remove file extensions from the list of acceptable part program types.

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Settings

Allow M65 Auto Reload

Select this option to allow part programs to be partitioned into smaller part programs
separated by the M65 code. During the download, the CNC downloads the individual
sections of the part program and allows the operator to execute that section of the part.
When that section of the program has been completed, the next section of the program is
automatically downloaded for execution. The downloads continue until an end-of-
program (M02) code is detected.

Use Multi Drop

Allows the link to be configured for communication with multiple CNCs through one
communication port on the host PC. Up to eight controls can be supported with the Multi-
Drop feature.

Note: The Using Phoenix Link parameter must be set to Yes at the control to enable this
feature. In addition, specific hardware for the control (serial communication board Rev
D or higher) and host PC may be required to support this feature. Contact your control
supplier for more details.

Add Control
Adds a new control to the list of controls to communicate with. The corresponding
control number must be assigned to the new control in the link set-up screen.

Remove Control
Removes a control from the list of controls with which the host PC communicates.

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Control Monitoring
Allows you to view control status at the host PC. Status for file name, position, cut
mode and cut information is displayed. This feature is only available with the Phoenix
Link communication software.

Installation
The list below outlines the step-by-step procedure for the communication setup of the
control and installation of the Phoenix Link communication software:

Minimum System Requirements

Processor: Pentium 100MHZ
Hard Drive Space 0.5 MB
Memory: 4MB
Display: VGA
Floppy Drive: 3.5”
Operating System: MS Windows 95, 98, NT, 2000, ME or XP
Serial Port: One RS-232 or RS422 serial port will be required per control.

Software
1. At the CNC, access the Special Password screen.
2. Insert a diskette or USB memory device into the floppy drive or USB port.
3. Press the Make Link Disk soft key. Three files are transferred to the memory device:
Link.exe
Setup.exe
Readme.txt

The Setup file creates a Link folder on the root directory of the host PC and copies
the Link software into it. The Readme file contains additional information about the
installation and setup of the Link software on the host computer.

4. When the light goes out on the floppy drive, transfer the floppy disk to the host
computer and place the disk into the floppy (A) drive.
5. Click the Windows Start button and select Run.
6. Enter A:\Setup.bat in the Open field and click OK.

The setup file expands the files and creates a Link folder on the root directory. The
Link.exe file is copied to this folder.

Note: The Link software must be located and run on the PC that is connected to the
communication cable coming from the control.
7. Click the Windows Start button and click Run.
8. Enter A:\Link\Link.exe in the Open field and click OK.
After the link software has been launched, two other files are created. A Link.ini file,

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which contains the Link software configuration information, and a Parts folder, which
is the default Master parts folder.
9. Create a shortcut to the Link.exe file on the desktop of the host PC..
10. At the host computer, create one or more folders in the Parts directory. Copy any part
programs that will be accessed by the control in these folders.

For example, to add the folders Workfile 1 and Workfile 2 to the parts directory, the
hierarchy of the files would resemble the following structure:

Path C:\Link\Parts\Workfile 1 and C:\Link\Parts\Workfile 2

Any part programs that will be viewed at and downloaded to the control should be
placed here. Only the sub folders Workfile 1 and Workfile 2 and the program files
located within them are viewed at the control.

Change Master Folder

If the host computer currently has existing part programs and folders, the Link software
can be configured to operate with the current folder names. This master part program
folder can be located on the host PC or on another PC that is networked to the host PC.

Note: The Link software must be located and run on the PC that is connected to the
communication cable coming from the control. This is accomplished by configuring the
Link software through the Change Master Folder feature to point the link to the folder
that contains the required part programs.

Launch the Link software at the host computer to view the Link window.

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Select Files > Change Master Folder.

To change the master file from the current folder, enter the selected path in the New
Master Folder field and click OK.

Use the same procedure to select a master folder on a network.

For example, if the folders that contain the part programs are currently located in a folder
named Jobs that is located on the PC named R drive, the Link.exe could be configured
with the Change Master folder option to access these files.

Example path: R:\Cad\Production\Jobs

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Again, start by launching the Link Software at the host computer. Select Files\Change
Master Folder.

The Master file may now be changed from the current folder to the selected “Jobs” folder
by typing in the path R:\Cad\Production\Jobs. Select OK to accept the change.

The final step to setup the Link software is to configure the Link software for Port, Baud,
Files and Settings to match those being used at the control. It is recommended that a
shortcut to the Link.exe be placed on the desktop of the host PC for ease of use.

Operating Multiple Links

To connect more than one control to the host PC without the use of the Multi-Drop
feature, you can install Link software specifically for each control. Each version of Link
that operates requires its own, dedicated communication port on the host PC.

1. Create individual folders for each cutting table.

2. Copy the Link.exe file into each folder.
3. Create a shortcut for each Link.exe on the desktop.
4. Right-click on each shortcut to open the shortcut properties dialog box.
5. Add to each shortcut the target command line information to indicate with which
table the Link will be communicating.

In the target command line example below, Table1 has been added to the end of the
command line to indicate the Link will be specific to communications with Table 1.

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This “table” information, added to the Target command line, is added to the title bar of
the Link window. The Link can now be launched from the shortcut and configured
specifically for this “table”. When the Link is closed, a “Table1.ini” with the specific
Link setup file will be saved in the folder.

Continue to configure each additional Link for communication to each control. The
separate Link files can be configured to point to the same or different master parts
folders.

Hardware
To set up communication, place the control next to the host computer and connect them
with a short communication cable. After communication is successfully established, the
control can be moved to the cutting table and connected to the host computer with the
appropriate cable or short-distance modem system.

1. Configure the selected RS232/RS422 serial port on the control for operation, as
described in the Serial Port information of this guide.
2. Test the control’s communication port in the Diagnostic Screen to confirm proper
operation of the serial port. Directions for testing of the serial port are described in
the Diagnostic section of this guide.
3. Enter the control’s Link setup screen to select the use of the desired communication
port, select the baud rate and select to use Phoenix Link. Start at the lowest baud rate
and increase it until the maximum is achieved. If you select a baud rate that is too
high characters or information can be lost and error messages will be displayed.
4. Enter the control’s Special Password screen to add the file extension of the part
programs that are being used to the current list of acceptable file extensions.
5. Load and configure the Link software at the host computer as described in the
Software section.
6. Test the host computer’s selected serial port with the “Test Port” feature of the Link
software as outlined in the Phoenix Link software overview.
7. Connect the control to the host computer’s selected communications port with the
appropriate cable or modem system.

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Operating Phoenix Link

The Phoenix Link software must be running on the host computer to communicate with
your CNC.
1. Start the Link software at the host PC from the desktop shortcut or select the
Windows Start Button, then select Run.
2. From the opening prompt, enter C:\Link\Parts\Link.exe (or the appropriate path to the
Link.exe) and click OK.
The Phoenix Link window appears. The Link software window can be minimized
during operation.
3. At the CNC, press the Files soft key and select to Upload or Download to Host. As
the control is connecting to the host computer, a status display in blue text for the
communication can be viewed in the lower right corner of the screen.
4. The control will initialize the port, open the port, and try to contact the host. If this
attempt at communication fails, an error message is displayed in red. If the attempt is
successful, the control downloads the available folder and part file names to be
viewed on screen.

Note: If you select No in the Show Host File Names field at the control, only folder
names can be viewed.
Common Errors
The following list describes common errors that you can encounter when you install a
communication system.

• The port selected at the host computer has already been assigned to another software
program.
• The host and control have been configured to different setup values.
• The cable has been connected to the incorrect port or software has been configured to
the incorrect port.
• The selected modem or cabling system being used has swapped the transit and
received signals, causing a communications failure.
• Trying to transmit over too long a cable without a modem or using incorrect wire for
the distance being traveled.
• Trying to communicate at too high a baud rate for the modem system selected.
• The correct file extension has not been entered at the control’s Special Password
screen, preventing part programs from being displayed at the control.

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Error Messages
The following list provides descriptions of common error messages and possible causes.

Unable to Open Port (control)

The selected communications port could not be opened. The wrong port has been
selected or the communications port has failed.

Unable to Open Port (host)

The selected communications port could not be opened. The wrong port has been
selected, the communications port has failed or another software application is using the
port.

Unable to Initialize Port

The selected communications port could not be initialized. The wrong port has been
selected, the communications port has failed or another software application is using the
port.

Port Failed
The Port Failed error message is displayed if the communications port test has failed for
the selected port. There could be a failure of the communications port or a fault in the
test wire connection that is incorrectly connected to the proper send and receive pins
location.

Host Not Responding

This message is displayed if the communication port has successfully opened the port but
has failed to establish communication with the Link software. There could be a fault with
the cable connection, cable configuration, or the host computer’s communications port.

Communication Failed
This message is displayed if, after establishing communication with the host, an expected
message from the host is not correct.

Communications Time Out

This message is displayed if the specified amount of time allowed for a response from the
host computer expires. This amount of time is configured in the Link setup screen.
There could be a fault in the cable connection, cable configuration, or the host computer’s
communications port.

Checksum Error
This message is displayed at the control after a part has been uploaded or downloaded if
the checksum calculated by the host and the control do not match. The checksum
calculation is performed by adding the numeric values of the ASCII codes that are used.
Possible reasons for this error are incorrect cabling or transmission at a speed that is too
high for the selected communications system.

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Warning: The Master Folder Selected does not Contain any Folders
This error message is displayed at the host computer if the selected master folder does not
contain any subfolders. You can choose to add subfolders if they do not exist. If
subfolders do exist, the path to the master folder may be incorrect.

For additional assistance in trouble shooting the Phoenix Link in the event of a failure,
contact your control vendor.

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 Sensor THC

Sensor THC
Overview
Sensor THC (Torch Height Control) system is designed for use with your shape cutting
control. Sensor THC utilizes the most current technology available to provide superior
plasma cut performance.

During the plasma cut process, variations in the distance between the torch tip and the cut
material affect the cutting arc voltage and ultimately, the quality of the cut. An
automated torch height control maintains the appropriate cut height for the set arc voltage
to obtain the optimum cut quality regardless of variations in plate positioning.

Sensor THC is operated as a separate closed-loop servo axis on the control and has
several setup parameters available to customize the system for optimal performance and
individual requirements. The THC system includes four parts: the control, the analog
input card mounted in the control, the voltage divider card and the mechanical slide with
a motor to operate the slide. The voltage divider card, which is mounted in the plasma
power supply, monitors the arc voltage of the cutting process at the torch then transmits
1/40th of this voltage to the analog input card in the control where it is restored to the
original value. This value is then compared to the value of the Set Arc Voltage field. If
the values are different, the control will raise or lower the torch on the slide to correct the
cut voltage. This Appendix will highlight the features which are unique to the Sensor
THC.

For operation, this feature must first be enabled in the password machine setups. Setup
parameters specific to the cut process and the THC axis will then be available for
configuration.

Warning! Installation, Setup and Calibration should only be performed by trained

service personnel. Extreme care should be used when installing this product.

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Cut Setups

THC Voltage Offset

Offsets the individual Sensor THC arc voltages from the master set arc voltage. This
allows the individual THCs to be adjusted to compensate for consumable wear and obtain
optimum cut quality.

Note: The THC Voltage Offset parameter can be automatically adjusted using the Volts
per Minute parameter of the Change Consumable screen. Refer to Change Consumables
for additional details.

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Plasma Setups

The test lifter soft key allows you to test the IHS function.

Test Lifter
Press the Test Lifter soft key to command the torch lifter to descend to the plate, sense
the plate, and retract to the pierce height.

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Press the Timing Diagram soft key to view the timing diagram from setups.

Retract Delay
Specifies the delay between the cut off and the torch retract.

Auto Voltage Set

Samples the Arc Voltage that is generated when cutting at a specific cut height. The Arc
Voltage value relative to the manual cut height sample is used when cutting the part
instead of a predetermined Arc Voltage.

Set Arc Voltage

The Arc Voltage to use for the material being cut.

Cut Height
Selects the cut height from the plate. This sets the initial cut height before arc voltage
control is activated when the system is operating in automatic mode.

Pierce Height
Selects the pierce height. This can be entered as a percentage of the cut height or as an
actual distance.

Voltage Control

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Allows the operator to select whether the Sensor THC operates in manual or automatic
mode. Manual mode disables the torch height control and allows the torch to cut at the
specified cut height and voltage. Automatic mode allows the THC to command the torch
up and down to maintain the voltage at the specified arc voltage set point.

Ignition Output
Enables the use of the ignition output to ignite the plasma torch. If your plasma system
requires a separate ignition signal, select On. If not, leave Ignition Off.

Voltage Tracking Range

Specifies the allowable variation in arc voltage from the set point. If the arc voltage goes
above or below this allowable range, the system faults and pauses cutting.

IHS in Manual
Allows the operator to select whether to use initial height sensing when operating the
Sensor THC in manual mode.

Retract Full/Partial
Allows the retract distance to be set at full or partial. During a full retract, the torch
retracts to the home position. During a partial retract, the torch retracts to the set retract
distance.

Partial Retract Distance

Selects the THC retract distance for a partial retract.

Start IHS Distance

Specifies the distance that the THC travels to move the torch at high speed before
switching to low speed and beginning initial height sense. Take care to select a distance
that allows the torch to clear the plate.

Skip IHS Within

Disables initial height sense at pierce points if IHS falls within the selected distance.
This setting increases cutting productivity. The distance is measured from the end point
of the cut segment to the next pierce point.

Preflow During IHS

Select On to activate preflow during the IHS cycle.

Early Preflow if Skip IHS

Select On to activate preflow during the traverse before the pierce if skip IHS is enabled.

Nozzle Contact IHS

Select On to require the Sensor THC to use contact sense to detect the plate during the
IHS cycle. Use this parameter when cutting light gauge material to prevent plate
deflection.

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Nozzle Contact During Cut

Select On to require the Sensor THC to use the contact sense input to detect the plate
contact during cut and pause operations.

Offset IHS
Activates a remote probe for plate detection and initial height sense. If this feature is
enabled, the control system executes the Tool Offset 9 or Marker Offset 9. The plasma
torch moves the distance of the offset, performs the IHS and then returns the torch to the
pierce location at each commanded pierce or cut on. The Z axis parameter is used to
adjust for height differences between the torch and the probe.

Auto Kerf Detect

Reduces the possibility of the torch diving into the plate. When Yes is selected, the THC
detects sudden changes in arc voltage when crossing a kerf path and freezes the height
motion of the THC.

Auto Kerf Voltage Change

Sets the change in voltage that disables the THC when the torch passes over a previous
cut. This setting prevents the torch from diving and requires that the Auto Voltage Lock
On parameter be active.

Kerf Detect Reacquire Time

Determines the amount of time after a change in voltage is detected that the CNC
disables THC height motion.

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Marker Setups

The test lifter soft key is available to test the IHS function.

Test Lifter
Press the Test Lifter soft key to command the torch lifter to descend to the plate, sense
the plate, and retract to the pierce height.

Purge Time
Specifies the time delay from torch ignition until motion is enabled.

Start Time
Specifies the time delay from when torch completes lowering until motion is initiated at
Creep Speed. Used to allow the Marker to completely transfer to the material before
moving.

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Sample Voltage
If this parameter is enabled, it samples the Arc Voltage that is recorded when cutting at a
specified cut height. The value of this sample arc voltage is used to cut the part instead
of a predetermined arc voltage.

Set Arc Voltage

Records the arc voltage for the material being cut.

Mark Height
Sets the cut distance from the plate. This value sets the initial cut height before arc
voltage control is activated when operating in automatic mode.

Start Height
Sets the start height for the cut. This can be entered as a percentage of the start height or
as an actual start height distance.

Voltage Control
Allows the operator to select the Sensor THC to operate in manual or automatic mode.
Manual mode disables the torch height control and allows the torch to cut at the specified
cut height and voltage. Automatic mode allows the THC to command the torch up and
down to maintain the voltage at the specified arc voltage set point.

Voltage Tracking Range

Sets the allowable variation in arc voltage from the set point. If the arc voltage exceeds
this range, the system faults and pauses cutting.

IHS in Manual
Allows the operator to select whether to use the initial height sense when the Sensor THC
is in manual mode.

Retract Full/Partial
Selects the retract distance. If Full is selected, the torch retracts to the home position. If
Partial is selected, the torch retracts to the distance set in the Partial Retract Distance
field.

Partial Retract Distance

Sets the distance that the THC retracts when partial retract is selected.

Start IHS Distance

Specifies the distance that the THC moves the torch at high speed before switching to
low speed and beginning initial height sense. Take care to select a distance that allows
the torch to clear the plate.

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Skip IHS Within

Disables initial height sense at pierce points if IHS falls within the selected distance.
This setting increases cutting productivity. The distance is measured from the end point
of the cut segment to the next pierce point.

Preflow During IHS

Select On to activate preflow during the IHS cycle.

Nozzle Contact IHS

Select On to require the Sensor THC to use contact sense to detect the plate during the
IHS cycle. Use this parameter when cutting light gauge material to prevent plate
deflection.

Process Watch

Input/Output
In addition to the standard I/O options, the Watch window can be configured to include
the status of the voltage tracking for the Sensor THC. This indicates when the automated
voltage tracking has “locked on” and is adjusting the torch height based on voltage.

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Position
The Sensor THC is operated as a separate axis on the CNC. Position information for the
THC axis can be displayed in the Watch window.

Plasma Process
Information critical to the THC operation may be added to the Lower Location. This
information includes Arc Voltage, the Set Arc Voltage, Cut Height and Pierce Delay.
Values for the Set Arc Voltage, Cut Height and Pierce Delay can be adjusted on the main
cut screen to customize the cut process.
Main Cut Screen
Automatic THC Mode

When the Sensor THC is cutting in automatic mode, three soft keys are available on the
main cut screen that allow the operator to manually increase and decrease arc voltage for
the cut and to switch to manual mode.

When the Sensor THC is cutting in manual mode, three soft keys are available on the
main cut screen that allow the operator to manually raise and lower the manual cut height
and to switch to automatic mode.

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Sensor THC Setups

Analog Input
The Sensor THC requires that additional inputs, outputs and analog voltage be
transmitted to the CNC to monitor the process. These signals are transmitted to the CNC
through an analog input card that is installed in the CNC. In addition to THC operations,
this analog input card can also be used for operation of an optional joystick and external
speed pots.

Note: The appearance of the view screens varies depending upon the analog input card
that has been installed.

Inputs / Outputs
Single-ended inputs and outputs located on the analog input card are displayed.

Analog Inputs
The analog input values shown in the upper right of the screen are the actual voltages
coming into the analog card. Analog inputs that are assigned to the THC axis and the
analog input for the THC are visible here.

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Sensor THC Axis Setups

The THC Axis screen is designed specifically for use with the Sensor THC.

Note: For proper operation, Sensor THC encoder counts should be approximately 20,
000 counts/ inch.

Stall Force Tolerance

The Stall Force Parameter allows the user to select the amount of Following Error (inches
/ mm) to be used as the motion limit when Homing or performing manual IHS / plate
sensing. Example: If the value is set to .1 inches, the THC Axis will continue to move
the axis until .1 inches of following error has been reached. This will indicate the Plate
location during IHS and will indicate the top of the slide during homing.

Slide Length
This parameter is used to specify the overall motion length of the Slide mechanism being
used for the THC. This information is used to set the travel limits of the slide after
homing.

Home
The Home parameter is used to activate use of the Home feature for the THC Axis.
Depending on the Slide mechanism used, the THC may be Homed to Hard Stop, Hard
Stop w/ Current Limit or Home Switch.

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Note:
If the “Home to Hard Stop Current Limited” option is selected, the CNC Nozzle Contact
Enable Output should be connected to the Current Limit Input of the amplifier to reduce
torque during homing.

The CNC Nozzle Contact Sense Input is used during Sensor THC Homing as the Home
Switch Input if the “Home to Switch” option is selected.

SERCOS Sensor THC Axis

Home/ IHS Current Limit

The Home / IHS Current limit parameter allows the user to select a percentage of current
limit to be used during homing and IHS functions.

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Sensor THC

THC Speeds

THC Acceleration Rate

This parameter allows the operator to set the acceleration rate for smooth and stable
movement of the Sensor Torch Height Control. The higher the acceleration rate, the
quicker the THC will get up to speed. The lower the acceleration rate, the smoother the
machine will position the cutting device. Values are entered in milliGs.

Maximum THC Speed

Enter the maximum speed for the Sensor THC movement in inches/millimeters per
minute.

THC Jog Speed

Enter a value for the desired THC jog speed.

THC Home/Fast IHS Speed

The THC Home/Fast IHS Speed entered here is used to home the torch at the top of the
slide and to quickly maneuver the torch from the selected IHS height to the plate.

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 Sensor THC

THC Slow IHS Speed

The THC IHS Speed is used to retract the torch after the plate has been sensed. The torch
will retract at this speed until the contact sense is lost. This determines the exact distance
to the plate, regardless of any flexing of the plate. A very small speed is recommended
for optimal accuracy.

Note: Due to the quick response time of the Sensor THC, generally there is no need for a
value to be entered at the “Distance to Corner” parameter to lock or “freeze” the position
of the torch. It is, however, suggested that a value be entered for the “Distance from
Corner” to stabilize the torch during acceleration.
THC I/O

Analog Offset 1 - 12
The Analog Offsets 1 through 12 are used to correct for any imbalance or “zero” the
incoming analog voltage to the Analog Input Card. Analog inputs are assigned to the
THC Axis and the Analog Offsets for the appropriate THC Analog input may be adjusted
here.

To calibrate the Analog Inputs, jumper the two pins specific to the input together and
view the incoming voltage at the Diagnostics Analog I/O screen. The incoming voltage
should be zero. If any voltage is displayed at the diagnostic screen, an Offset Voltage

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Sensor THC

equal to the incoming voltage being read can be entered here to “zero” the incoming
voltage. Please refer to the installation instructions later in this section for more details.

Sensor THC Part Program Support

Sensor THC offers the ability to configure THC setup parameters through part program
codes.

The following parameters are available for use using EIA-274D G59 codes:

• Arc Voltage
• Pierce / Start Time
• Pierce/ Start Height Factor
• Cut / Mark Height

Setup is obtained using the following format.

Example: G59 V601 Fvalue

Misc. G Code

Variable Identity
V600 = Plasma 1 Arc Voltage
V601 = Plasma 1 Pierce Time
V602 = Plasma 1 Pierce Height Factor – User units
V603 = Plasma 1 Cut Height
V604
V625 = Plasma 2 Arc Voltage
V626 = Plasma 2 Pierce Time
V627 = Plasma 2 Pierce Height Factor
V628 = Plasma 2 Cut Height
V629
V650 = Marker 1 Arc Voltage
V651 = Marker 1 Start Time
V652 = Marker 1 Start Height Factor
V653 = Marker 1 Mark Height

V675 = Marker 2 Arc Voltage

V676 = Marker 2 Start Time
V677 = Marker 2 Start Height Factor
V678 = Marker 2 Mark Height

Variable Value
The selected value for the variable

Installation and THC Interface

The Sensor THC is supported through various hardware configurations to offer single and
multiple Sensor THC operation. Please refer to your exact CNC hardware configuration
when installing the Sensor THC.

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 Sensor THC

Warning! Due to potentially high voltages, extreme care should be taken when
working inside the plasma power supply. Work should only be performed by trained
service personnel. Please refer to Power Supply manufacturer instructions.

427
Sensor THC

428
Command THC
The Command THC from Hypertherm is an automated Torch Height Control system that
adjusts the distance between the plasma torch and the work surface to provide improved
cut quality. After the Command TCH is set up using the password-protected parameters,
you can set up operational parameters for the Command THC on the Plasma Setups
Screen. For additional information on the use of the Command THC, refer to the
operating instructions provided with the Command THC system.

Additional soft keys:

Clear Error
The Clear Error soft key allows you to clear an error at the Command THC control box.
After the soft key is pressed, a message will be posted on the control displaying a
description of the error.

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Command THC

Test Cycle ON/OFF

Press the Test Cycle ON/ OFF soft key to operate the Command THC in Test mode. In
Test mode, the Command THC completes the cycle without firing the torch.

Test Lifter
Press the Test Lifter soft key to command the torch lifter to lower to the plate, sense the
plate and retract to its pierce height.
Press the Timing Diagram soft key to view the timing diagram from setups.

Purge Time
Specifies the time delay from torch ignition until motion is enabled, if the value for Arc
On Feedback is Off.
Enter 0 (zero) for the Purge Time if the value for Arc On Feedback is On.

Pierce Time
Specifies the delay between the time that the torch is fully lowered until motion is
initiated at Creep Speed. This value allows the plasma torch to pierce the material
completely before moving.

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 Command THC

Creep Time
Specifies the amount of time that the torch travels at creep speed after piercing the
material. Creep Speed is a percentage of the programmed cut speed and is determined by
a setup parameter on the Speed Setup Screen. After Creep Time has elapsed, the control
accelerates to full cut speed.

Arc Off Time

Specifies the amount of time to wait before indicating a lost cut signal. This delay helps
minimize nuisance trips when the torch travels over previously cut paths in complex
nested layouts.

Stop Time
Specifies the amount of time that motion pauses at the end of a cut. This pause allows
the torch to raise completely and clear cut irregularities before advancing to the next cut
segment.

Accel Delay
Delays the activation of the Automatic Voltage Control so the cutting table can reach a
steady cutting speed. This parameter should be set as low as possible without allowing
the torch to dive excessively at the beginning of a cut.

Retract Delay Time

Specifies the delay between the end of the cut signal and retracting the torch.

Ignition
Enables the Ignition output to ignite the plasma torch. If your plasma system requires a
separate ignition signal, select ON. If your system does not require a separate ignition
signal, select OFF.

Voltage Control
Allows the operator to select manual or automatic mode for the Command THC. Manual
mode disables the torch height control and allows the torch to cut at the specified cut
height and voltage. Automatic mode allows the THC to command the torch up and down
to maintain the voltage at a specified set point.

Retract Full/Partial
Selects a full or partial retract distance for the torch. In the Full retract mode, the torch
retracts to the Home position. In Partial retract mode, the torch retracts to the set retract
distance.

Retry On Transfer Fail

Specifies the number of times the control attempts to fire the torch if the torch fails to
ignite.

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Command THC

Transfer Time
Specifies the amount of time to attempt ignition of the torch. The ignition is confirmed
by the Arc Sense Input (Arc on Feedback) to the control.

Set Arc Current

Allows the user to set the arc current at the plasma supply. This feature uses the “Set
Current BCD” output from the control to activate the BCD inputs at the plasma supply
and supports EIA RS-274D part program code G59 Vvalue Fvalue for setting current.

Corner Current Percent

Allows the operator to improve cut quality at corners by selecting a reduced current
setting for cutting corners. This value is a percentage of the Set Current (above) and is
active when the Torch Height Disable Output is on.

Set Arc Voltage

Selects the desired Arc Voltage for the material being cut.

Cut Height
Selects the desired cut distance from the plate and sets the initial cut height before Arc
Voltage control is activated.

Retract Distance
Selects the THC Retract Distance when partial retract mode is configured.

Pierce Height Factor

Is a factor that is multiplied by the Cut Height value to set the pierce height distance.

IHS Stall Current

Sets the lifter downward force to detect when the torch makes contact with the plate
during the IHS cycle. This is a relative factor between 1 and 10. The limited stall force
is always used if nozzle ohmic sense is turned off.

IHS Speed
Sets the lifter downward speed during the IHS cycle. This is a relative factor between 1
and 10.

Homing Speed
Determines the retract or homing speed. This is a relative factor between 1 and 10.

Nozzle Ohmic Contact

Select ON for the Command THC when using Ohmic Contact Sense to detect the plate
during the IHS cycle.

Preflow During IHS

Select ON to activate preflow during the IHS cycle.

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 Command THC

Auto Kerf Detect

Select ON to reduce the possibility of the torch diving into the plate. When this feature is
enabled, the THC detects sudden changes in arc voltage when it crosses a kerf path and
freezes the THC.
Main Cut Screen

Automatic THC Mode

Increase/Decrease Arc Voltage

These two soft keys, display on the main cut screen while the Command THC is
operating in automatic mode,. These soft keys allow you to increase and decrease the
Arc Voltage for the cut.

Extend
Press this soft key during the pierce cycle to extend the pierce timer until it is stopped
either by the Set-Now or Release soft key.

Set Now
Press the Set Now soft key to end the pierce cycle and save the new pierce time. The Set
Now soft key is often used in with the Extend soft key to modify the preset pierce time.

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Command THC

Release
Press the Release soft key to end a pierce cycle without modifying the original pierce
time. The original pierce time is saved for the remaining pierces.

Manual THC Mode

Raise/Lower Torch
These two soft keys, display on the main cut screen while the Command THC is
operating in Manual mode. These soft keys allow you to raise and lower the torch for the
cut.

Extend
Press this soft key during the pierce cycle to extend the pierce timer. To stop the timer,
press either the Set-Now or Release soft key.

Set Now
Press the Set Now soft key to end the pierce cycle and save the new pierce time. The Set
Now soft key operates with the Extend soft key to modify the preset pierce time.

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 Command THC

Release
Press the Release soft key to end a pierce cycle but keep the original pierce time.
Diagnostics

The current Command THC Interface and Real Time Revision Levels are displayed at the
Control Information screen when enabled.
Machine Interface

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

Port Designation
Serial communication for the Command THC is automatically set to the serial port which
is not selected for serial communications. For example, if Serial Port 1 is designated for
use as the link to the host PC for downloading part programs, HD4070 communications
are established on Serial Port 2.

Type “V” control may select the serial port designation at the Ports configuration screen.

RS-422 Connections to Command THC with 25-pin D-type connector

Command THC Control

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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Command THC

436
Motion Overview
This section provides an introduction to motion theory.

Note: System tuning should be performed by a qualified service technician. Improper

tuning can cause personal injury or damage to the system.

Outline of Information
1. Closed loop servo control
2. Encoders
3. Following error
4. Position and servo error
5. Edge per inch parameter
6. Gain
7. Recommended tuning procedures
Closed Loop Servo Control
A servo system is the means of accurately controlling electrical motors to create force.
The motor output is connected to a gear system to translate the rotational force of the
motor into linear motion. In addition, this gear system modifies the strength and speed of
the motion.

Closed loop servo control is the continuous process of monitoring position, or velocity
commands, or both compared to actual position and velocity and adjusting the output
accordingly. A servo system without feedback devices and automatic adjustment
capabilities is called an open loop servo control.

The drawing below outlines a typical velocity and position loop system. The most
important aspect for motion control is the position loop. The process starts with the
motion control providing a motion command (voltage) to the motor to move at a specific
speed to a position. Position is tracked during the motion by means of a feedback device,
or encoder, that provides both directional and distance information. Based on this
feedback, the control adjusts its motion command, or voltage, to the motor to ensure that
the motor is accurately positioned on the designated motion path at the correct speed.

Position Velocity Current Current Error Signal

Current Amplifier
Loop Loop Loop Servo
+ + +
∑ ∑ ∑ RS M Motor
- - Current -
Position Velocity Command or
Command Command Velocity Error Current Feedback
Signal
T
Velocity Feedback Signal Tachometer

E
437 Encoder
Motion Overview

Typical Velocity and Position Loop System

The motion command starts as digital output within the control and is converted to a +/-
10 Vdc analog output for use by the motors. This conversion of the motion command
within the control is referred to as the digital to analog converter (DAC) output and is
performed by the motion control card. After the analog output leaves the control, it
travels to a drive amplifier that increases the voltage output to the motor and creates
motion. Also, there is usually a linear relationship between the voltage sent and the
machine speed. For example, if 10 volts is the maximum machine speed, 5 volts is half
maximum machine speed. Additionally, the polarity of the output (DAC polarity +/-) to
the amplifier dictates the direction of the motor rotation. In most applications and in the
following application description, the feedback device is an encoder.

Encoders
An encoder is a feedback device that provides
signal pulses as the motor turns. The diagram at
the right illustrates the basic concept of an encoder.
Although this does not represent all encoder
feedback device technology, this illustration
provides a visual aid to help understand the
process.

The illustration shows a disk with small holes cut

out along the outer edge. The light source projects
a beam of light downward through the holes in the
disk. As the disk turns on the end of the motor
shaft, the light passes through the disk and creates pulses. The receiver below the disk
picks up the light pulses and sends that feedback to the control.

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 Motion Overview

There is a direct relationship between the rotation of the motor shaft, the encoder light
pulses, and the distance of the motion. Therefore, the control is able to calculate distance
by counting the encoder pulses it receives, which closes the position loop. This
relationship, shown as a simplified formula is:

encoder pulses x motor revs = distance

The encoder generates a square wave signal as

illustrated in the Encoder Signal diagram to the
right. Most encoders provide two main signals,
A and B, and the complements, A/ and B/.
These signals are also referred to as channels.
The compliment channels are not always used
but if they are used, they can provide increased
noise immunity. The rotational direction, or
encoder polarity, can be determined by the
signal that is received, either ABABA or
BABAB.

The channel Z signal is produced only once a revolution and is called the marker pulse.
This marker pulse is quite often used for accuracy in homing routines.

The pulses are called counts. The holes in the disk are also called lines. The pulses that
the receiver picks up may actually be the beginning and end of each pulse for a line on
both channels (A&B) so that the receiver picks up four pulses for each line. This is
called a 4x mode encoder. Thus, a 1000 line encoder in 4x mode would produce 4000
counts for each revolution of the motor. The more counts an encoder produces, the more
accurate the motion is.

Following Error
Following error or servo error is the distance between the position that the control
commands and the actual position of motion. Some following error is normal because
the resistance of the load prevents the response of the motor to reach the ideal command
of the system. This latent response is similar to driving a car away from a stop light. It
takes time for the engine to produce the force that is required to move the weight of the
car to the desired speed. Following error for each axis can be selected to be viewed in the
Watch Window / Status Window of the control. This is a quick reference tool for
monitoring the performance of the actual machine motion as compared to the control
command.

The important consideration for X/Y coordinate motion is that the response for the X and
Y motion is similar. If the response is dissimilar, poor results for commanded motion
will result. An example of a dissimilar tuned response would be that when a circular
motion is commanded, an oval or elliptical motion will result as one axis out performs the
other.

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Motion Overview

Position and Servo Error

A position, or servo, error occurs when the distance between the ideal motion position
and the actual motion position exceeds a pre-defined servo error tolerance value. A
position error indicates that the response from the motion command was not executed,
was executed too slowly or was executed incorrectly. The Servo Error Tolerance is a
user definable value within the control and is usually set to a value twice the following
error during normal operation. This allows the system to operate without nuisance faults
caused by temporary resistance to the motion, such as dirt on motion rails or temporary
tension from motor cabling.

Note: It is important to remember that in the closed position loop, the output command
adjusts to maintain speed and positioning. Thus, a loss of encoder feedback causes the
control to send its maximum motion command to the motor so the motor “runs away”
without control. Conversely, if the motor fails to turn while feedback is enabled, a
position error results and the command output stops when the fault occurs.

Encoder Counts and Maximum Machine Speed

Remembering that the position loop uses the pulses or counts from the encoder to
calculate distance, it is important to determine how many encoder pulses are equal to a
specific distance of machine motion. The control uses the encoder counts per inch/mm
value as the constant to calculate distance and speed.

The encoder counts per inch/mm is a calculation based on the number of pulses generated
by the encoder for one revolution of the motor and how much distance is traveled from
that motor motion through the gearing being used. The following formula illustrates this
relationship:

counts/line x counts/rev x 1 rev/inch = encoder counts/inch

For example, the resolution of a 4X – 1000 line encoder counts both edges (lines) of
channel A and channel B to equal 4 counts per line multiplied by the 1000 lines per
revolution equaling 4000 counts per revolution. If the encoder revolutions per inch of
travel are 1:1, we would have 4000 encoder counts per inch of travel.

4 counts/line x 1000 lines/rev x 1 rev/inch = 4000 encoder counts/inch

Determining Maximum Machine Speed

The following formula is used to establish the proper value for determining maximum
machine speed.

max RPM of the motor x of inches of travel per revolution = maximum machine speed
in inches per minute.

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 Motion Overview

For example:

4000 RPM Motors x .125 inches per rev = 500 inches per minute

Note: Through test or calculation it is determined that the table moves 1/8 inches per
revolution of the encoder.

With the maximum speed, encoder counts per inch, DAC and encoder polarities
determined and entered into control setups, a simple test of machine motion can be made
in the control Drive Diagnostics screen. This test should be made with the motors
disengaged for safety. This is a basic motion test of the system and does not use gain
terms or the position loop for motion. Refer to the Speeds information in this guide for
more information on this feature.

Gain

Proportional Gain
In a feedback control system, the error term is acted on by the control system and it alters
the output. Proportional gain is amplification of the error term. In a closed loop control
system, this is proportional to the error signal. Thus, the output is proportional gain
multiplied by error.

In most systems, proportional gain is the primary tuning parameter for improving the
response of the position loop.

Integral Gain
Proportional gain cannot completely eliminate error. The system can become unstable if
only proportional gain is used to eliminate error in a system. When the response of a
system is satisfactory, but steady state error is excessive, the error can be further reduced
by increasing system gain only for long term accumulations of error over time. Integral
gain is sometimes used to compensate for static load disturbances like torque loading,
gravity bias, and offset.

Note: Integral gain can cause instability in a system because it has a more instant effect at
the beginning of a move profile. Therefore, it is rarely used for velocity drives. However,
integral gain can provide improved response with current drives. Only small adjustments
to integral gain should be made if indications of steady state error exist. In almost all
applications, this value is set to zero. Use the feed forward gain for closing following
error that occurs during a move profile.

Derivative Gain
Derivative gain responds to the rate of change of the signal and can produce corrections
before the error term becomes large, therefore it is useful in improving the transient
response of a system. Since it opposes change in the controlled output, it can produce a
stabilizing effect by damping a tendency toward oscillation. This is the reason we
promote tuning by following error to the maximum Proportional Gain then setting

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Motion Overview

Derivative Gain at 10% of Proportional Gain as a rule of thumb. Do not overdo

Derivative Gain as it can have a detrimental effect on the overall response of the system.

Feed Forward
Feed forward “pushes” the commanded output ahead to reduce or eliminate the difference
between the actual position and the commanded position during motion, called dynamic
following error. Feed forward corrects for a “lag” in the system and has an effect similar
to proportional gain. Do not make large increases in feed forward gain because it can
cause positive following error and excessive overshoot.

Velocity Gain
When using a current loop amplifier, the internal velocity loop in the control can provide
dampening without an external tachometer.

Using the internal velocity loop with a current loop amplifier can result in higher static
stiffness, smoother machine motion, and less overshoot.

Recommended Tuning Procedures for Hypertherm Automation Motion

Controls

Using the information previously provided as a core understanding of the position loop
process, we can now look at tuning motion for the desired motion performance. Due to
potential safety hazards and the potential possibility for machine damage from incorrect
tuning, it is recommended that this operation be performed by trained and experienced
personnel.

Prior to performing motion tuning, values for DAC Polarity, Encoder Polarity and
maximum machine speed should be calculated and entered into control setups. Servo
Error Tolerance for the axes should be set to maximum (5 inch max for X/Y motion).

Initially, it is recommended that basic tuning start with the motors disengaged from the
machine to allow the user to confirm controlled motion and response of the motion axes.
An initial Acceleration Rate of 10 Mg’s can be used to begin the motion tuning. It is
important to remember that after the motors are engaged to the machine for motion, the
load requirements for each axis will change requiring additional tuning. Additionally, if
the acceleration rate is increased after the initial tuning, additional adjustments to Gain
tuning may be required for proper machine motion.

Procedure for Velocity Type Drives

We recommend tuning the system by performing manual moves at a slow speed with all
gains set to zero with the exception of Proportional Gain. Proportional Gain should start
with a small value of 10. Engage the motors to the machine frame and beginning raising
the Proportional Gain to allow movement. If the axes start to vibrate or oscillate, this
indicates the selected gain value is too high and should be lowered. It may also require
de-tuning the response of the Drive amplifier.

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 Motion Overview

Now that you have some basic control of the system, set up the Watch Window to display
Position and Following Error for the selected Axes. Load and automatically “Trial” the
Test Pattern simple shape from the shape library. You will be able to follow the response
of the system by watching the performance of the Motor /Encoder feedback and its ability
to maintain path on the control preview screen.

Systematically increase Proportional Gain until it has little or no effect on the following
error or until instability becomes noticeable. Then reduce Proportional Gain to eliminate
instability. Derivative Gain may be used to provide a dampening effect. For a Velocity
Loop Servo Drive, Integral Gain should be set to zero. After tuning for the best response,
increase Feed Forward Gain systematically to further reduce following error if necessary.
It is not required that you eliminate following error but it is wise to ensure that Following
Error for each axis is similar. Please Note: Feed Forward Gain will reduce steady state
following error, but may cause overshoot.

It is important to note that some following error is desirable, following error terms should
be nearly the same from one axis to another, and the polarity of the following error term
must be the same as the direction of travel.

Finally, check the system tuning by placing a pen on the system. “Draw” the test pattern
provided in the simple shape library and observe the cornering capability, arc/ circle
contouring and the ability to position at the center crossings. When troubleshooting
tuning issues, varying the size and trial speed can often provide valuable information
through observations of the pen tracing.

After the system has been successfully tuned, adjust the Servo Error Tolerance to equal
twice the normal Following Error for the axes (note: This is a common approach to
setting the Servo Error Tolerance but is up to the discretion of the service agent) . This is
allows the system to operate without nuisance faults caused by temporary resistance to
the motion, such as dirt on motion rails or temporary tension from motor cabling, etc.

Procedure for Current Type Drives

Similar to tuning for Velocity Type Drives, the recommended tuning procedure focuses
on response of the motion. The process begins with low initial values that are increased
to get a desired response. If the axes start to vibrate or oscillate, this indicates the
selected gain value is too high and should be lowered. It is recommended that basic
tuning start with the motors disengaged from the machine to allow the user to confirm
controlled motion and response of the motion axes. Motors can then be engaged to fine
tune for desired performance.

Set up the Watch Window to display Position and Following Error for the selected Axes.
Load and automatically “Trial” the Test Pattern simple shape from the shape library.
You will be able to follow the response of the system by watching the performance of the
Motor /Encoder feedback and its ability to maintain path on the control preview screen.

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Motion Overview

Systematically increase the Velocity Gain until it has little or no effect on the following
error or until instability becomes noticeable. Proportional Gain would then be used to
increase the “stiffness” of response. Integral Gain can be used to improve the steady state
performance. Derivative Gain may then be used to provide a dampening effect.

After tuning for the best response, increase Feed Forward Gain systematically to further
reduce following error if necessary. It is not required that you eliminate following error
but it is wise to ensure that Following Error for each axis is similar. Please Note: Feed
Forward Gain will reduce steady state following error, but may cause overshoot.

It is important to note that some following error is desirable, following error terms should
be nearly the same from one axis to another, and the polarity of the following error term
must be the same as the direction of travel.

Finally, check the system tuning by placing a pen on the system. “Draw” the test pattern
provided in the simple shape library and observe the cornering capability, arc/ circle
contouring and the ability to position at the center crossings. When troubleshooting
tuning issues, varying the size and trial speed can often provide valuable information
through observations of the pen tracing.

After the system has been successfully tuned, adjust the Servo Error Tolerance to equal
twice the normal Following Error for the axes (note: This is a common approach to
setting the Servo Error Tolerance but is up to the discretion of the service agent) . This is
allows the system to operate without nuisance faults caused by temporary resistance to
the motion, such as dirt on motion rails or temporary tension from motor cabling, etc.

444
 Motion Overview

Motion Tuning Watch Windows

Position and Following Error may be displayed.

Command Voltage allows the user to view directional motion command voltage being
sent to the amplifier for velocity type drives. This displayed voltage also equates to
current being commanded for motion in current type drives. Peak voltage can be
displayed for a specified amount of time.

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Motion Overview

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 Motion Overview

SERCOS Interface Overview

The acronym “SERCOS” refers to SErial Real time COmmunication System servo drive
interface. This approach to communication with the drive amplifiers is performed
through use of a fiber optic ring and replaces the traditional +/- 10VDC analog output
motion control card with a new fiber optic driver card. Motion commands from the
amplifier to the motor are the same as in a traditional servo loop.

SERCOS has been widely accepted and is approved by International standard (IEC 61491
in 1995) and European standard (EN 61491 in 1998).

Due to the expandable nature of the SERCOS interface, Mariner can support up to 12
axes of motion currently available in control software. Additional I/O modules may be
added to expand the total number of digital and analog I/O.

The SERCOS Drive Interface has a number of unique advantages.

1. Reduced CNC - machine interface wiring by use of a single fiber optic connector.
2. Fast 32 bit communications between the drive and CNC.
3. Improved noise immunity due to the fiber optic communication.
4. Long fiber optic cable lengths supported.

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Motion Overview

5. SERCOS is an open standard that is cross vendor compatible.

For more information on SERCOS, contact SERCOS North America at

http://www.sercos.com/

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ASCII Codes

ASCII Codes
This appendix provides the 128 ASCII codes (American Standard Code for Information
Interchange) as defined by ANSI (American National Standards Institute) Standard X3.4-
1977.

Control Codes

Hex Dec Character Name Description

00 0 ^@ NUL Null
01 1 ^A SOH Start of Header
02 2 ^B STX Start of Text
03 3 ^C ETX End of Text
04 4 ^D EOT End of Transmission
05 5 ^E ENQ Enquiry
06 6 ^F ACK Acknowledge
07 7 ^G BEL Bell
08 8 ^H BS Backspace
09 9 ^I HT Horizontal Tab
0A 10 ^J LF Line Feed
0B 11 ^K VT Vertical Tab
0C 12 ^L FF Form Feed
0D 13 ^M CR Carriage Return
0E 14 ^N SO Shift Out
0F 15 ^O SI Shift In
10 16 ^P DLE Data Link Escape
11 17 ^Q DCI Device Control 1
12 18 ^R DC2 Device Control 2
13 19 ^S DC3 Device Control 3
14 20 ^T DC4 Device Control 4
15 21 ^U NAK Negative Acknowledge
16 22 ^V SYN Synchronous Idle
17 23 ^W ETB End Transmission Block
18 24 ^X CAN Cancel
19 25 ^Y EM End of Medium
1A 26 ^Z Sub Substitute
1B 27 ^[ ESC Escape
1C 28 ^\ FS File Separator
1D 29 ^] GS Group Separator
1E 30 ^^ RS Record Separator
1F 31 ^_ US Unit Separator
20 32 SP Space

449
ASCII Codes

All Codes

Hex Dec Symbol Hex Dec Symbol Hex Dec Symbol

00 0 ^@ 2B 43 + 56 86 V
01 1 ^A 2C 44 , 57 87 W
02 2 ^B 2D 45 - 58 88 X
03 3 ^C 2E 46 . 59 89 Y
04 4 ^D 2F 47 / 5A 90 Z
05 5 ^E 30 48 0 5B 91 [
06 6 ^F 31 49 1 5C 92 \
07 7 ^G 32 50 2 5D 93 ]
08 8 ^H 33 51 3 5E 94 ^
09 9 ^I 34 52 4 5F 95 _
0A 10 ^J 35 53 5 60 96 `
0B 11 ^K 36 54 6 61 97 a
0C 12 ^L 37 55 7 62 98 b
0D 13 ^M 38 56 8 63 99 c
0E 14 ^N 39 57 9 64 100 d
0F 15 ^O 3A 58 : 65 101 e
10 16 ^P 3B 59 ; 66 102 f
11 17 ^Q 3C 60 < 67 103 g
12 18 ^R 3D 61 = 68 104 h
13 19 ^S 3E 62 > 69 105 i
14 20 ^T 3F 63 ? 6A 106 j
15 21 ^U 40 64 @ 6B 107 k
16 22 ^V 41 65 A 6C 108 l
17 23 ^W 42 66 B 6D 109 m
18 24 ^X 43 67 C 6E 110 n
19 25 ^Y 44 68 D 6D 111 o
1A 26 ^Z 45 69 E 70 112 p
1B 27 ^[ 46 70 F 71 113 q
1C 28 ^\ 47 71 G 72 114 r
1D 29 ^] 48 72 H 73 115 s
1E 30 ^^ 49 73 I 74 116 t
1F 31 ^_ 4A 74 J 75 117 u
20 32 4B 75 K 76 118 v
21 33 ! 4C 76 L 77 119 w
22 34 “ 4D 77 M 78 120 x
23 35 # 4E 78 N 79 121 y
24 36 $ 4F 79 O 7A 122 z
25 37 % 50 80 P 7B 123 {
26 38 & 51 81 Q 7C 124 |
27 39 ‘ 52 82 R 7D 125 }
28 40 ( 53 83 S 7E 126 ~
29 41 ) 54 84 T 7F 127 ←
2A 42 ‘ 55 85 U

450
Program Codes
0B

EIA RS-274D
1B

The control supports EIA RS-274D part programs. An EIA RS-274D program lists the
sequence of lines, arcs, speeds, kerf and I/O functions that are used to create a part. While the
user is free to program in EIA using the standard text editor, it is recommended that the
ShapeWizard Graphical Programming environment be used instead.

Following is a list of the EIA codes that are directly supported, mapped, or currently
unsupported by the control. Mapped EIA codes are automatically converted upon program load
into directly supported EIA codes. Unsupported EIA codes are ignored. All other EIA codes
generate an error.

Directly Supported EIA Codes

10B

EIA CODE DESCRIPTION

Fvalue Machine Speed (if Speed Override enabled)
Nvalue Line Number
(text) Comments
Xvalue X Axis Endpoint or other Data
Yvalue Y Axis Endpoint or other Data
Ivalue I Axis Integrand or Part Option Data
Jvalue J Axis Integrand or Part Option Data
Ovalue Svalue Output (1-64), State (0-Off or 1-On)
Wvalue Svalue Wait for Input (1-64), State (0-Off or 1-On)

G00 Rapid Traverse Linear Interpolation

G00 Avalue Sets Tilt angle – A is the angle value in degrees
G00 XYval Aval Performs Linear Interpolation of Tilt angle along line segment.
G01 Avalue Fvalue Sets Tilt angle value in degrees with a speed command in RPM
G00 Xn Yn Traverse command where n = value to move the desired axes a distance.
G00 Zx.xx Tx Index Sensor™ THC height “Z” distance for torch “T”. Manual mode
only.
G00 Cxx Move to rotate “C” position
G01 Cxx Fxx Move to rotate “C” position with Speed “F” command in RPM
G00 C180- Rotate Axis offset 180 degrees will continue to rotate in the proper
direction
G00 C-180- Rotate Axis offset -180 degrees will continue to rotate in the proper
direction
G01 C180- Fxx Rotate Axis offset 180 degrees with speed
G01 C-180- Fxx Rotate Axis offset -180 degrees with speed
G01 Linear Interpolation (at Cut Speed)
G02 Clockwise Circular Interpolation
G03 Counterclockwise Circular Interpolation
G04 Preset Dwell (uses Setup Dwell Time)
G04 Xvalue Program Dwell in Seconds

451
Program Codes

G08 Xvalue Repeat Subroutine X Times

G20 Select English Units (inches)
G21 Select Metric Units (mm)
G40 Disable Kerf Compensation
G41 Enable Left Kerf Compensation
G42 Enable Right Kerf Compensation
G43 Xvalue Kerf Value
G41 D1-200 Enables Left Kerf using a Kerf Table variable
G42 D1-200 Enables Right Kerf using a Kerf Table variable
G43 D1-200 Sets the current Kerf value via the Kerf Table using prior set Left / Right
Kerf
G59 D1-200Xvalue Sets Kerf table variable from 1-200
G59 Vvalue Fvalue Sets the Plasma Supply current through Outputs or Serial Link for
Vprocess (504,514,524,534) at Fcurrent value
V504 – Current Setting Plasma 1
V514 – Current Setting Plasma 2
V524 – Current Setting Marker 1
V534 – Current Setting Marker 2
G66 Dval Bval Cval Auto Align 3 Point Method with Long Offset Distance, Fast Speed, Slow
Speed values respectively
G82 Oxy-Fuel Cut Mode
G83 Oxy-Fuel Cut Mode Contour Bevel Head
G84 Plasma Cut Mode
G85 Plasma Cut Mode Contour Bevel Head
G90 Absolute Programming Mode
G91 Incremental Programming Mode
G92 Set Axis Presets
G97 Program Repeat Pointer
G97 Tvalue Program Repeat Pointer. Executes the repeat T times
G98 Repeat at G97, or start of program if no G97
G99 Part Options

M00 Program Stop

M01 Optional Program Stop (uses Setup Parameter)
M02 End of Program
M07 Cutting Device On
M08 Txx.xx Cutting Device Off (Temporary Optional Time Delay from –1 to 99.99
seconds)
M09 Enable Marker 1
M10 Disable Marker 1
M11 Marker Offset 1 On
M12 Marker Offset 1 Off
M13 Enable Marker 2
M14 Disable Marker 2
M15 Cut On
M16 Cut Off

452
 Program Codes

M17 Oxy Gas On

M18 Oxy Gas Off
M19 Cancel All Stations
M26 Station Select On
M27 Station Select Off
M28 CBH / Rotator(s) Disable
M29 CBH / Rotator(s) Enable
M30 End of Program (same as M02)
M31 Reset Functions (Cut Off, Marker Off, Kerf Off)
M32 Unclamp / Unlock All Stations
M32 Tvalue Unclamp / Unlock ‘T” Station, where T = 1 through 19
M33 Unclamp / Lock All Stations
M34 Clamp / Unlock All Stations
M34 Tvalue Clamp / Unlock ‘T” Station, where T = 1 through 19
M35 Clamp / Unlock All Stations Mirror
M35 Tvalue Clamp / Unlock Mirror “T” Station, where T = 1 through 19
M36 Tvalue Process Select “T” where T value selects the process
1 – Plasma 1
2 – Plasma 2
3 – Marker 1
4 – Marker 2
5 – Laser
M37 Tvalue (1-20) Select Station “T” where T = 1 through 20
M38 Tvalue (1-20) Deselect Station “T” where T = 1 through 20
M40 Start of Subroutine
M40 Xvalue Start of Subroutine. Executes the repeat X times
M41 End of Subroutine
M48 Speed Override Enable
M49 Speed Override Disable
M50 Height Sensor Disable
M51 Txx.xx Height Sensor Enable (Temporary Optional Time Delay in seconds
before Enable)
M52 Height Sensor Disable and Raise Torch
M53 Height Sensor Enable and Lower Torch
M63 User Defined 1 On
M64 User Defined 1 Off
M54 User Defined 2 On
M55 User Defined 2 Off
M56 User Defined 3 On
M57 User Defined 3 Off
M58 User Defined 4 Off
M59 User Defined 5 On
M65 End of Program (same as M02) or Auto Reload
M72 Marker Offset 2 Off
M73 Marker Offset 2 On
M75 A Axis/Tilt Go to Home Command - Rapid Index

453
Program Codes

M76 C Axis/Rotate Go to Home Command - Rapid Index

M77 Go to Home position Y Axis
M78 Go to Home position X Axis
M79 Tvalue (1-4) Go To Home Position (1-4)
M90 Aligns CBH / Rotator to Tangent angle of next cut segment
M90- Align rotator negative, when not using shortest path motion
M274 Marker Offset 3 Off
M275 Marker Offset 3 On
M276 Marker Offset 4 Off
M277 Marker Offset 4 On
M278 Marker Offset 5 Off
M279 Marker Offset 5 On
M280 Marker Offset 6 Off
M281 Marker Offset 6 On
M282 Marker Offset 7 Off
M283 Marker Offset 7 On
M284 Marker Offset 8 Off
M285 Marker Offset 8 On
M286 Marker Offset 9 Off
M287 Marker Offset 9 On
M288 Marker Offset 10 Off
M289 Marker Offset 10 On
M290 Marker Offset 11 Off
M291 Marker Offset 11 On
M292 Marker Offset 12 On
M293 Marker Offset 12 On
M301 Assigns the current X/Y position to Home Position 1
M302 Assigns the current X/Y position to Home Position 2
M303 Assigns the current X/Y position to Home Position 3
M304 Assigns the current X/Y position to Home Position 4
M305 Assigns the current X/Y position to Home Position 5
M306 Assigns the current X/Y position to Home Position 6
M307 Assigns the current X/Y position to Home Position 7
M308 Assigns the current X/Y position to Home Position 8
M309 Assigns the current X/Y position to Home Position 9
M310 Assigns the current X/Y position to Home Position 10
M311 Assigns the current X/Y position to Home Position 11
M312 Assigns the current X/Y position to Home Position 12

454
 Program Codes

Mapped EIA Codes

1B

EIA CODE
47B47B 47B47B DESCRIPTION MAPPED TO
G04 Fvalue Program Dwell G04 Xvalue
G05 Set Axis Presets G92
G21 Linear Interpolation G01
(at cut speed)
G22 CW Circular Interpolation G02
G23 CCW Circular Interpolation G03
G41 Kvalue Left Kerf with Value G41 with Kerf Value
G42 Kvalue Right Kerf with Value G42 with Kerf Value
G97 TValue Subroutine Loop G08 Xvalue and M40
G45 Lead In to Kerfed Part G01, G02, or G03
G70 Select English Units G20
G71 Select Metric Units G21
G98 End of Subroutine Loop M41
M03 Cutting Device On/Off M07 (Oxy Fuel) or M08 as appropriate
M04 Cutting Device On M07
M05 Cutting Device Off M08 (Oxy Fuel)
M06 Cutting Device Off M08
M06 Enable Marker 2 M13
M07 Disable Marker 1 or 2 M10 or M14 as appropriate
M08 Enable Marker 1 M09
M09 Disable Marker 1 or 2 M10 or M14 as appropriate
M10 Enable Marker 2 M13
M14 Height Sensor Disable M50
M15 Height Sensor Enable M51
M20 Cutting Device On/Off M07 or M08 as appropriate (Plasma)
M21 Cutting Device On/Off M07 or M08 as appropriate (Plasma)
M20 Output 9 On O9 S1
M21 Output 9 Off O9 S0
M22 Output 12 On O12 S1
M23 Output 12 Off O12 S0
M24 Wait for Input 7 On W7 S1
M25 Wait for Input 8 On W8 S1
M25 CBH Enable M29
M26 Wait for Input 7 Off W7 S0
M26 CBH Disable M28
M27 Wait for Input 8 Off W8 S0
M67, M02 Kerf Left G41
M68, M03 Kerf Right G42
M69, M04 Kerf Off G40
M65, M70 Cutting Device On M07
M66, M71, M73 Cutting Device Off M08
M70 Marker Offset 1 Off M12
M71 Marker Offset 1 On M11
M70T01 Marker Offset 1 Off M12

455
Program Codes

M71T01 Marker Offset 1 On M11

M70T02 Marker Offset 2 Off M72
M71T02 Marker Offset 2 On M73
M70T03 Marker Offset 3 Off M274
M71T03 Marker Offset 3 On M275
M70T04 Marker Offset 4 Off M276
M71T04 Marker Offset 4 On M277
M70T05 Marker Offset 5 Off M278
M71T05 Marker Offset 5 On M279
M70T06 Marker Offset 6 Off M280
M71T06 Marker Offset 6 On M281
M70T07 Marker Offset 7 Off M282
M71T07 Marker Offset 7 On M283
M70T08 Marker Offset 8 Off M284
M71T08 Marker Offset 8 On M285
M98 End Comment )
M99 Start Comment (
M221 No Mirror, No Rotate G99 X1 Y0 I0 J0
M222 Mirror Y, No Rotate G99 X1 Y0 I0 J1
M223 Mirror X and Y G99 X1 Y0 I1 J1
M224 Mirror X, No Rotate G99 X1 Y0 I1 J0
M225 Mirror X/Y on -45 Deg G99 X1 Y270 I1 J0
M226 Rotate 90 Deg CCW G99 X1 Y90 I0 J0
M227 Mirror X/Y on +45 Deg G99 X1 Y270 I0 J1
M228 Rotate 90 Deg CW G99 X1 Y270 I0 J0
M245 Output 1 On O1 S1
M246 Output 1 Off O1 S0
M247 Output 2 On O2 S1
M248 Output 2 Off O2 S0
M249 Output 3 On O3 S1
M250 Output 3 Off O3 S0
M251 Output 4 On O4 S1
M252 Output 4 Off O4 S0
M253 Wait for Input 1 On W1 S1
M254 Wait for Input 1 Off W1 S0
M255 Wait for Input 2 On W2 S1
M256 Wait for Input 2 Off W2 S0
M257 Wait for Input 3 On W3 S1
M258 Wait for Input 3 Off W3 S0
M259 Wait for Input 4 On W4 S1
M260 Wait for Input 4 Off W4 S0

456
 Program Codes

Unsupported EIA Codes

12B

EIA CODE DESCRIPTION

G30 Mirror Off
G46 Table 0 Select
G94 Feed per minute
G95 Feed per rev
G99 Freestanding G99
G103 Qname Stop Current Program/ Load New Program
G201 Incremental Line In2
G202 Incremental CW Arc In2
G203 Incremental CCW Arc In2
G211 Incremental Line In3
G212 Incremental CW Arc In3
G213 Incremental CCW Arc In3
G221 Absolute Line In2
G222 Absolute CW Arc In2
G223 Absolute CCW Arc In2
G231 Absolute Line In3
G232 Absolute CW Arc In3
G233 Absolute CCW Arc In3
G240 Programmable Kerf
G247 Table 1 Select
G248 Table 2 Select
G249 Table 3 Select
G250 Table 4 Select
G276 Internal Variable Load
G277 External Variable Load
G278 X Axis Home
G279 Y Axis Home
G280 X Home Return
G281 Y Home Return
M66 PLC Control Code
M75 Ignored if not using CBH, Tilt Rotator(s)
M76 Ignored if not using CBH, Tilt Rotator(s)
M210 X Sign Toggle
M211 Y Sign Toggle
M212 X and Y Swap and Toggle
M231 Aux. State Reset
M261 Aux. Torch Master On
M262 Aux. Torch Master Off

457
Program Codes

The unsupported EIA codes previously noted are ignored when read. Some of these codes may
be supported in the future. Any EIA codes that are not listed above will result in a translator
error upon loading the EIA program. Known EIA codes that will not be accepted include, but
are not limited to:

Pvalue Program Number

Dvalue Indexed Kerf Operations
Vvalue Internal Variable Load
EIA Comments
13B

Comments may be placed into the part program to be displayed on screen and viewed by the
operator. The comment line must first be preceded by a program stop command (EIA M00
code or ESSI 0 code).

EIA Example:

M00 – Pauses Program

(Comment) – Text to be displayed

458
 Program Codes

ESSI
2B2B 2B2B

The control supports ESSI part programs as defined by the International Standards
Organization in ISO 6582. An ESSI program lists the sequence of Lines, Arcs, Speeds, Kerf
and I/O Functions used to create a part. While the user is free to program in ESSI using a
standard text editor, it is recommended that the ShapeWizard Graphical Programming
environment be used instead.

While the user is free to download ESSI programs to the control, it is important to note that all
Part Programs will be internally converted to EIA for execution in the control. Following is a
list of the ESSI codes that are mapped into the control, or currently unsupported by the control.
Mapped ESSI codes are automatically converted upon program load into directly supported
EIA codes. Unsupported ESSI codes are ignored. All other ESSI codes will generate an error.

Mapped ESSI Codes

14B

ESSI CODE
49B49B 49B49B DESCRIPTION MAPPED TO EIA
% Start of Program Not Used-Automatic
+/-value… Line or Arc G00, G01, G02 or G03 as appropriate
0 End Program or Stop M02 or M00 (if 64 is End Program)
3 Start Comment (
4 End Comment )
5 Enable Rapid Traverse Not Used-Automatic
6 Disable Rapid Traverse Not Used-Automatic
7 Cutting Device On M07
8 Cutting Device Off M08
9 Enable Marker 1 M09
10 Disable Marker 1 M10
11 Marker Offset 1 On M11
12 Marker Offset 1 Off M12
11+1 Marker Offset 1 On M11
12+1 Marker Offset 1 Off M12
11+2 Marker Offset 2 On M73
12+2 Marker Offset 2 Off M72
11+3 Marker Offset 3 On M275
12+3 Marker Offset 3 Off M274
11+4 Marker Offset 4 On M277
12+4 Marker Offset 4 Off M276
11+5 Marker Offset 5 On M279
12+5 Marker Offset 5 Off M278
11+6 Marker Offset 6 On M281
12+6 Marker Offset 6 Off M280
11+7 Marker Offset 7 On M283
12+7 Marker Offset 7 Off M282
11+8 Marker Offset 8 On M285
12+8 Marker Offset 8 Off M284
13 Enable Marker 2 M13

459
Program Codes

14 Disable Marker 2 M14

15 Marker Offset 2 On M73
16 Marker Offset 2 Off M72
21 No Mirror, No Rotate G99 X1 Y0 I0 J0
22 Mirror Y, No Rotate G99 X1 Y0 I0 J1
23 Mirror X and Y G99 X1 Y0 I1 J1
24 Mirror X, No Rotate G99 X1 Y0 I1 J0
25 Mirror X/Y on -45 Deg G99 X1 Y270 I1 J0
26 Rotate 90 Deg CCW G99 X1 Y90 I0 J0
27 Mirror X/Y on +45 Deg G99 X1 Y270 I0 J1
28 Rotate 90 Deg CW G99 X1 Y270 I0 J0
29 Enable Left Kerf Comp G41
30 Enable Right Kerf Comp G42
38 Disable Kerf G40
39+value Machine Speed Fvalue
40+value Programmable Kerf G43 Xvalue
41 Preset Dwell G04
41+value Program Dwell in mSec G04 Xvalue
45 Ht Sensor Enable/Lower M53
46 Ht Sensor Disable/Raise M52
47 Ht Sensor Enable M51
48 Ht Sensor Disable M50
51 CBH Enable M29
52 CBH Disable M28
53 Cutting Device On M07
54 Cutting Device Off M08
63 Reset Functions M31
64 End Program M02
65 End of Program/ Reload M65
67 Ht Sensor Disable M50
68 Ht Sensor Enable M51
70 Select English Units (in) G20
71 Select Metric Units (mm) G21
79+1 Go To Home Position 1 M79 T1
79+2 Go To Home Position 2 M79 T2
79+3 Go To Home Position 3 M79 T3
79+4 Go To Home Position 4 M79 T4
81 Incremental Mode G91
82 Absolute Mode G90
83 Set Axis Presets G92
90 End of Program M02
97 Program Repeat Pointer G97
97+value Subroutine Loop M40 Xvalue
98 Repeat at 97, Subroutine loop G97, G98 or M41 as appropriate
or start of program if no 97
99 End of Program M02

460
 Program Codes

245 Output 1 On O1 S1
246 Output 1 Off O1 S0
247 Output 2 On O2 S1
248 Output 2 Off O2 S0
249 Output 3 On O3 S1
250 Output 3 Off O3 S0
251 Output 4 On O4 S1
252 Output 4 Off O4 S0
253 Wait for Input 1 On W1 S1
254 Wait for Input 1 Off W1 S0
255 Wait for Input 2 On W2 S1
256 Wait for Input 2 Off W2 S0
257 Wait for Input 3 On W3 S1
258 Wait for Input 3 Off W3 S0
259 Wait for Input 4 On W4 S1
260 Wait for Input 4 Off W4 S0
282 Marker Offset 3 On M275
283 Marker Offset 3 Off M274
284 Marker Offset 4 On M277
285 Marker Offset 4 Off M276
286 Marker Offset 5 On M279
287 Marker Offset 5 Off M278
288 Marker Offset 6 On M281
289 Marker Offset 6 Off M280
290 Marker Offset 7 On M283
291 Marker Offset 7 Off M282
292 Marker Offset 8 On M285
293 Marker Offset 8 Off M284

Unsupported ESSI Codes

15B

ESSI CODE DESCRIPTION

103+Name Stop Current Program/ Load New Program
237 X Sign Toggle
238 Y Sign Toggle
239 X and Y Swap and Toggle
266 Table 1 Select
267 Table 2 Select
268 Table 3 Select
269 Table 4 Select
276 Internal Variable Load
277 External Variable Load
278 X Axis Home
279 Y Axis Home
280 X Home Return
281 Y Home Return

461
Program Codes

The unsupported ESSI codes above are ignored when read. Some of these codes may be
supported in the future. Any ESSI codes that are not listed above will result in a translator error
upon loading the ESSI program.

ESSI Comments
16B

Comments may be placed in to the part program to be displayed on screen and viewed by the
operator. The comment line must first be preceded by a program stop command (EIA M00
code or ESSI 0 code).

ESSI Example:

0 – Pauses Program
3 – Start Comment
Comment – Text to be displayed
4 – End Comment

462
 Program Codes

Advanced Feature Codes

3B3B 3B3B

Kerf Table
17B

CODE DESCRIPTION
G59 D1-200Xvalue Sets kerf table variable from 1-200
G41 D1-200 Enables Left Kerf using a Kerf Table variable
G42 D1-200 Enables Right Kerf using a Kerf Table variable
G43 D1-200 Changes current kerf value via Kerf Table using previously set Left or
Right kerf

Tilt / Rotator Part Codes

18B

CODE
73B73B 73B73B DESCRIPTION
G00 Avalue Sets Tilt angle as a preparatory command – A is the angle value in
degrees
G00 XYvalue Avalue Performs Linear Interpolation of Tilt angle along line segment.
G00 Avalue Fvalue Sets Tilt angle – Angle value in degrees with a speed command in RPM
M28 Disables Follower
M29 Enables Follower
M90 Preparatory Cmd - Aligns Rotator to Tangent angle of next cut segment
M90- Align rotator when not using shortest path motion
M75 A axis/Tilt Goto Home Cmd - Rapid Index
G00 Cxx Move to rotate “C” position
G01 Cxx Fxx Move to rotate “C” position with Speed “F” command
G00 C180- Rotate Axis align 180 degrees will continue to rotate in the proper
direction
G00 C-180- Rotate Axis align -180 degrees will continue to rotate in the proper
direction
G01 C180- Fxx Rotate Axis align 180 degrees with speed
G01 C-180- Fxx Rotate Axis align -180 degrees with speed

19B Automatic Torch Spacing Program Codes

CODE
74B74B 74B74B DESCRIPTION
M32 Unclamp / Unlock All Stations
M33 Unclamp / Lock All Stations
M34 Clamp / Unlock All Stations
M34Tvalue Clamp / Unlock ‘T” Station, where T = 1 through 19
M35 Clamp / Unlock All Stations Mirror
M35Tvalue Clamp / Unlock Mirror “T” Station, where T = 1 through 19
M77 Go to Home position Y Axis
M78 Go to Home position X Axis

463
Program Codes

Station Selects
4B

Stations (Lifter / THCs) may be selected and de-selected using a EIA-274D program code with
the following format.

CODE
75B75B 75B75B DESCRIPTION
M19 Tvalue Cancel All Station Selections
M37 Tvalue Select Station 1-20 (Tvalue)
M38 Tvalue De-Select Station 1-20 (Tvalue)

Additionally, these Station Select program codes may be overridden using the user selected
THC inputs to the control. The feature to override the part program must be enabled at the
Cutting Setup screen.

Process Selects
20B

Process Selections may be selected using a EIA-274D program code with the following format.

Example: M36 Tvalue

U U U U

Misc. M Code
54B

Valve Identity
5B

T1 = Plasma Process 1
T2 = Plasma Process 2
T3 = Marker Process 1
T4 = Marker Process 2
T5 = Laser Process

Station Configuration Variables

21B

The following options are available for the station configuration

Lifter
2B

None
Sensor THC
Command THC (w/ Serial Link)
HD4070 Integrated THC 1 or 2 (used only with the HD4070 power supply)
Other (any stand alone Lifter Station)

Power Supplies
23B

None HD4070 Torch 1or 2 Powermax series

Max100/ 100D HT4001 FineLine 100
Max200 HT4100 FineLine 200
HT2000 HT4400 Other (any other Plasma system)
HD3070 HPR130

Marker
24B

None ArcWriter FineLine 100 & 200

HD4070 Torch 1or 2 HPR130 Other (any stand alone Marker)

464
 Program Codes

Laser
25B

Rofin RF 40 & 50 Rofin DC 35 Rofin TR 60 Other

5B Automatic Torch Spacing

The automatic torch spacing feature uses codes within the part program, and designated
outputs, to perform precise positioning of individual torch stations for multi-torch cutting
processes.

This feature must be enabled in Machine Setups. The Auto Torch Spacing Override feature in
Cutting Setups must also be enabled.

In this process, the primary torch station has a fixed mount to the transverse axis and the other
secondary torch stations have the ability to clamp to the mechanics of the transverse axis during
use or lock to the gantry or beam when not in use.

For the example, in the following illustration, Torch 1 is the primary station and Torch 2-4 are
the secondary stations.

Typical use is as follows:

1) Unclamp and unlock all stations (except the first which is fixed and slides the others)
2) Go to Home Command on Transverse Axis (M77 or M78 depending on orientation)

465
Program Codes

3) Clamp and Unlock all carriages and G00 index inward on transverse (optional command -
may used to space all stations away from edge / OT switch of machine)
4) Lock and Unclamp all and G00 index to space first station (remember-first station has no
clamping/locking on board)

5) Unlock and Clamp next station and G00 index to space the next station.

6) Repeat Step 5 until as many stations as needed are spaced.

Note: Homing also automatically includes the commands necessary to push the stations to the
side and lock / clamp them whenever the transverse is homed, if Auto Torch Spacing is

466
 Program Codes

enabled. Unclamp/ Clamp and Unlock / lock commands execute a one second delay before
moving.

26B Automatic Torch Spacing Program Codes

Code
76B76B 76B76B Description
M32 Unclamp / Unlock All Stations
M33 Unclamp / Lock All Stations
M34 Clamp / Unlock All Stations
M34Tvalue Clamp / Unlock ‘T” Station, where T = 1 through 19
M35 Clamp / Unlock All Stations Mirror
M35Tvalue Clamp / Unlock Mirror “T” Station, where T = 1 through 19
M77 Go to Home position Y Axis
M78 Go to Home position X Axis
G00 Xn Yn Traverse command where n = value to move the desired axes a distance.

27B Automatic Torch Spacing I/O

Station Lock 1-19 The Station lock is used to Lock the unused torch station to the
gantry or beam when not in use.

Station Clamp 1-19 The Station Clamp is used to Clamp the selected torch station to
the transverse axis for standard cutting.

Station Mirror 1-19 Station Clamp is used to Clamp the selected torch station to the
transverse axis for mirrored cutting.

Example Part Program

28B

Transverse axis defined as X axis

Three station cut of 20 inch vertical rip.
CODE
57B57B 57B57B DESCRIPTION
G70 English Units
G91 Incremental Mode
G99 X1 Y0 I0 J0 Axes Preset zero Scaling
M32 Unclamp / Unlock All Stations
M78 Home X Axis (move all stations to Home position)
M34 Clamp All / Unlock All
G00X2Y0 Traverse X axis 2 inches (to move off edge/ switch)
M33 Unclamp All / Lock All
G00X10Y0 Traverse X axis 10 inches (to set 10 inch space – station 1)
M34 T1 Clamp Station 1 / Unlock Station 1
G00X10Y0 Traverse X axis 10 inches (to set 10 inch space– station 2)
M34 T2 Clamp Station 2 / Unlock Station 2
G41 Left Kerf
M07 Cut On
G01 X0 Y20 Line segment (Y axis 20 inches)
M08 Cut Off
G40 Kerf Off

467
Program Codes

M02 End of Program

Sensor THC Part Program Support

6B

Sensor THC allows you to configure THC setup parameters through part program codes.

The following parameters are available for use using EIA-274D G59 codes:

• Arc Voltage
• Pierce / Start Time
• Pierce/ Start Height Factor
• Cut / Mark Height
• Transfer Height Factor

Setup is obtained using the following format:

468
 Program Codes

Example: G59 V601 Fvalue

U U U U U

Misc. G Code
56B

Variable Identity
57B

V600 = Plasma 1 Arc Voltage

V601 = Plasma 1 Pierce Time
V602 = Plasma 1 Pierce Height Factor
V603 = Plasma 1 Cut Height
V604 = Plasma 1 Transfer Height Factor
V605 = Plasma 1 Cut Height Delay
V606 = Plasma 1 Kerf Detect Reaquire Time

V625 = Plasma 2 Arc Voltage

V626 = Plasma 2 Pierce Time
V627 = Plasma 2 Pierce Height Factor
V628 = Plasma 2 Cut Height
V629 = Plasma 2 Transfer Height Factor
V630 = Plasma 2 Cut Height Delay
V631 = Plasma 2 Kerf Detect Reaquire Time

V650 = Marker 1 Arc Voltage

V651 = Marker 1 Start Time
V652 = Marker 1 Start Height Factor
V653 = Marker 1 Mark Height

V675 = Marker 2 Arc Voltage

V676 = Marker 2 Start Time
V677 = Marker 2 Start Height Factor
V678 = Marker 2 Mark Height

Variable Value
58B

The selected value for the variable

THC Index code

59B

G00 Zx.xx Tx Index Sensor THC height “Z” distance for torch “T”. Manual mode only.
Subparts
7B

Subparts allow the user to call and execute a separate part file within a part program using a
simple line of text.

To configure a subroutine part for use, the user must first create a folder on the CNC hard drive
named “SUBPARTS”. To create a folder on the hard drive, select Load From Disk. With the
folder location highlighted, press the + key to create a new folder.

469
Program Codes

Save the desired part program in the SUBPARTS folder.

To execute the part, insert a line of code at the desire location within the part with the following
format.

PFILENAME

Start the line of code with the letter P to indicate that a Sub Part is to be executed, followed by
the filename for the desired part program.

For example, to execute subpart L-Bracket after completing a simple 5” x 5” square with a
programmed traverse, the part program would look something like the following example:

(Rectangle - Piece)
G20
G91
G99 X1 Y0 I0 J0
G41
M07
G01 X-5.2 Y0
G01 X0 Y5
G01 X5 Y0
G01 X0 Y-5.2
M08
G00 X.75 Y0
PL-BRACKET
G40
M02

When executed, this program would be represented as the original part plus the additional
subpart, including the programmed traverse.

470
 Program Codes

Note: Subparts can also contain subparts. After being translated by the CNC, the final text of
the part will contain the complete text of the original part and subpart.

Marker Font Generator

8B

The Marker Font Generator feature can be used to label or identify parts with a marking device
before cutting. This is accomplished by use of a simple command string within the part
program code to call existing text characters (fonts) and execute marking of the selected text.

The program code uses a specific format and is structured to provide information to be used
when marking. Information on the font source location, scale factor, angle, marker tool, tool
offset and text are entered as information blocks in the command string. Each section or
information block in the command string is separated by a space. The format of this command
code is outlined as follows:

Note: If a value is not present for a specific information block, the default values will be used.
The default values are:

Font (F): Internal Angle (A): 0° Offset (O): #1

Scale (S): One Marker (M): #1

471
Program Codes

Example of a simple command string: <F2 S1 A45 M2 O2 <TEST 123>

< <” symbol to indicate the Marker Font

The program command must begin with the “<
Generator feature is being used.

F The first block of information is the Font Source location. The “F” indicates “Font” and
is followed by a digit to indicate the location. Number 1 indicates the internal font in the
control software, number 2 indicates to use a font located on the control hard drive, and
number 3 indicates to source the font to be used from diskette or USB memory. If no font
is found at the selected location, the default internal font will be used. For the example
given, the font location would be from the hard drive.

S The second information block determines the scale of the text. The “S” is used to indicate
“Scale” and is followed by a digit to indicate a numeric scale factor. For the example
given, the Scale factor would be two or twice as large as the original font dimensions.

A The third information block determines the angle of the text. The “A” is used to indicate
“Angle” and is followed by a numeric value for the degree of angle. For the example
given, the angle would be 45°.

M The fourth information block determines the Marker Tool to be used. The “M” is used to
indicate “Marker” followed by the number of the Marker Tool (Marker Enable Output) to
be used. Up to two marker enables are supported.

O The fifth information block determines which tool Offset to be used. The “O” indicates
offset followed by a number indicating one of the nine different tool offsets previously
configured in control setups is to be used. The example shown indicates that tool offset
number two should be used.

< > The final information block is used to specify the marker text to be executed. The text
must be enclosed in the ”<” and “>” marks to be valid and understood as the selected text.
For the example given, the marker text executed would be “TEST 123”

Translated by the control, the example command string given above would generate the Marker
Text “TEST 123” onto the plate as shown here in Shape Wizard.

472
 Program Codes

To improve the ease of use for the part program designer and control operator, the marker font
generator always inserts a traverse segment to return to the original start point at the beginning
of the marking text.

Internal Fonts
29B

The internal fonts located within the control software are 1” high and are limited to characters
available on the control keypad. Alphabetical characters are limited to upper case letters only.

External Fonts
30B

External fonts can be loaded from a floppy disk or from the control hard drive. When the CNC
generates the text, the CNC searches for part files to correspond to the selected character. The
part file names must be based on their ASCII numeric equivalent and have a .txt file extension.

For example, for the marker text “Ab 12”, the control searches for the following files to
generate the text:

Text ASCII No. File Name

Capital A 65 Ascii65.txt
Lower case b 98 Ascii98.txt
Space 32 Ascii32.txt
No 1 49 Ascii49.txt
No 2 50 Ascii50.txt

473
Program Codes

Refer to the ASCII Codes section of this guide for additional ASCII code information.
Font programs may be saved on the control hard drive by creating a folder labeled “Fonts”
using the “Save to Disk” feature and saving the font programs within this folder. Remember, if
a corresponding part file to text requested is not found at the selected source location, the
internal font file will be used.

Custom Fonts
31B

As previously noted, customer-selected custom fonts can be used when using the marker font
generator. To construct these font files, certain guidelines should be adhered to.

1. Programming format must be EIA

2. Only M09 and M10 maybe used to enable and disable the marker.
3. Only G00, G01, G02 and G03 codes may be used.
4. The program must end in an M02.
5. The proper file name must be assigned to the font program.
6. The font program must begin in the lower left and end in the lower right.
U U

7. Font programs should have the consistent dimensional limits (i.e. 1’ high, etc.).

Example: The letter “B” – File Name Ascii66.txt

M09
G01 X0 Y1
G01 X0.321429 Y0
G02 X0 Y-0.5 I0 J-0.25
G01 X-0.321429 Y0
M10
G00 X0.321429 Y0
M09
G02 X0 Y-0.5 I0 J-0.25
G01 X-0.321429 Y0
M10
G00 X0.571 Y0
M02

The darker lines in the drawing represent the Traverse segment and the lighter lines represent
the Marking lines. You can see by this illustration that at the end of the font program, a
traverse is used to continue motion to the bottom right corner.

Note: The Burny 3/5 style of programming for the Marker Font Generator feature is also
supported for the default internal font source.

474
 Program Codes

Serial Messaging
9B

The Serial Messaging feature may be used to pass commands embedded within a part program
through a selected serial port to an external device. Both RS-232 and RS-422 are supported.
TCP/ IP protocol is not supported at this time. There are 2 Serial Messaging ports available.

Overview
32B

Serial Messaging has a fairly basic communication protocol that has three simple formats to
send ASCII codes as command strings. During the messaging function, a status indicator for
“Message Transmit”, “Message Delay” or “Message Verify” will be displayed in the Watch
window.

Options
3B

1. While the selected message is sent to the external device, the part program will be
temporarily suspended. After completion of the transmission, the part program will then
automatically resume. No acknowledgement from the external device is required. An
additional Time Delay may also be added.
2. A message is sent concurrent to execution of the part program and no delay is encountered.
No acknowledge is required. No Delay Time is allowed.
3. The message is sent with a suspension of the program during transmission as in option one,
but an Acknowledge from the external device (ACK) is required before the part program
can continue. A Non-Acknowledge (NAK) response from the external device will prompt a
retransmit of the message from the control. An optional Time Out value may be added to
the program code. If no Time Out code is used in the program code the Default time out
value at the Ports setup screen will be used. Additionally, an optional automatic retry
feature may be enabled at the Ports setup screen.

To enable use of this feature, assign Messaging to the selected port(s) at the Ports setup screen.

475
Program Codes

After enabling Messaging, the flow control parameters to communicate with the external device
will then need to be selected. The user may also select how messaging is handled for the

476
 Program Codes

The following parameters must be configured. Hardware and flow control configuration
information must match the external device.

Baud Rate
34B

Select a communication speed from 1200 Baud to 115200 Baud

Parity
35B

Select None, Odd or Even.

Data Bits
36B

Select 7 or 8 Data Bits.

Flow Control
37B

Select to use None, Xon/Xoff or Hardware.

During Jog on Path

38B

The user may select whether messages will be sent when jogging Forward or Backward on Path
while at the Pause screen. Note: All messaging will stop when the Stop Key has been pressed
or the Remote Pause input becomes active.

Note: The Message Type 21 will transmit the message concurrent to the associated motion
segment during “Backup on Path”.

Retry on Time Out

39B

For the Message Type 22 (which requires an acknowledgement from the external device after
the message) an automatic retransmit of the message may be sent. The user may select the
number of retries allowed before faulting from a lack of response from the external device. The
fault prompt “Message Error” will be displayed when in a Time Out condition.

Time Out
40B

The Time Out value may be used for the Message Type 22 (which requires an
acknowledgement from the external device after the message) if there is no Time Out value
used in the command string of the program code. Refer to the Delay Time / Time Out
information for more information.

Programming Code
41B

The ASCII message string follows a unique program message format. Each command begins
with a “>” character and ends with a “<” character. These characters are used as delimiters to
frame the command (Message Type, Optional Format and Optional Delay Time/ Time Out)
instructions for the message.

477
Program Codes

Message Information
42B

The format of this command code is outlined as follows:

EIA Example: (>20+Format+Delay Time/Time Out+Port<Message)

U U U U U U U U U

Message Command Type

60B

>20< Direct message with Delay

>21< Direct message without Delay
>22< Message that requires Acknowledge
(see Message Command Type below)
Optional Format Value
61B

This optional Format value allows the user to add

Line Feed and Carriage Return commands, etc.,
message string. 0,1,16,17,32,33,48,49,64,65,80,81,
96,97,112,113 are supported (see Format Value below).
Optional Delay Time/Time Out Value
62B

Time in seconds (see Time Out Value below)

Optional Port
63B

The serial port to use (0 = Default Port 1, 1 = Port 2)

Message Text
64B

The message content (see the message text below)

Note: Message format is always within comment characters and the command portion of the
program code is between the “>” Character and the “<” Character.

ESSI Example:
U U U EIA Example:
3 (>20,1,1,0<Message)
>20,1,1,0<Message
4

See below for Format, Delay and Port settings information.

Note: For the example provided, the plus sign (+) character was used as delimiter between
fields for the command instruction. In addition to the plus sign (+), the hyphen (-), comma (,)
or space may be used as delimiters.

Example:
UU UU

Using spaces, the EIA command would look like this: (>20 Format Timeout Port<Message
Text)
Message Command Type
43B

>20< This command delays the part program until all bytes have been transmitted, then
optionally waits the Delay Time, if specified.

>21< A message is sent concurrent to execution of the part program and no delay is
encountered. No acknowledge is required.

>22< The message is sent with a suspension of the program during transmission as in option
one, but an Acknowledge from the external device (ACK = Hexadecimal 06) is required
before the part program can continue. A nonacknowledge (NAK = Hexadecimal 15)

478
 Program Codes

response from the external device will prompt a retransmit of the message from the
control.

An optional Time Out value may be added to the program code. If no Time Out code is
used in the program code the Default time out value at the Ports setup screen will be
used. Additionally, an optional automatic retry feature may be enabled at the Ports
setup screen.

With the automatic retry feature the message will automatically be retransmitted if no
response is detected. The retry is executed after the Time Out value has elapsed. The
number of retries can be defined on the Ports configuration screen.
Optional Format Value
4B

Specialty characters for the format may be sent in addition to command string.
Specialty Characters Supported
45B

HEX
UU UU UU UU Name
UU UU UU UU Description
UU UU

01 SOH Start of Header

02 STX Start of Text
03 ETX End of Text
04 EOT End of Transmission
0A LF Line Feed
0D CR Carriage Return
BCC “Exclusive Or” Check Byte

Note: Checksum is always an 'Exclusive OR' of the Data ONLY as it does not include any of
the 'Format' chars including the CR/LF option.

479
Program Codes

Optional Format Character Assignments

46B

VALUE
UU UU UU UU ASSIGNMENT
UU UU

0 No Special assignment(must be used in the format location if a Delay or

Port is required but no Format options are required).
Append a Carriage Return (<CR> = Hex value OD) and a Line Feed
(<LF> = Hex Value0A)
16 Append an “Exclusive OR” (<BCC>) to the end of the message.
17 Appends a combination of 16 and 1.
32 Encloses the message with Start of Text (<STX> = Hex Value 02) and End of
Text (<ETX> = Hex Value 03). The <ETX> follows the message and the
optional <CR><LF>> append codes but precedes the Check Byte <BCC>.
33 Appends a combination of 1 and 32.
48 Appends a combination of 16 and 32.
49 Appends a combination of 1, 16 and 32.
64 Append a Start of Header (<SOH> = Hex value 01) and a End of Transmission
(<EOT> = Hex Value04) to the Message.
65 Appends a combination of 1and 64.
80 Appends a combination of 16 and 64.
81 Appends a combination of 1, 16 and 64.
96 Appends a combination of 32 and 64.
97 Appends a combination of 1, 32, and 64.
112 Appends a combination of 16, 32 and 64.
113 Appends a combination of 1, 16, 32 and 64.
Optional Delay Time/Time Out Value
47B

The Delay Value will issue a delay in seconds at the end of the message for Message Type 20.

No delay is supported for Message Type 21.

This value also works as a Time Out value for Message Type 22. An error will be displayed if
the message is not acknowledged (ACK Hexadecimal 06) within the specified time. If no
Time Out Delay is defined in the command, the Time Out parameter on the Ports screen will be
used.

The value is in a 3.2 format where a value of 5 is equal to 5.00 seconds. Accepted limits for the
value is range of 0.00 to 999.99 seconds.

If there is no delay, but the optional port below is being selected, then 0 is required to be
entered in the optional delay location.

Optional Port
48B

The Optional Port setting selects which Messaging Port to use. The default messaging port to
use is Port 1 if this parameter is omitted. If the optional port is used, 0 = Messaging Port 1 and
1 = Messaging Port 2.

480
 Program Codes

Message Text Content

49B

Up to 300 data characters in each command string may be sent. The Command characters
(information between and including the “>” and “<” signs) are included in this maximum.

Printable and Non- Printing ASCII codes can be used in the message string. Refer to the ASCII
Code appendix of this manual for more information on ASCII codes and the Hexadecimal
value.

Non-printing characters are supported by use of a two-character command and can send a
Binary Code in the Range from 0-255. Double byte character to support combinations will
affect the maximum length count with each pair reducing the maximum data characters by 1.
Refer to the Non-printing Character information later in this section for information on these
values.

Non – Printing Characters

50B

Non Printing Characters are supported through use of a pair of two printing codes to equal the
non-printing code. This pair of characters is retained in the program code but sent as single 8-
bit code when transmitted.

There are three types of character pairs and each performs a different operation based on the
first character of the pair. This produces a single modified character for transmission.

Character Options
51B

1. The “&” two-character pair clears the 0x40 bit from the 2nd character code value.
2. The “!” two-character pair clears the 0x40 bit and sets the 0x80 bit set in the 2nd character
code.
3. The “$” two-character pair clears the 0xC0 bit in the 2nd character.

To transmit the single character with a value 0x01, use the two character sequence ”&A”. This
converts the “A” value of 0x41 to 0x01 by clearing the 0x40 bit. To transmit 0x81, use “!A” or
to transmit)xC1 use “$A”.

Exceptions / Additions
52B

As the “&”, “!” and “$” are used as key indicators for the Non-print characters, there is a
special format used when these characters are used as a print character in the message text.
Simply use the character twice. “&&” = “&”

The ESSI style part program uses several unique characters which requires special two
character codes to be used. For example, the message code “&K” in the part program will
transmit the code value of 0x2B which is the ASCII code for the plus sign (+). In order to send
the + character the code “&K” must be used.

481
Program Codes

The following are unique codes used in WORD ADDRESS and ESSI programs

U CODE U U CODE VALUE U U DESCRIPTION

&’ 0x20=space At end of ESSI program
&h 0x28 = “(“ To transmit “(” from WORD ADDRESS program
&i 0x29 = “)“ To transmit “)” from WORD ADDRESS program
&? 0x7F = DEL Non-printable DELETE code
&K 0x2B = “+” To transmit “+” from ESSI program
Non Printing Character Table
53B

65B ASCII codes less than Hexadecimal 20

Code
U U Hex
U U Code
U U Hex
U U Code
U U Hex
U U Code
U U Hex
U

&@ 00 &H 08 &P 10 &X 18

&A 01 &I 09 &Q 11 &Y 19
&B 02 &J 0A &R 12 &Z 1A
&C 03 &K 0B &S 13 &[ 1B
&D 04 &L 0C &T 14 &\ 1C
&E 05 &M 0D &U 15 &] 1D
&F 06 &N 0E &V 16 &^ 1E
&G 07 &O 0F &W 17 &_ 1F

8 bit character codes greater than Hexadecimal 80

6B

Code
U U Hex
U U Code
U U Hex
U U Code
U U Hex
U U Code
U U Hex
U

!@ 80 !H 88 !P 90 !X 98
!A 81 !I 89 !Q 91 !Y 99
!B 82 !J 8A !R 92 !Z 9A
!C 83 !K 8B !S 93 ![ 9B
!D 84 !L 8C !T 94 !\ 9C
!E 85 !M 8D !U 95 !] 9D
!F 86 !N 8E !V 96 !^ 9E
!G 87 !O 8F !W 97 !_ 9D

!` A0 !h A8 !p B0 !x B8
!a A1 !I A9 !q B1 !y B9
!b A2 !j AA !r B2 !z BA
!c A3 !k AB !s B3 !; BB
!d A4 !l AC !t B4 !< BC
!e A5 !m AD !u B5 != BD
!f A6 !n AE !v B6 !> BE
!g A7 !o AF !w B7 !? BF

$@ C0 $H C8 $P D0 $X D8
$A C1 $I C9 $Q D1 $Y DD
$B C2 $J CA $R D2 $Z DA
$C C3 $K CB $S D3 $[ DB

482
 Program Codes

$D C4 $L CC $T D4 $\ DC
$E C5 $M CD $U D5 $] DD
$F C6 $N CE $V D6 $^ DE
$G C7 $O CF $W D7 $_ DF

$` E0 $h E8 $p F0 $x F8
$a E1 $I E9 $q F1 $y F9
$b E2 $j EA $r F2 $z FA
$c E3 $k EB $s F3 $; FB
$d E4 $l EC $t F4 $< FC
$e E5 $m ED $u F5 $= FD
$f E6 $n EE $v F6 $> FE
$g E7 $o EF $w F7 $? FF

483
Program Codes

484
Automated Plasma Interface
The following information outlines features relates to automated plasma supply functions and
diagnostics. These systems require communication between the CNC and the relevant plasma power
supply.
HPR and HD4070 Interface
Hypertherm Automation controls offer the additional option of interfacing directly to a Hypertherm
HPR and HD4070 HyDefinition Power Supplies for setup. Note: MicroEdge and Edge II controls can
be operated in Voyager mode to add this feature. This feature has the ability to improve the ease of
power supply setup and operational accuracy, while having the flexibility to fine tune the process
specific to the operator’s needs.
When using this advanced feature, all necessary power supply settings are transmitted from the control
directly to the Plasma Supply configuring it for use via serial communications. The Plasma Supply setup
is performed through the use of a Cut Chart (cut process parameter database) which is based on eight
process variables. The combination of these eight process variables are tied to the settings for the cut
process parameters (e.g. arc voltage, pierce delay, etc.) that are transmitted to the supply. For additional
convenience, consumable part numbers for the Plasma supply are displayed at the Change Consumable
screen.
This database allows the user to select factory recommended settings or amend the database for
personalized settings. The Cut Chart information may be saved or loaded via the hard drive or floppy
drive. The Cut Chart files containing the factory recommended settings are available from Hypertherm.
Access to the Cut Chart data is available from the Plasma Cut Types or Marker Cut Types screen using
the shift key, as indicated below. The Plasma Supply parameters must first be enabled in the password
protected Station Configuration setups to allow the Cut Chart Information for the Plasma Supply to be
available for use.

Note: Screen information will vary depending on the THC that is selected.

485
Automated Plasma Interface

Cut Charts

The Cut Chart Database contains the cut process parameters that the CNC transmits to the power supply.
Each cut chart is based on the following process variables:
• Torch type
• Material type
• Specific material
• Process current
• Plasma/shield Gas
• Material thickness
Depending on the power supply that you have selected, there may be other basic parameters, as well.
The default cut charts that are loaded into the system at the factory, provide values for all remaining
parameters for the cut chart and these are displayed on the right of the Cut Chart screen. You can edit
the values for these parameters and save them in an edited cut chart. The default cut charts are
distinguished by their .fac file extension. Files that you or other users edit have a .usr file extension.
Torch Type
Select a torch for your power supply.

486
 Automated Plasma Interface

Material Type
Select the type of material for this cut chart; mild steel, stainless steel, or aluminum.

Specific Material
Select a custom database from the dropdown list.
You can also use this field to create or modify a custom database of characteristics of the material type.
For more information, see Custom Cut Charts.

Process Current
Enter the appropriate current setting for the material thickness and material type that you selected.

Plasma / Shield Gases

Select the appropriate plasma and shield gases for the process.

Material Thickness
Select the thickness of the material.
The following are the Cut Process parameters within the database which are used to configure the
process. Appropriate parameter information is transmitted to the power supply.

Preflow Setting
Select the appropriate plasma and shield preflow percentages for the process.

Cutflow Setting
Select the appropriate plasma and shield cutflow percentages for the process.

Cut Speed
Specifies the speed for the selected process variables.

Kerf
Specifies the amount of kerf that is applied to the current part program.

Pierce Time
Specifies the time delay from when torch completes lowering until motion is initiated at Creep Speed.
Used to allow the plasma torch to completely pierce the material before moving.

Cut Height Delay

Specifies, in seconds, the delay between moving from pierce height to cut height while X and Y motion
advances.

Creep Time
Specifies the amount of time after piercing the part that the torch travels at Creep Speed. Creep Speed is
determined by a setup parameter at the Speeds setup screen and is a percentage of the programmed cut
speed. After the creep time is completed, the control accelerates to full cut speed.

487
Automated Plasma Interface

Cut Height
Specifies the height of the torch from the plate during cutting.

Transfer Height
Species the height of the torch from the plate during transfers. Transfer height allows for a higher pierce
height by initiating the transfer at a lower height than moving to pierce height, away from pierce dross.
This value can be entered as a percentage of the cut height or as an actual transfer height distance.

Pierce Height
Specifies the height of the torch during pierces. This value can be entered as a percentage of the cut
height or an actual pierce height distance.

Set Arc Voltage

Enter the arc voltage for the material that has been selected.

Set Arc Current

Enter the number of amps for the material that has been selected. This field is not supported on all
plasma supplies.

Preflow Time
Specifies the amount of time the Preflow gases are on.

Purge Time
Specifies the time delay from torch ignition until motion is enabled.

Save Process
Press the Save Process soft key to save the current process settings to the hard drive and create a custom
user database based on the process variables selected.

Reset Process
Press the Reset Process soft key to reset the current settings to factory recommend factory defaults based
on the process variables selected.

Save Cut Charts

Press the Save Cut Charts soft key to save the current user and factory databases to a diskette or USB
memory stick. The default, factory files have a .fac file extension. Files that can be edited have a .usr
file extension.
Examples of default and user-edited file names.
Mild Steel-HT4400-HD4070.fac
Mild Steel-HT4400-HD4070.usr

488
 Automated Plasma Interface

Load Cut Charts

Press the load Cut Charts soft key to load the factory default database files which are supplied by
Hypertherm in a text file (.txt), user files (.usr) or factory files (.fac) from a diskette or USB memory
stick.
Factory text file names.
Mild Steel Cut Chart Data mschart.txt
Aluminum Cut Chart Data alchart.txt
Stainless Steel Cut Chart Data sschart.txt
The database should be updated through the control rather than the Power Supply if the serial
communications link is enabled.

Test Preflow
Pressing the Test Preflow soft key performs the Test Preflow Gases feature at the Plasma supply.

Test Cutflow
Pressing the Test Cutflow soft key performs the Test Cutflow Gases feature at the Plasma supply.

Notes:
• Refer to the power supply operator’s manual for complete information on the operation and setup of
the plasma supply.
• A serial communications port for the plasma supply must first be selected at the Port configuration
screen to enable the feature for use.
• The plasma supply parameters must first be enabled in the password protected Station Configuration
screen to allow the cut chart information for the plasma supply to be available.
• Power Supplies equipped with the integrated Command THC may be used with the control setups.
The Command THC must first be enabled for use in the password protected Station Configuration
Screen.

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Custom Cut Charts

Custom cut charts are enabled on the Special password screen. In the Status/Feature table, select Allow
for Adding Processes, Removing Processes, and Changing Processes.

To create a custom cut chart:

1. Select an existing entry in the Specific Material dropdown list to copy as the basis for your new cut
chart. To simplify the process, select an entry that is similar to the cut chart you want to create.

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None is the factory default value for this parameter. If it is the only option, no custom cut charts
have been created.
2. Double-click on the message in blue at the bottom of the screen.
3. Press or click Add on the message popup.
4. Enter the name of the new specific material on the online keyboard and press or click OK.

The name that you enter appears in the Specific Material dropdown list. All other values are copied to
this new custom chart from the original cut chart that you selected.
5. To add a value in the Process Current dropdown list, open the list and double click on the message
in blue at the bottom of the screen.
a. Press or click Add on the message popup.
b. Enter the new value on the online keyboard and press or click OK.
To remove a process current as an option in the custom cut chart, select it from the dropdown list,
and double click on the message in blue at the bottom of the screen.
a. Press or click Remove on the message popup.
b. Press or click Yes to confirm the removal.
6. To add a pair of process/shield gasses, open the list and double click on the message in blue at the
bottom of the screen.
a. Press or click Add on the message popup.
b. Select the new plasma/shield pair from the dropdown list and press or click OK.
To remove a pair of plasma/shield gasses as an option in the custom cut chart, select it from the
dropdown list, and double click on the message in blue at the bottom of the screen.

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a. Press or click Remove on the message popup.

b. Press or click Yes to confirm the removal.
7. To add a material thickness, open the list and double click on the message in blue at the bottom of
the screen.
a. Press or click Add on the message popup.
b. Select the new thickness from the dropdown list and press or click OK.
To remove a thickness as an option in the custom cut chart, select it from the dropdown list, and
double click on the message in blue at the bottom of the screen.
a. Press or click Remove on the message popup.
b. Press or click Yes to confirm the removal.
8. Change the remaining values on the right of the screen as necessary to accommodate the process
changes you just made for the custom cut chart.
9. To save the new, custom cut chart, press or click Save Cut Chart.
Press or click Yes on the next two confirmation message popups.
10. To use a custom cut chart, select it from the Special Material dropdown list on the Cut Chart screen
or in the CutPro wizard:

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Change Consumable

When the power supply link feature has been enabled, consumable data information may be viewed at
the Change Consumable screen.

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I/O and Diagnostics

Power supply I/O and remote diagnostics screens are accessed through the standard Diagnostic screen
after serial link communications has been established. Status for the supply Software Revisions, Gas
Pressure, Usage, I/O and Remote tools will be available.

Information
Status items for the supply are available at the Information Screen.
HD4070 Diagnostics

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 Automated Plasma Interface

HPR Diagnostics

Test Preflow
Press the Test Preflow soft key to perform the Test Preflow Gases feature at the power supply. This
feature is used to set the inlet gas pressures under normal flow conditions to the recommended level.

Test Cutflow
Press the Test Cutflow soft key to perform the Test Cutflow Gases feature at the power supply. This
feature is used to set the inlet gas pressures under normal flow conditions to the recommended level.

Test HPR Gas Console

This feature provides automated test features for the HPR AutoGas console. Please contact an
authorized service agent for use of these tests.

Coolant Override
Pressing the Coolant Override soft key allows to user to override a coolant error and to test the coolant
pump. This is useful to bypass the error and purge the coolant line of air bubbles at initial power up.

Update Software
Pressing the Update Software soft key will initiate the process of the Software Update at the power
supply. Step by step instructions will be displayed on screen to guide the user through the process.

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Inputs

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Inputs

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Outputs

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Outputs

Note: Similar to the standard Output Diagnostic screen, the output screen shows the current status of the
listed supply outputs. Note: Outputs for the supply cannot be activated through the diagnostic screen.
Serial Communication Interface

RS-422C Connections to HPR CNC Interface

Control (male) Supply (male)
Signal Name DB-9 Pin Signal Name DB-37 Pin
TxD- 2 RxD- 1
RxD- 3 TxD- 2
TxD+ 4 RxD+ 20
RxD+ 7 TxD+ 21

RS-422C Connections to HD4070 CNC Interface

Control (male) Supply (male)
Signal Name DB-9 Pin Signal Name DB-37 Pin
TxD- 2 RxD- 2
RxD- 3 TxD- 1
TxD+ 4 RxD+ 21
RxD+ 7 TxD+ 20

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Multiple Supplies
The Serial Communication Link supported by the CNC can also be extended to multiple power supplies.
This unique feature is implemented through the use of the serial link and I/O points. It is assumed that
the all systems are configured similarly and will be used simultaneously. If any of the selected power
supplies has a fault, the fault must be cleared before the cut can begin.
Specific hardware and software versions for both the control and the power supply are required. Please
refer to the power supply manual for additional information on operation and installation.

Inputs and Outputs

Raise 1-4 and Lower 1-4

The Raise / Lower inputs will be used to control the Integrated Command THC lifters on multi-dropped
supplies for the selected process.
Note: When using this feature with the Sensor THCs rather than the Integrated Command THCs, the
Sensor THC Torch Raise and Torch Lower commands for the selected process may be made through the
software soft keys or through the use of these external inputs to the control.

Cut Sense 1-4

THC Cut Sense Input (arc on feedback) is used to verify that the plasma torch or marker tool has
established the arc for the selected torch. This indicates to the control that motion can begin.

Ready to Fire PS 1-4

This signal is an output from each supply and is used in multiple plasma systems. It notifies the CNC
that the THC has completed the IHS cycle and Preflow is complete. This indicates that the torch is ready
to fire. On the supply this signal is used along with the CNC Plasma Sync Input. The CNC Hold Ignition
output is connected to the supply “CNC Plasma Sync” inputs. When all configured supplies return
active “Ready to Fire” signals, the “Hold Ignition” signals are removed.

Hold Ignition
The Hold Ignition Output is used to delay ignition of the external plasma supply and allow the
individual supplies to complete Preflow and IHS before torch ignition. For this application, the Hold
Ignition would be tied to the Plasma Sync Inputs for multi-dropped supplies.

Reduce Current
Used with the supply to switch the plasma to low current mode. This signal is functionally different
from the Torch Height Disable Output in that it is not active during the initial torch ignition, pierce, and
accelerate to speed after Plasma Start. For this application, the Reduced Current output would be tied to
the Corner Hold Inputs for multi-dropped power supplies.
The Corner Current Parameter located on the Plasma Setup Screen, is a user defined value for setting the
percentage of the corner current.
Note: Proper multi-drop operation requires a Rev C or higher breakout board in the HD4070, as well as
Rev K or higher control software in the HD4070.

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RS-422 Multidrop Interface to Multiple power supplies

CNC Controller HD4070

Torch #1
Interlock Interlock ID = 0
Cut Sense 1,2 Determined
Transfer
Rdy to Fire 1, 2 by DIP
Ready to Fire switch
Hold Ignition
Plasma Sync
Reduce Current
Corner Hold

Torch #2
Plasma Start 1, 2
System Start
RS422 RX RS422 TX
RS422 TX RS422 RX

HD4070

Torch #1
Interlock ID = 1
Cut Sense 3, Transfer Determined
by DIP
Rdy to Fire 3, Ready to Fire
switch
Plasma Sync

Torch #2
Corner Hold
System Start Termination
RS422 TX Resistor by
DIP switch
RS422 RX

Raise 1
Supply #1 Note:
Lower 1
Active Torch
determined by
Raise 2 selected
Supply #2
Lower 2 process

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HPR and HD4070 Part Program Support

The same Cut Chart data which is used at the Cut Chart setup screen may also be used within a part
program to configure the power supply for use. This code is used to select the set point for each
variable.
It is not necessary to have a line of code for each Cut Chart variable within a part program. Only those
variables which are changing need be inserted into the part program (e.g. Material Thickness or Material
Type).
Part program codes for the power supply should be grouped together at the beginning of the program.
The three variables which may be set through the part program are Material Type, Current Setting and
Material Thickness.
Cut parameters for the power supply may be configured using the EIA-274D G59 code with the
following format.
Example: G59 V503 F5

Misc. G Code
Variable Identity

V503 – Material Type Plasma 1

V513 – Material Type Plasma 2
V523 – Material Type Marker 1
V533 – Material Type Marker 2

V504 – Current Setting Plasma 1

V514 – Current Setting Plasma 2
V524 – Current Setting Marker 1
V534 – Current Setting Marker 2

V507 – Material Thickness Plasma 1

V517 – Material Thickness Plasma 2
V527 – Material Thickness Marker 1
V537 – Material Thickness Marker 2

Variable Value

V503, V513, V523, V533 – Material Type

Add .0x for Specific Material x (for example: V503 F1 .01 for mild steel, specific material 1)
1 = Mild Steel
2 = Stainless Steel
3 = Aluminum

V504, V514, V524, 534 – Current Setting

7 = 7A 70 = 70A
10 = 10A 80 = 80A
15 = 15A 100 = 100A
18 = 18A 130 = 130A
30 = 30A 200 = 200A
45 = 45A

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 Automated Plasma Interface

V507, 517, 527, 537 – Material Thickness

EIA Number Gauge and Fraction Decimal Metric

1 None None None
2 or 3 28GA 0.015” 0.35mm
4 or 5 27GA 0.016” 0.4mm
6 or 7 26GA 0.018” 0.5mm
8 or 9 24GA 0.024” 0.6mm
10 or 11 22GA 0.030” 0.8mm
12 or 13 20GA 0.036” 0.9mm
14 19GA 0.040” 1mm
15 or 16 18GA 0.048” 1.2mm
17 or 18 16GA 0.060” 1.5mm
19 1/16” 0.063” 1.6mm
20 or 21 14GA 0.075” 2mm
47 13GA 0.090” 2.2mm
22 3/32” 0.094” 2.4mm
23 or 24 12GA 0.105” 2.5mm
48 11GA 0.120” 3mm
25 1/8” 0.125” 3.2mm
26 or 27 10GA 0.135” 3.5mm
49 9GA 0.150” 3.8mm
52 8GA 0.164” 4mm
50 7GA 0.180” 4.5mm
28 3/16” 0.188” 4.8mm
53 6GA 0.194” 5mm
51 5GA 0.210” 5.5mm
29 1/4” 0.25” 6mm
30 5/16” 0.313” 8mm
31 3/8” 0.375” 10mm
32 7/16” 0.438” 11mm
33 1/2” 0.5” 12mm
34 9/16” 0.563” 14mm
35 5/8” 0.625” 15mm
36 3/4” 0.75” 20mm
37 7/8” 0.875” 22mm
38 1” 1” 25mm
39 1 1/8” 1.125” 30mm
40 1 1/4” 1.25” 32mm
41 1 3/8” 1.375” 35mm
42 1 1/2” 1.5” 38mm
54 1 5/8” 1.625” 40mm
43 1 3/4” 1.75” 45mm
55 1 7/8” 1.875” 48mm
44 2” 2” 50mm
56 2 1/8” 2.125” 55mm
45 2 1/4” 2.25” 60mm
46 2 1/2” 2.5” 65mm

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Automated Plasma Interface

HD3070 Auto Gas Interface

This section outlines information specific to the Hypertherm HD3070 auto gas interface. The Auto Gas
screen is available from the Cut Types screen.
Note: The Auto Gas feature must first be enabled at the Special Password screen and is designed for use
with the six valve autogas console only

The top of the Auto Gas screen lists the valve parameter settings for the HD3070. Valve settings for the
3070 Auto Gas console are documented in the HD3070 manual. When the values are set, these become
the current setting and the operator can choose to save the file to the diskette, USB memory or hard
drive.
The settings at the supply are updated at control power up, whenever the settings are changed at this
screen or through commands in a part program. Supply settings are also updated if power is lost and re-
enabled at the power supply. There may be a brief delay as these power supply settings are
communicated from the control to the power supply.

Save Data
Pressing the Save Data soft key will allow the operator to save the current autogases setting to diskette,
USB memory or hard drive for future use.

Load Data
Press the Load Data soft key to allow the operator to Load stored autogases setting from diskette, USB
memory or hard drive.

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 Automated Plasma Interface

If you save the data, a file is created with G59 codes with the selected valve settings. Here is an
example of the data file where all percentages are set to zero.
G59 V65 B0
G59 V66 B0
G59 V67 B0
G59 V68 B0
G59 V69 B0
G59 V70 B0
G59 V71 B0
Test Cutting Gases
Pressing the Test Cutting Gases soft key allows the operator to test the HD3070 Cut Gases.

Test Preflow Gases

Pressing the Test Preflow Gases soft key allows the operator to test the HD3070 Preflow Gases.

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Automated Plasma Interface

HD3070 Auto Gas I/O

The Interface to the HD3070 Auto Gas console is made through use of Single Ended and BCD (Binary
Coded Decimal) inputs. The BCD style of interface allows for exact settings by use of multiple inputs
being active at any time. The active BCD input values are summed together to obtain the exact set
point.
These I/O points are wired in the same fashion as our other Single Ended I/O points. The following I/O
points are supplied for use with the HD3070 Auto Gas Console

Inputs
Gas Control Read Complete
Gas Control Error

Outputs
Gas Control Write Remote Test Operate
Remote Test Preflow Remote Air Plasma
Remote H35/ N2 Plasma Remote O2 Plasma
Gas Flow Set 1-100 (BCD) Valve Select 1-8 (BCD)

HD3070 Part Program Support

The same valve setting data which is used at the Auto Gas setup screen may also be used within a part
program to configure the HD3070 for use. This code is used to select the valve and indicate the valve
set point.
Using a EIA-274D G59 code with the following format.
Example: G59 V65 B5

Misc. G Code
Valve Identity
V65 = Preflow Shield Gas - Valve 1
V66 = Preflow Shield Gas - Valve 2
V67 = Cut Shield Gas - Valve 3
V68 = Cut Shield Gas - Valve 4
V69 = Cut Plasma Gas - Valve 5
V70 = Cut Plasma Gas - Valve 6
V71 = Remote Plasma Gas Type

Valve Value
For Valves V65 – V70
A whole integer is used to set the desired percentage value.
For Valve 71
0 = Oxygen
1 = H35/N2
2 = Air

For the example given, the part program code (G59 V65 B5) would set the Autogas Preflow Shield Gas
valve to 5%. Multiple G59 codes can be used to set and adjust the all desired valves.

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 Automated Plasma Interface

FineLine Overview
Hypertherm Automation controls offer the additional option of interfacing directly to INNERLOGIC’s
FineLine Power Supply for setup via a user selected RS-422 serial port. This advanced feature transmits
all necessary power supply settings from the control directly to the FineLine power supply configuring it
for use.
The power supply setup is performed through the use of a Cut Chart (cut process parameter database)
which is based on eight process variables. The combination of these eight process variables are tied to
the settings for the cut process parameters (e.g. arc voltage, pierce delay, etc.) that are transmitted to the
supply. For additional convenience, consumable part numbers for the FineLine are displayed at the
Change Consumable screen.
This database allows the user to select factory recommended settings or amend the database for
personalized settings. The Cut Chart information may be saved or loaded via the hard drive or floppy
drive. Specialized Cut Chart files containing the factory recommended settings are available from the
control vendor.
The Power Supply parameter must first be enabled in the password protected Station Configuration
setups to allow the Cut Chart Information for the feature to be enabled for use. Once selected at the
Station Configurations screen, the port must then be selected for communications on the Ports setup
screen and the selected port must then be configured as RS-422. For more information on configuration
of the port, refer to the Ports information section of this guide.
Station Configuration

Access to the FineLine Cut Chart data is available from the Plasma Cut Types or Marker Cut Types
screen using the shift key, as indicated below.

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Automated Plasma Interface

Note: Screen information will vary depending on THC selection.

Cut Chart

The Cut Chart Database (cut process parameters) transmitted to the power supply is based on the
following eight process variables.

Material Type
The Material Type, such as Mild Steel, Stainless Steel or Aluminum, may be selected.

Specific Material
A custom database from the dropdown list may be selected. The factory default is None.

Current Settings
The appropriate current setting for the material thickness and material type may be selected.

Plasma / Shield Gases

The appropriate Plasma / Shield gases for the desired process may be selected.

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 Automated Plasma Interface

Material Thickness
The desired material thickness may be selected.
The following are the Cut Process parameters within the database which are used to configure the power
supply. Appropriate parameter information is transmitted to the power supply.
• Material Type – Mild Steel, Stainless Steel, Aluminum, or Mild Steel (Cold Rolled).
• Thickness
• Set Current
• Pierce Delay
• Set Preflow Pressure
• Set Plasma Gas type
• Set Plasma Pressure
• Set Shield Gas Type
• Set Shield Pressure
• Set Process (Cut/Mark)
The following items are stored in the Cut Chart Data file and will be automatically updated on the
control.

Cut Speed
Specifies the speed for the selected process variables.

Kerf
Specifies the amount of kerf (cutter compensation) that will be applied to the current part program.

Preflow Time
Specifies the amount of time the Preflow gases are on.

Purge Time
Specifies the time delay from torch ignition until motion is enabled.

Pierce Time
Specifies the time delay from when torch completes lowering until motion is initiated at Creep Speed.
Used to allow the plasma torch to completely pierce the material before moving.

Creep Time
Specifies the amount of time after piercing the part that the torch travels at Creep Speed. Creep Speed is
determined by a setup parameter at the Speeds setup screen and is a percentage of the programmed cut
speed. After the Creep Time is completed, the control accelerates to full cut speed.

Database Features

Save Process
Pressing the Save Process soft key allows the user to save the current process settings to the Hard drive
creating a custom user database based on the eight process variables selected.

Reset Process

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Automated Plasma Interface

Pressing the Reset Process soft key allows the user to reset the current settings to factory recommend
factory defaults based on the eight process variables selected.

Save Cut Charts

Pressing the Save Cut Charts soft key allows the user to save the current User and Factory databases to
Diskette or USB memory stick. User files are designated with a .usr file extension and the factory files
are designated with a .fac file extension
Examples of user and factory file names.
Mild Steel-Fineline200-Fineline200.usr
Mild Steel- Fineline200-Fineline200.fac

Load Cut Charts

Pressing the load Cut Charts soft key allows the user to the factory default database files which are
supplied by Hypertherm as a user files (.usr) or factory files (.fac) from Diskette or USB memory stick.
It is recommended that the Database be updated through the control rather than the Power Supply if the
serial communications link is enabled.

Test Preflow
Pressing the Test Preflow soft key performs the Test Preflow Gases feature at the HD4070 Power
supply.

Test Cutflow
Pressing the Test Cutflow soft key performs the Test Cutflow Gases feature at the HD4070 Power
supply.

Notes:
• Refer to the power supply operator’s manual for complete information on the operation and setup of
the FineLine Power Supply.
• The FineLine Power Supply parameters must first be enabled in the password protected Station
Configuration Screen to allow the Cut Chart Information for the FineLine to be available for use.
• Serial communications for the FineLine Power supply are established on the user select
communication port. The port must be configured for RS-422 operation.

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Change Consumable

When the FineLine feature has been enabled, consumable data information may be viewed at the
Change Consumable screen.

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FineLine Part Program Support

The same Cut Chart data which is used at the Cut Chart setup screen may also be used within a part
program to configure the FineLine for use. This code is used to select the set point for each variable.
It is not necessary to have a line of code for each Cut Chart variable within a part program. Only those
variables which are changing need be inserted into the part program (e.g. Material Thickness or Material
Type).
Part program codes for the FineLine should be grouped together at the beginning of the program. The
three variables which may be set through the part program are Material Type, Current Setting and
Material Thickness.
Cut parameters for the FineLine may be configured using an EIA-274D G59 code with the following
format.
Example: G59 V503 F5

Misc. G Code
Variable Identity

V503 – Material Type Plasma 1

V513 – Material Type Plasma 2
V523 – Material Type Marker 1
V533 – Material Type Marker 2

V504 – Current Setting Plasma 1

V514 – Current Setting Plasma 2
V524 – Current Setting Marker 1
V534 – Current Setting Marker 2

V507 – Material Thickness Plasma 1

V517 – Material Thickness Plasma 2
V527 – Material Thickness Marker 1
V537 – Material Thickness Marker 2

Variable Value

V503, V513, V523, V533 – Material Type

Add .0x for Specific Material x (for example: V503 F1 .01 for mild steel, specific material 1)

1 = Mild Steel
2 = Stainless Steel
3 = Aluminum

V504, V514, V524, 534 – Current Setting

8 = 8A 50 = 50A
9 = 9A 70 = 70A
10 = 10A 100 = 100A
30 = 30A 200 = 200A

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V507, 517, 527, 537 – Material Thickness

EIA Number Gauge and Fraction Decimal Metric

1 None None None
2 or 3 28GA 0.015” 0.35mm
4 or 5 27GA 0.016” 0.4mm
6 or 7 26GA 0.018” 0.5mm
8 or 9 24GA 0.024” 0.6mm
10 or 11 22GA 0.030” 0.8mm
12 or 13 20GA 0.036” 0.9mm
14 19GA 0.040” 1mm
15 or 16 18GA 0.048” 1.2mm
17 or 18 16GA 0.060” 1.5mm
19 1/16” 0.063” 1.6mm
20 or 21 14GA 0.075” 2mm
47 13GA 0.090” 2.2mm
22 3/32” 0.094” 2.4mm
23 or 24 12GA 0.105” 2.5mm
48 11GA 0.120” 3mm
25 1/8” 0.125” 3.2mm
26 or 27 10GA 0.135” 3.5mm
49 9GA 0.150” 3.8mm
52 8GA 0.164” 4mm
50 7GA 0.180” 4.5mm
28 3/16” 0.188” 4.8mm
53 6GA 0.194” 5mm
51 5GA 0.210” 5.5mm
29 1/4” 0.25” 6mm
30 5/16” 0.313” 8mm
31 3/8” 0.375” 10mm
32 7/16” 0.438” 11mm
33 1/2” 0.5” 12mm
34 9/16” 0.563” 14mm
35 5/8” 0.625” 15mm
36 3/4” 0.75” 20mm
37 7/8” 0.875” 22mm
38 1” 1” 25mm
39 1 1/8” 1.125” 30mm
40 1 1/4” 1.25” 32mm
41 1 3/8” 1.375” 35mm
42 1 1/2” 1.5” 38mm
54 1 5/8” 1.625” 40mm
43 1 3/4” 1.75” 45mm
55 1 7/8” 1.875” 48mm
44 2” 2” 50mm
56 2 1/8” 2.125” 55mm
45 2 1/4” 2.25” 60mm
46 2 1/2” 2.5” 65mm

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514
Serial Ports
Both of the serial ports that are provided are shipped in the RS-232C wiring
configuration. To change either port to an RS-422 configuration, you must change a
jumper setting on the Serial Isolation Board that is inside the CNC on the back panel.
Find the appropriate jumper for the desired port at the bottom of the board and move the
jumper from the RS-232C position to the RS-422 position. These positions are clearly
marked on the board.

Warning! Configure the port for RS-422 operation before connecting RS-422
compatible devises.

The serial ports in the CNC are specifically designed to operate with a standard nine-pin
serial port connector. Specifications for these ports are as follows:

Channel Type Optically Isolated RS-232C or RS-422.

Information Code ASCII
Baud Rate User-selectable up to 115.2K baud.
Number of Start Bits 1
Number or Stop Bits 1
Word Length User selectable 7 or 8 bits.
Parity User-selectable None, Even or Odd.
Data Synchronization XON (Control-Q) / XOFF (Control-S).
Time Out User-selectable in one-second increments.
Transmit Delay User-selectable in one one/hundredths of a second
increments.
Rear Panel Connector IBM-PC/AT compatible 9-pin D-type female.

Control RS-232C DB-9 Pinout

Pin Signal Name Description
1 Shield Chassis ground
2 TxD Transmit data to external device
3 RxD Receive data from external device
4 No connection
5 Common Ground
6 No connection
7 No connection
8 No connection
9 No Connection

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Serial Ports

RS-232C Connections to Host PC with 9-pin D-type connector

Host PC Control
Signal Name DB-9 Pin Signal Name DB-9 Pin
Shield 1 Shield 1
RxD 2 TxD 2
TxD 3 RxD 3
Common 5 Common 5

RS-232C Connections to Host PC with 25-pin D-type connector

Host PC Control
Signal Name DB-25 Pin Signal Name DB-9 Pin
Shield 1 Shield N/C
RxD 3 TxD 2
TxD 2 RxD 3
Common 7 Common 5

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 Automatic DXF Import

Automatic DXF Import

Overview
Hypertherm Automation controls offer two styles of automated DXF import. The first
DXF feature allows the CAD designer to prepare a DXF file that includes the location of
pierces, pierce order and direction. When this file is loaded into the control, an EIA
format part program will be created for use at the control.

The second type of DXF file is a fully automatic DXF import feature that allows the
control operator to select lead style and length. The CNC Auto DXF software
automatically places the lead-in and lead-out based on the operator selections and creates
an EIA format part program ready for use and the CNC.

Load DXF Files

To load a DXF file, access the Files Load screen and select the source location and file.

If the file includes the lead-in and direction, the control detects this and translates the file
for use. For more information, see Prepared DXF Files.

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Automatic DXF Import

If the file contains no pierce or lead-in /lead-out information, the HyperDxf utility
prompts the user for this information. For more information, see Raw DXF Files.

Note: To load DXF files the DXF extension must first be added to the Special Setups
screen.
Raw DXF Files
If the control does not detect pierce information in the DXF file, the operator has the
option to use the Hyper DXF translation utility to import the file and add - and lead-out
information.

If the user selects YES, a configuration screen displays fields to define the lead-in/ lead-
out format.

Lead Type
Select a Straight or Radius lead-in or lead-out.

Length / Radius
Select the lead-in or lead-out length or radius.

Angle

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 Automatic DXF Import

Select angle in degrees for lead-in or lead-out.

Auto Position Lead-in

If this box is checked, the software attempts to find a suitable corner for the lead-in.

Auto Corner Align Lead-in

If this box is checked, the software attempts to find a suitable corner for the lead-in.

Inside Lead-out
If this box is checked, a lead-out is used on both internal and external cuts. If the box is
not checked, lead-outs are added to external cuts only.

Overburn
Overburn provides an overlapping cut in the lead-in/ lead-out area of a hole.
After import, an EIA part program with a .txt extension is created and placed in the
source folder. Note the BRKT1.dxf and BRKT1.txt in the following example.

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Automatic DXF Import

Prepared DXF Files

The DXF Translator software allows the control to load and translate a DXF style
drawing created in Autocad ® or Autocad LT® into an EIA part program. Certain
guidelines must be observed when creating the CAD drawing to allow the control to load
and understand the file. The optional DXF translation utility is enabled through a
password provided by your control supplier.

Drawing Format
There should be nothing on the cut layer except lines, arcs, circles and text commands.
Do not put dimensions or notes on the same layer as cut data.

Elliptical segments, squares and polylines are not supported. Divide these elements into
short arcs or line segments. You can use the ACAD EXPLODE command to convert
POLYLINES into segments.

The end angles of two arcs from any intersection point cannot be within the same
quadrant.

Text commands determine cut sequence, and determine the path through multi-segment
intersections. Text commands are placed on the drawing with the text feature of your
CAD program. The size of the text is not important. However, the location of the text is
extremely important. Text must be left justified and text commands must be “snapped to
the appropriate intersection or pierce points.

Text commands indicate pierce points and cut direction. Note that the directional
commands should only be used to determine the direction of the next line segment when
more than one exit path exists at an intersection of segments.

Text Commands
1 Indicates the first pierce point (subsequent pierce points follow in numerical order)
+ Indicates a Counter-Clockwise circle
- Indicates a Clockwise circle

Directional Commands
The following commands indicate the next segment’s direction, if it is a line, or the
ending angle, if it is an arc, if the angle is:

R 350° to 10°
RU 0° to 45°
UR 45° to 90°
U 80° to 100°
UL 90° to 135°
LU 135° to 180°
L 170° to 190°
LD 180° to 225°

520
 Automatic DXF Import

DL 225° to 270°
D 260° to 280°
DR 270° to 315°
RD 315° to 360°

Traverses are automatically determined between pierce points and do not need to be
entered on the CAD drawing.

The following example is a basic bolt hole rectangle with the lead-in and lead-out for the
rectangle as part of the top and side line segments. The numbers indicate the order of the
pierces and the “+” sign indicates a counter-clockwise rotation for the circles.

1 + 2 +

3 + 4 +

If the lead-in and lead-out are created as additional line segments added to the top and
side line segments, additional text is required to indicate which direction the next line
segment should take as part of the part program, as shown in the following diagram:

5 R

1 + 2 +

3 + 4 +

In this example, the letter “R” has been snapped to the intersection of the four line
segments to indicate that the next line segment after lead-in (pierce 5) would be the

521
Automatic DXF Import

segment which is located at 350 to 10 degrees and then to the other connected segments
on the square. After the left side (vertical) segment has been cut, no additional text is
required to indicate which line should be cut. The Lead-out segment is the only segment
left to cut because the lead-in and the first segment have already been cut.

Notes:
• There should be nothing on the cut layer except lines, arcs, circles and text /
directional commands.
• Line segments must be connected to complete the cut path.
• If multiple line segments or arcs need to be repeated, each line segment should be
drawn rather than copied and pasted.
• Features for marking are not available.
• No traverse lines are required. All lines in the CAD drawing are assumed to be cut
lines.
• Left kerf is assumed.

522
Networking
This chapter describes how to connect a CNC to a local area network and some of the issues that can
arise due to that connection. There are many different network configurations, so you may need to
consult a network technician.

Network Operating System

Note: The Network functions involve operational knowledge of Windows® XP operating system
and should only be performed by qualified personnel.

The Hypertherm Automation CNCs are designed to work with Microsoft domain- or workgroup-based
networks. These instructions assume a domain-based network. If you are connecting to a workgroup,
refer to Attaching to a Workgroup at the end of this chapter.

In each case, the CNC uses the local administrator account on the CNC. Local logon is required
because the system must have administrative rights on the CNC. You can map network connections to a
share on the host network using the user name provided by the network administrator. If the network
mapping is set to be re-established on power-up when it is created, it will automatically be set up when
the CNC is turned on.

Do not create user accounts on the CNC or try to have the CNC log in directly to your network domain.
The new user accounts create performance issues on the CNC. Use the local administrator account and
map your network drive as described in this chapter.

Configuring the Network Interface Card

To include the CNC on the network, you must attach a keyboard and mouse to the CNC so you can
configure the network interface card (NIC).

Notes:
• If a NIC is set up to use a DHCP server, but is not connected to a DHCP server, it can cause startup
delays and other problems.
• Only one NIC should be active on the CNC and be connected to the shared LAN.

Before you begin, you need to know:

• Whether you will be using a DHCP server on the network.

Note: The use of a DHCP server is recommended because it ensures that the TCP/IP settings are
correct.

If you are not using a DHCP Server, what are the TCP/IP network settings?

523
Networking

• IP address: _____________
• Subnet mask: _____________
• Default gateway: _____________
• Preferred DNS server _____________
• Alternate DNS server _____________

For more information about configuring TCP/IP settings, see Hardware Considerations.

• Will the controller be part of a Windows domain or workgroup?

• What is the name of the domain or workgroup?
• Has the operator’s user name and password been added to the server?

Connecting the CNC to a Network

To attach the CNC to the network:

1. Create a user account on your network file server (Windows Server ). You will need to set up:
a. The user name, for example: operator.
b. The password for the new user name, for example: 1234
2. Attach the keyboard and mouse to the controller, and plug the fiber optic card into the fiber-to-
copper converter box, if the fiber connection is to be used.
3. Connect the LAN cable to the network connector on the converter box or to the CNC, as
appropriate.
4. Turn on the power to the CNC.
The CNC will power up and be connected to the network. You will be logged into the CNC as the
administrator. This is not the same as being an administrator on the LAN. At this point the CNC is
attached to the network and has an address but is not logged into the LAN.

Mapping a Connection to a Network Share

Note that the following procedure requires that the PC you are mapping be logged into the LAN

To map to a network share:

1. Press ALT+F4 to return to the Windows desktop.
2. From the Start menu select Windows Explorer.
3. Right-click on My Computer.

524
 Networking

4. Select Map Network Drive.

5. Select a letter for the drive from the Drive dropdown list.

6. Enter a path to the network share in the Folder field.

7. Select Reconnect at logon.

525
Networking

8. Click Finish.
You may see a prompt for the user name and password for your network server. If you are in a
domain system, enter it with your user name in the User name field (domain\username).

To access the share from the CNC software, press the Files soft key on the Main screen to map the
drive.
Note: Mapping must be enabled in the Phoenix software on the Special password setup screen.

526
 Networking

Use UNC format to perform the mapping.

9. Click OK.

Connecting the CNC to a Workgroup

The CNC is set up as a member of a workgroup. If you are going to connect the CNC to a workgroup,
the name of the workgroup must be changed to the name of the workgroup on the computer that shares
files with the CNC.

To connect to a workgroup:
1. Connect a keyboard and mouse to the CNC.
2. Press Alt + F4 to return to the Windows desktop.
3. Select Start > Settings > Control Panel.
4. Double-click on the System icon.

527
Networking

5. Select the Computer Name tab.

528
 Networking

6. Click Change.
7. Enter the name of your CNC in the Computer name field.
8. In the Member of group box, select Workgroup.
9. Enter the workgroup name of the computer with which you share files.

Use the procedure in Mapping a Connection to a Network Share to map to the shared directory on the
PC.

Hardware Considerations

If you are using a Hypertherm Automation CNC with the networking option included, it may be shipped
with a fiber optic network card installed. The operating system is set up to use DHCP to obtain the
required TCP/IP address. This setup allows the CNC to obtain all the necessary network settings
automatically when it is turned on and eliminates the need for a network administrator to keep manual
records of assigned IP addresses and insures that the address, net mask, DNS server, and gateway
addresses are automatically set to be compatible with your network.

If your network does not support DHCP, it will be necessary to go into the network setting screen and
change the TCP/IP settings by hand on the network settings screen to make the CNC compatible with
the network. To make these changes here involve attaching a keyboard and mouse to the CNC and
accessing the Windows XP network setup parameters.

529
Networking

1. Double-click on any network adapters that are not being used.

The Local Area Connection 2 Status window opens.

530
 Networking

2. Click Disable to prevent Windows from trying to service these unused adapters.

3. Click Close.
4. After you have disabled all the adapters that are not being used, double-click the network adapter
that is being used.

531
Networking

5. Click Properties.
The Connection Properties screen for the adapter you selected displays the features for its network
connection.

6. Select Internet Protocol (TCP/IP).

7. Click Properties.

532
 Networking

8. To use DHCP, leave the default settings.

If a DHCP server is not available, enter the TCP/IP address information in the IP address, Subnet
mask, and Default gateway fields. Note that you must provide a valid IP address that has not been
used elsewhere in the network.
In addition, enter the appropriate DNS server address information in the Preferred DNS server and
Alternate DNS server fields.

9. Click OK.

533
Networking

10. Verify that only one network card is active.

11. Reboot the system.

534
MicroEdge
Overview

The MicroEDGE™ PC based motion MicroEDGE™

control from Hypertherm Automation is
specifically for the metal cutting
industry. This control package provides
a unique combination of flexible table
configurations, expandable features and
an unparalleled ease of use.

MicroEDGE utilizes our proprietary

Graphical User Interface (GUI) and
SoftMotion Technology with motion
control operation of up to four axes with
24 I/O signals.

This product offers a unique approach to Rear View

the motion control market by allowing
custom configuration the final package
by adding a PC style Monitor, Keyboard
and Mouse.

Additional features such as Joystick,

Speed Pots, Integrated Sensor THC,
networking, CAD/CAM Software,
Nesting Software provide unlimited
combinations of options for increased
productivity.

Operation and maintenance of automated

equipment involves potential hazards.
Personnel should take precautions to
avoid injury. This equipment should only
be opened by trained service personnel.

535
MicroEdge

Keyboard Layout

Typical Keyboard Layout

Keyboard Functions
Function Keys F1-F8 are equivalent to the soft keys on the display screen.
Function Key F9 is equivalent to the START key.
Function Key F10 and Pause Key are equivalent to the STOP key.
Function Key F11 is equivalent to the MANUAL MODE key.
Function Key F12 is equivalent to the HELP key.
Arrow direction keys are used for manual motion.
The HOME key is equivalent to the PREV field key.
The END key is equivalent to the NEXT field key.
The [ key is equivalent to the purple arrow shift key.
The ] key is equivalent to the blue arrow shift key.
The Esc key is equivalent to the CANCEL key.
To exit the control software press Alt F4.
To switch between applications press Alt Tab.

A color coded key cap sticker set is provided to allow easy reference to the keys used by
the control software.

System Requirements
Monitor Requirements (CRT or LCD)
Standard VGA capable 1240 x780 analog monitors or better with 15 pin High Density D-
sub connector. Touch screen displays are also supported.

Keyboard Requirements
Standard 101/ 104 Key PS/2 or USB Compatible Keyboard

Optional Mouse Requirements

PS/2 or USB Compatible Mouse

536
 MicroEdge

THC, Joystick & Speedpots

Optional features for two Sensor THC, one Joystick and two Speedpots are offered.

Note: Use of some monitors and other devices may require loading of a device driver for
operation. Many standard device drivers are located in the C:\CABS or C:\CABS\I386
folders.

Machine Interface
The MicroEDGE shape cutting control is an extremely versatile product offering up to
four configurable axes of motion, configurable I/O locations and a convenient table
interface for ease of installation. The control features may also be expanded through use
of optional analog and network interface cards.

The rear panel of the control has several cable connectors to connect the control to power,
I/O and communication ports. These connectors are clearly labeled as to their function.

AC Input
The AC power cable is inserted into the AC power connector and plugged into a standard
3-way 110 or 220 volt outlet. The control has a universal AC input power module that
allows the user to plug into either voltage without changing additional jumpers. In
addition, the AC Power connector contains an integral fuse receptacle and line filter.

537
MicroEdge

A remote communications link can be connected to one of the two serial ports and an
external ground (PE) lug for earth grounding of the unit is also provided.

Serial Port
Please refer to the Ports Information section of the Installation Guide for additional
information on configuration of Serial ports for communication. Note: Serial ports for
the MicroEDGE are not optically isolated. Appropriate grounding or after market port
isolator or protocol converter to add optical isolation is recommended.
I/O Configuration
The cables that connect the control to the cutting machine are attached to the I/O
(Input/Output), and the DRIVE/ENCODER connectors. For the purposes of this guide
Single Ended I/O is referred to as Type “P” configuration.

The information provided here is the basic information for connection of the shape
cutting control to the cutting table. Each machine interface will vary slightly based on
the cutting table configuration and features. Additionally, I/O pinout information may
vary slightly based on the configuration of the selected I/O and their locations. Changes
to the I/O configuration may be made in the password protected I/O screen. All controls
are shipped with the default selection of Inputs and interface locations for the selected
control Interface (I/O) configuration. Installation and service should only be performed
by a qualified service technician.

I/O Connector

The I/O connector is a standard sex circular CPC connector from AMP. This connector
was specifically chosen for its rugged industrial design and its metal insulation
characteristics for EMI/RFI noise immunity.

In the single ended I/O scheme, a ground is provided on the I/O pin. The advantage to
single ended I/O is that it takes one pin for each point versus two for the double-ended
I/O scheme, thus increasing the total number of I/O points available to the user.

I/O Mating Connector

Connector AMP #208470-1
Backshell AMP #208945-8
Sockets (16-18 ga) AMP #66101-3
Sockets (20-24 ga) AMP #66105-3

538
 MicroEdge

I/O Interface
Connecting single ended I/O to the control. These examples assume a +24V power
supply has been connected across pins 34 and 36 of the control, or that the optional
internal +24V power supply has been installed.

Output tied to external Cut On Input tied to Cut Sense Relay

539
MicroEdge

Examples of possible circuits

Output

Input

540
 MicroEdge

Single Ended I/O Pinout

The Single Ended I/O offers 12 outputs which are rated at 24VDC for up to 1-amp loads
and 12 inputs rated for 24VDC.

Pin I/O Description

1 Input 1 Torch Up Sense
2 Input 2 Torch Down Sense
3 Input 3 Preheat Sense or X -Overtravel Switch
4 Input 4 Cut Sense
5 Input 5 Tracer on Path or Z Home Switch
6 Input 6 Spare or Y -Overtravel Switch
7 Input 7 Spare
8 Input 8 Spare or Remote Pause
9 Input 9 X Home Switch
10 Input 10 X Overtravel Switch or X +Overtravel Switch
11 Input 11 Y Home Switch
12 Input 12 Y Overtravel Switch or Y +Overtravel Switch
13 N/C No Connection
14 +24 VDC + I/O Power Supply
15 +24 VDC + I/O Power Supply
16 N/C No Connection
17 24V Common I/O Power Supply Common
18 24V Common I/O Power Supply Common
19 N/C No Connection
20 N/C No Connection
21 Output 1 Torch Up
22 Output 2 Torch Down
23 Output 3 Ignition Control
24 Output 4 Torch Height Disable/Dual Grid Control
25 Output 5 CNC/Tracer
26 Output 6 Marker Enable
27 Output 7 Cut Control
28 Output 8 Spare
29 Output 9 Spare or Low Preheat
30 Output 10 Preheat Control
31 Output 11 Key Press Indicator or Motion Indicator
32 Output 12 Spare or Plasma Select
33 I/O Shield Chassis Ground
34 +24 VDC +I/O Power Supply
35 +24 VDC +I/O Power Supply
36 24 V Common I/O Power Supply Common
37 24 V Common I/O Power Supply Common

541
MicroEdge

Drive/Encoder Connector
The Drive/Encoder connector is a reverse sex circular CPC connector from AMP. This
connector was specifically chosen for its rugged industrial design and its metal insulation
characteristics for EMI/RFI noise immunity.

NOTE: For optimum noise immunity, cable shields may be tied externally to the control
enclosure or to the metal AMP connectors.

Drive/Encoder Mating Connector and Cable

Connector AMP #208472-1
Backshell AMP #208945-8
Pins (16-18 ga) AMP #66099-3
Pins (20-24 ga) AMP #66103-3
Cabling: Use Belden # 9504 or equivalent for encoder signals
Cabling: Use Belden # 9501 or equivalent for drive signals

Axes Assignments

Axes Axes Assignment

1 (X) Transverse or Rail
2 (Y) Transverse or Rail
3 (Z) Dual Gantry, CBH, Rotate or THC
4 (W) CBH, Tilt or THC

542
 MicroEdge

Drive/Encoder Pinout
Pin Description
2 Encoder Power Supply Input (+5V or +12V*)
3 Encoder Power Supply Common
7 Encoder Power Supply Shield
8
*NOTE: For Rev A + B MCC’s +12V Encoders require a switch to be set on the
interface board.

X Axis Y Axis Description

4 1 Encoder Power Output
8 6 Encoder Power Common
9 5 Encoder Channel A input
14 11 Encoder Channel /A Input
15 10 Encoder Channel B Input
21 17 Encoder Channel /B Input
22 16 Encoder Channel Z Input
28 23 Encoder Channel /Z Input
13 12 Encoder Shields
24 26 Drive Enable In (relay contact)
25 27 Drive Enable Out (relay contact)
37 34 Drive Power Input (+12 or +15)
33 29 Servo Output (± 10V)
32 30 Drive Power Common
36 35 Drive Power Input (-12 or –15)
20 18 Servo Output Common
19 31 Drive/Servo Shield

Drive/Encoder Pinout (For 3 and 4 Axes units)

Pin Description
2 Encoder Power Supply Input (+5V or +12V)
3 Encoder Power Supply Common
7 Encoder Power Supply Shield

Z Axis W Axis Description

4 1 Encoder Power Output
8 6 Encoder Power Common
9 5 Encoder Channel A input
14 11 Encoder Channel /A Input
15 10 Encoder Channel B Input
21 17 Encoder Channel /B Input
22 16 Encoder Channel Z Input
28 23 Encoder Channel /Z Input
13 12 Encoder Shields
24 26 Drive Enable In (relay contact)
25 27 Drive Enable Out (relay contact)

543
MicroEdge

37 34 Drive Power Input (+12 or +15)

33 29 Servo Output (± 10V)
32 30 Drive Power Common
36 35 Drive Power Input (-12 or –15)
20 18 Servo Output Common
19 31 Drive/Servo Shield

THC and Joystick Interface

MicroEdge has dedicated connectors for THC 1, THC and Joystick / Speedpots.

Series 1 PCI Analog Card

Note: The Analog Card will be designated as PCI-AIC Rev A in the Control Information
Diagnostic screen.

Board Marking PCI Analog 1 Part # PCBS-0074

THC 1
Pin # Designation Description
1 Common Common
2 Input 5 + Nozzle Contact Sense + ( Relay Contact )
3 Input 5 – Nozzle Contact Sense - ( Relay Contact )
4 Output 1 + Nozzle Contact Enable + ( Relay Contact )
5 Output 1 – Nozzle Contact Enable - ( Relay Contact )
6 Analog Input 1 + THC +
7 Analog Input 1 – THC –
8 Output 2 + Hold Ignition ( Relay Contact )
9 Output 2 – Hold Ignition ( Relay Contact )
Ground Stud Shield

Mating Connector
Connector AMP #206708-1
Backshell AMP #206966-1
Sockets (20-24 ga) AMP #66105-3
Cabling: Use Belden # 9504 or equivalent

THC 2
Pin # Designation Description
1 Common Common
2 Input 6 + Nozzle Contact Sense + ( Relay Contact )
3 Input 6 – Nozzle Contact Sense – ( Relay Contact )
4 Output 3 + Nozzle Contact Enable + ( Relay Contact )
5 Output 3 – Nozzle Contact Enable – ( Relay Contact )
6 Analog Input 2 + THC +
7 Analog Input 2 – THC –
8 Output 4 + Hold Ignition ( Relay Contact )
9 Output 4 – Hold Ignition ( Relay Contact )
Ground Stud Shield

544
 MicroEdge

Mating Connector
Connector AMP #206708-1
Backshell AMP #206966-1
Sockets (20-24 ga) AMP #66105-3
Cabling: Use Belden # 9504 or equivalent

Joystick
Pin # Designation Description
1 Input 1 Joystick UP
2 Input 2 Joystick DWN
3 Input 3 Joystick LT
4 Input 4 Joystick RT
5 Common Common
6 Analog Input 3 + Speed Pot 1
7 Analog Input 3 – Speed Pot 1
8 Analog Input 4 + Speed Pot 2
9 Analog Input 4 – Speed Pot 2
Ground Stud Shield

Note: Joystick inputs are activated by passing the Common signal ( pin 5 ) to the desired
input.
Analog inputs for the speedpots are rated at 0 - +10VDC

Mating Connector
Connector AMP #206708-1
Backshell AMP #206966-1
Sockets (20-24 ga) AMP #66105-3
Cabling: Use Belden # 9504 or equivalent

THC and Joystick Cable Grounding

Cable shields should be tied to the external PE studs for optimum noise immunity.

545
MicroEdge

Sensor THC

This section refers to following hardware configuration. Note: The Analog Card will be
designated as Rev 0 in the Control Information Diagnostic screen.

Series 1 PCI Analog Card (Board Marking PCBS-0073) Part # PCBS-0074

Series 3 Voltage Divider Card Part # PCBS-0061

Instructions
If the voltage divider card has not been installed in the plasma power supply, mount the
card in an accessible location away from high electrical noise areas. Wire the VDC to the
appropriate signal inside the power supply as outlined in the following pinout information

Voltage Divider Card Pinout (Series 3)

Divider PCB - 2C Connector J1

Pin # Description
1 85 -265 VAC Power Input (47-63Hz)
2 285 -265 VAC Neutral Input

Mating Connector
2C Phoenix Connector – Phoenix Part # 1840366

Divider PCB - 8C Connector J2 To Control

Pin # Description
1 +24 VDC Common
2 +24 VDC
3 Nozzle Contact Sense
4 Nozzle Contact Enable
5 +24 VDC Common
6 Analog Out +
7 Analog Out –
8 E Ground

Mating Connector
8C Phoenix Connector – Phoenix Part # 1803633

Divider PCB - 5C Connector J3 to Power Supply / Table

Pin Number Description
1 Ground (Chassis Ground)
2 Electrode (Plasma DC –)
3 Work (Plasma DC +)
4 NC
5 Shield (Nozzle Contact)

546
 MicroEdge

Mating Connector
Terminal Connections
Control & Cable Pinout for Sensor THC

I/O Configuration Type “P”

Note: A 9C Amp connector is provided on the back of the control (I/O Type “P”) for
interfacing.

Control 9C Divider J2
Analog Pin # Description Pin #
1 24V Common 1
2 Nozzle Contact Sense + 2
3 Nozzle Contact Sense – 3
4 Nozzle Contact Enable + 4
5 Nozzle Contact Enable – 5
6 Analog + 6
7 Analog – 7
8 Hold Ignition + N/A (direct to power supply)*
9 Hold Ignition – N/A (direct to power supply)*
Ground Stud Shield No Connection

Analog Mating Connector

Connector AMP # 206708-1
Backshell AMP #206966-1
Sockets #66105-3 (20-24 ga)

VDC Mating Connector

8C Phoenix Connector – Phoenix Part # 1803633

Cable
Belden #9505 or equivalent

* Note: It is recommended that the Hold Ignition input be wired to the Power Supply
through an external relay for noise immunity. Please refer to Instructions from the supply
manufacturer for details on connection to the Hold Ignition Input.

547
MicroEdge

Calibration

Series 1 Analog Card

Note: The Series 1 Analog Card will be designated as Rev 0 in the Control Information
Diagnostic screen.

Board Marking PC-012-1098 Rev. B Part # PCBS-0010-B

After the voltage divider card and control cabling have been connected, the system is
ready to be calibrated for use.

Analog Offset: To adjust the Analog Offset, place a jumper on the Analog In signals on
the Analog input card or at the 9C connection for the Analog Input Card located at the
back of the control. The analog input voltage would then be viewed at the I/O
Diagnostics screen to read any incoming voltage for the THC. If any voltage is displayed
at the diagnostic screen, an Offset Voltage equal to the incoming voltage being read can
be entered at the Password protected Analog I/O screen to correct for any imbalance and
“zero” the incoming voltage

Example: If an incoming Analog Input Voltage is reading .1 volts, simply enter .1 at the
Analog Offset and correct the imbalance.

548
Edge Ti
Overview
The Edge Ti shape cutting control is an
extremely versatile product offering up to Edge Ti™
four configurable axes of motion, built-in
Servo Amplifiers and configurable I/O. Use
of built in relay contacts for I/O increases
interface options and minimizes external
interface components.

Hypertherm Automation PC based CNC

controls for the shape cutting industry utilize
our proprietary Graphical User Interface
(GUI), and SoftMotion Technology to
increase productivity, reduce operational
costs while providing unsurpassed operational
flexibility. The control features may be
further expanded through use of integrated
Sensor™ THC interface and networking

Touch Screen Rear View

The 15” display used in the Edge Ti is a
patented IntelliTouch Surface Wave
technology which provides precise drift free
touch accuracy and unsurpassed clarity. Pure
glass construction with tiny transducers on
the back of the touch screen preserves color
purity and works even if scratched. There is
no known wear out mechanism as there are
no layers, coatings or moving parts.
IntelliTouch technology has been tested by
the supplier for more than 50 million touches
in one location without failure.

THC, Joystick & Speedpots

Features for Joystick and Speedpots are
offered as standard. Optional features for
integrated Sensor THC are available.

Note: Use of some devices such as USB

memory devices may require loading of a
device driver for operation. Many standard
device drivers are located in the C:\CABS or
D:\CABS\I386 folders.
549
Edge Ti

Operation and maintenance of automated equipment involves potential hazards. Personnel

should take precautions to avoid injury. This equipment should only be opened by trained
service personnel.

Machine Interface
The information provided here is the basic information for connection of the shape
cutting control to the cutting table. Each machine interface will vary slightly based on
the cutting table configuration and features. Additionally, I/O pinout information may
vary slightly based on the configuration of the selected I/O and their locations. Changes
to the I/O configuration may be made in the password protected I/O screen. All controls
are shipped with a default selection of Inputs and interface locations for the selected
control Interface (I/O) configuration. Installation and service should only be performed
by a qualified service technician.

The rear panel of the control has several cable connectors to connect the control to power,
I/O and communication ports. These connectors are clearly labeled as to their function.

AC Input
The AC power cable is inserted into the AC power connector and plugged into a standard
3-way 115 or 230 volt outlet. The AC Power connector contains an integral fuse module
and line filter. AC input power can be selected by the user by changing position of the
fuse module so that the selected voltage is displayed.

WARNING! Ensure proper orientation of fuse module for input power before
applying power to the CNC. Component damage could occur with incorrect voltage
setting.

Recommended AC Fuses
Different fuse ratings are recommended based on incoming voltage selected.

550
 Edge Ti

Voltage Input: 120Vac uses 8 amp (slow blow) Littlefuse part #313008
Voltage Input: 220Vac uses 5 amp (slow blow) Littlefuse part #313005
Size: ¼” x 1¼” or 5mm x 20MM fuse can be used

Serial Port
Please refer to the Ports Information section of the Installation Guide for additional
information on configuration of Serial ports for communication.

A remote communications link can be connected to one of the two serial ports and an
external ground (PE) lug for earth grounding of the unit is also provided.

I/O Configuration
The Edge – Ti provides several options for I/O interfacing with built in circuitry
providing interface flexibility and reducing the need for external components. Inputs are
through optoisolators and outputs are through relays. Contacts for both normally closed
and normally open outputs are available for use.

551
Edge Ti

Input Mode
Note that the inputs have two different modes that are selectable using DIP switch SW1-
3. When this switch is OFF the inputs are in the sourced input mode and an external
voltage source of between 12V and 24V is required to activate each input.

When DIP switch SW1-3 is ON, the inputs are all in the dry contact mode and require an
external switch to common to activate the inputs. The logic states sensed by the CNC are
reversed between the two input modes.

In a sourced input circuit, an inactive input will produce a logic low and an active input
will produce logic high. In dry contact mode these logic levels are reversed with an
inactive input producing logic high and an active input producing a logic low.

Switch SW1-3

I/O Interface
The following illustration shows the details of connecting the I/O to common circuitry.
All outputs are relay contacts rated at 1 AMP 250VAC maximum

Example Inputs Edge-Ti Internal Circuitry Example Outputs

External Circuitry Inputs Outputs External Circuitry
Dry Contact Inputs
DIP Sw 1-C Closed Use External +12V Supply
Dry Contact Inputs & normally Closed Contact
Note: Logic Level Reversal +24V Field COM
3900 LED
NC +
12V
SWITCH 3900 NO RESISTOR
GND

GND_External
GND_External
RELAY SPDT
Normal Sourced Inputs
Normal Sourced Inputs DIP Sw 1-C Open Use External +5V Supply
Use External +12V Supply Open & normally Open Contact
COM
3900
+
NC
5V
3900 NO
GND RESISTOR

OPTO ISOLATOR
+ GND_External
12V RELAY SPDT OPTO ISOLATOR
GND_External Normal Sourced Inputs
Normal Sourced Inputs DIP Sw 1-C Open Use External 120 Vac
Use External +24V Supply Open & normally open contact
COM
3900
NC
+ 3900 NO
24V GND 120 Vac
RELAY
RELAY

RELAY SPDT

GND_External

552
 Edge Ti

WARNING! Do not exceed 24Vdc or 10mA into any optoisolator input. Use care
to observe the correct signal polarities or damage may occur! Do not exceed 250 Vac or 1
Amp through any relay output.

I/O Pinout
Three inputs and three outputs are provided per connector

Connector I/O 1-3 Connector I/O 4-6

Pin# Signal Pin# Signal
1 OUT1 Common 1 OUT4 Common
2 OUT1 Normally Closed 2 OUT4 Normally Closed
3 OUT1 Normally Open 3 OUT4 Normally Open
4 OUT2 Common 4 OUT5 Common
5 OUT2 Normally Closed 5 OUT5 Normally Closed
6 OUT2 Normally Open 6 OUT5 Normally Open
7 OUT3 Common 7 OUT6 Common
8 OUT3 Normally Closed 8 OUT6 Normally Closed
9 OUT3 Normally Open 9 OUT6 Normally Open
10 IN1 10 IN4
11 IN1 Common 11 IN4 Common
12 IN2 12 IN5
13 IN2 Common 13 IN5 Common
14 IN3 14 IN6
15 IN3 Common 15 IN6 Common
16 Cable Shield 16 Cable Shield

Connector I/O 7-9 Connector I/O 10-12

Pin# Signal Pin# Signal
1 OUT7 Common 1 OUT10 Common
2 OUT7 Normally Closed 2 OUT10 Normally Closed
3 OUT7 Normally Open 3 OUT10 Normally Open
4 OUT8 Common 4 OUT11 Common
5 OUT8 Normally Closed 5 OUT11 Normally Closed
6 OUT8 Normally Open 6 OUT11 Normally Open
7 OUT9 Common 7 OUT12 Common
8 OUT9 Normally Closed 8 OUT12 Normally Closed
9 OUT9 Normally Open 9 OUT12 Normally Open
10 IN7 10 IN10
11 IN7 Common 11 IN10 Common
12 IN8 12 IN11 (shared w/ lifter Lower
limit input)
13 IN8 Common 13 IN11 Common
14 IN9 14 IN12 (shared w/ lifter Upper
limit input)
15 IN9 Common 15 IN12 Common
16 Cable Shield 16 Cable Shield

553
Edge Ti

Shared Inputs
Note that general inputs #11 and #12 are shared with the Lifter Interface Limit Switch
inputs. These inputs can only be used as general purpose inputs if they are NOT used by
the Lifter limit switches.

If you are using the Lifter Interface and limit switches are connected to these inputs you
must set DIP switches SW1-1 and SW1-2 to ON and you should not connect to inputs
#11 and #12. Note that the standard Hypertherm Lifter does not use limit switches and
the DIP switches SW1-1 & SW1-2 should be OFF so that inputs #11 and #12 can be
used.

Switch SW1-1 and SW1-2

I/O Mating Connector

The I/O connector is a standard sex circular CPC connector from AMP
Connector AMP 16C #206037-1
Backshell AMP #206070-1
Sockets 20-24AWG AMP #66105-3

I/O Setup Screen

The I/O setup screen is used to define inputs, outputs and their logic state.

554
 Edge Ti

Note: The input logic for the first twelve I/O would need to be inverted for Dry Contact
Mode Inputs so that logic state is shown correctly for operational mode. An Inputs
Inverted parameter has been provided for this purpose.

Front Panel I/O

Edge TI has dedicated I/O for operation of front panel switches. NOTE: For proper
operation, these inputs should not be reassigned.

Input # Description
24 Front Panel Start
25 Front Panel Stop
26 Front Panel Forward on Path
27 Front Panel Forward on Path
28 Raise Torch 1
29 Lower Torch 1
30 Front Panel Manual
31 Front Panel E-Stop
Lifter Interface
Edge Ti offers the option of an integrated Torch Height Control. The lifter interface
connector is provided for this use. Lower Limit, Upper Limit and Breakaway inputs are
sinking inputs to Field Common. Please refer to Sensor™ PHC manual for additional
information.

Lifter Pinout (9 Pin Dsub)

Pin# Description
1 Field +12VDC
2 Lower Limit (shared w/ general input 11)
3 Upper Limit (shared w/ general input 12)
4 Breakaway (Torch Collision)
5 Field Common
6 Field Common
7 Plate Contact -12Vdc
8 Plate Contact Sense
9 Plate Contact Common

Shared Inputs
Note that general inputs #11 and #12 are shared with the Lifter Interface Limit Switch
inputs. These inputs can only be used as general purpose inputs if they are NOT used by
the Lifter limit switches.

If you are using the Lifter Interface and limit switches are connected to these inputs you
must, close DIP switches SW1-1 and SW1-2 and you should not connect to inputs #11
and #12. Note that the standard Hypertherm Lifter does not use limit switches and that

555
Edge Ti

the DIP switches SW1-1 & SW1-2 should be left open so that inputs #11 and #12 can be
used.

Switch SW1-1 and SW1-2

Mating Connector
Use Hypertherm cable CABL-0207 or recommended 9 Pin Dsub (or equivalent)

Connector AMP #205204-3

Backshell Northern Technology #C88000209
Pins AMP #1-66506-0
Cabling: Use Belden # 9540 or equivalent

Plasma Interface
A plasma interface is provided as standard for Edge TI. This feature is used in
conjunction with a Plasma Interface Module to provide connections at the Plasma
Supply. Inputs and outputs are dry contact mode. Arc voltage is assigned to Analog
Input 5. Please refer to Sensor™ PHC manual for additional information.

Plasma Interface Pinout (15 Pin Dsub)

Pin# Description
1 Field +12VDC
9 Field +12VDC
2 Plasma Start Output (Cut Control)
10 Plasma Start Output (Cut Control)
3 Hold Ignition Output +
11 Hold Ignition Output -
4 Transfer Input + (Cut Sense)
12 Transfer Input - (Cut Sense)
5 Field Common
6 Field Common
7 Field Common
13 Field Common
14 Field Common
15 Electrode Arc Voltage (–)
8 Work Arc Voltage (+)

Mating Connector
Use Hypertherm cable CABL-0208 or recommended 15 Pin Dsub (or equivalent).

Connector AMP #205206-1

Backshell Northern Technology #C88000207

556
 Edge Ti

Pins AMP #1-66506-0

Cabling: Use Belden # 9541

External Interlock
An external interlock is provided to remotely disable servo power.

Interlock Pinout
Pin# Description
1 Interlock Relay Coil (24VDC)
2 GND
3 GND
4 +24VDC (50 milliamps maximum)

Additional Notes:
1. For Servo Drive Amplifiers to operate, Pin 1 must be connected to GND Pin 2,
typically through a remote mushroom type switch. If no remote switch is to be
used, connect pin 1 to pin 2 with a jumper or the servo drives will not power on.
2. 24VDC is provided for use to activate the digital inputs only in the case where
sourced inputs are selected, it must not be used for any other auxiliary purpose.

Mating Connector
Connector AMP #206060-1
Backshell AMP #206062-3
Sockets 20-24AWG AMP #66105-3

Motor Encoder Connections

Edge Ti supports DC brush and brushless motors. Switch SW1 on the drive interface can
be used to select motor type being used. Please note the location and setting in the
following illustration.

Drive Type selection on Axes Setup screen must be set to CURRENT mode.

557
Edge Ti

Motor Requirements
250 Watts (each amplifier, 1,000 watts total)
70 VDC Bus
4 Amps Continuous, 6 Amps Peak (for 2 seconds)
+5VDC differential encoders
Brushless motors also require Hall Effect sensors phased at 120 degrees

Axes Assignments

Axes Axes Assignment

1 (X) Transverse or Rail
2 (Y) Transverse or Rail
3 (Z) Dual Gantry, CBH, or THC
4 (W) CBH, or THC

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 Edge Ti

Motor Power Pinout

Pin# Description
1 Brushless Motor-A or Brush +
2 Brushless Motor-B or Brush -
3 Brushless Motor-C
4 Brake + (24VDC, 250ma max)
5 Brake -
6 Cable Shield
7 No Connect

Additional Notes:
1. Brake output is limited to 250ma total. This output is only used on the THC vertical
axis.

Drive Motor Mating Connector

Connector AMP #211399-1
Backshell AMP #206966-1
Sockets 16-18AWG AMP #66101-3
Cabling: Use Belden # 9552 or equivalent for brushed motor signals
Cabling: Use Belden # 9553 or equivalent for brushless motor signals

Encoder Pinout:
1 Encoder +5V
2 Encoder GND
3 Encoder Channel A
4 Encoder Channel A/
5 Encoder Channel B
6 Encoder Channel B/
7 Encoder Channel Z
8 Encoder Channel Z/
9 +V Hall Out (6V @ 30MA max)
10 Hall GND
11 Hall - A
12 Hall - B
13 Hall - C
14 Cable Shield

Additional Notes:
1. Only 5 Volt encoders are supported.
2. Hall Sensors are used with Brushless motors only.
3. Inside the Edge Ti, dipswitches are used to select Brush or Brushless mode, 2
switches per axis. Can mix Brushed and Brushless if switches are set properly.

559
Edge Ti

4. For optimum noise immunity, cable shields may be tied externally to the control
enclosure.

Encoder Mating Connector

Connector AMP #206044-1
Backshell AMP #206070-1
Pins (20-14AWG) AMP #66103-3
Cabling: Use Belden # 9504 or equivalent for brushed motor signals
Cabling: Use Belden # 9507 or equivalent for brushless motor signals

Reminder: Drive Type selection on Axes Setup screen must be set to CURRENT mode.

560
Voyager III
Overview

The Voyager III™ PC based CNC control Voyager III™

for the metal cutting industry utilizes our
proprietary Graphical User Interface (GUI)
and SoftMotion Technology. Voyager III
provides the user with increased
performance and greater operational
flexibility utilizing a 15” touch screen
display, 2.4Ghz Intel processor, proprietary
operational software and a unique
SERCOS/Analog machine interface.
Common applications for Voyager class
controls include: bevel head systems,
multiple Sensor Torch Height Controls and
other advanced systems requiring more than
four axes for machine interfacing.

Touch Screen
The 15” display used in the Voyager III is a
patented IntelliTouch Surface Wave
technology which provides precise drift free
touch accuracy and unsurpassed clarity. Rear View
Pure glass construction with tiny transducers
on the back of the touch screen preserves
color purity and works even if scratched.
There is no known wear out mechanism as
there are no layers, coatings or moving
parts. IntelliTouch technology has been
tested by the supplier for more than 50
million touches in one location without
failure.

THC, Joystick & Speedpots

Optional features for Sensor THC, Joystick
and Speedpots are offered.

Note: Use of some devices such as USB

memory devices may require loading of a
device driver for operation. Many standard
device drivers are located in the C:\CABS or

561
Voyager III

Voyager III incorporates a unique machine interface designed by Hypertherm

Automation to convert SERCOS (Serial Real Time Communication) to a traditional
analog interface. For those not familiar with SERCOS, it is a fiber optic communication
ring for commanding motion and controlling I/O that is available from many drive
suppliers.

This new interface approach allows Voyager III to offer three styles of machine interface,
increasing system flexibility for wiring and features.

Interface options:

1) The standard configuration of Voyager III uses SERCOS internally but provides a
traditional and familiar analog machine interface on the back of the CNC.

2) Standard SERCOS interface with a fiber optic cable connected to SERCOS amplifiers
and I/O.

3) The new SERCOS to Analog conversion card (part # ASSY-0191) is mounted

externally using fiber optic communications to the card. The card then provides a
traditional analog interface output to motion amplifiers and I/O.

Each interface card offers two axes of motion, thirty-two (16/16) 24VDC positive logic
inputs and outputs, plus two analog inputs for Speedpot and Sensor THCs.

The information contained in this section is intended to provide the basic information for
connection of the Voyager III™ Shape Cutting Control to the cutting table. Each
machine interface will vary slightly based on the cutting table configuration and features.
Additionally, I/O pinout information may vary slightly based on the configuration of the
selected I/O and their locations. Changes to the I/O configuration may be made in the
password protected I/O screen. All controls are shipped with the default selection of
Inputs and interface locations for the selected control Interface (I/O) configuration.
Installation and service should only be performed by a qualified service technician. For
more information regarding the I/O process definitions, please refer to the Setups section
of this guide.

562
 Voyager III

Setups

Drive Type
The manufacturer of the SERCOS style drive being used would be selected. This allows
proper operation and tuning parameters to be available. SMCC is the default setting for
Voyager III.

Update Rate
The update rate for the ring may be selected for motion and I/O. One millisecond is the
default setting for Voyager III.

Baud Rate
Communication rate for the ring may be selected. 16 Mbaud is the default setting for
Voyager III.

Light Level
The user has the ability to adjust the intensity of the light pulses used on the fiber optic
ring. This feature is used to compensate for diminished signal due to issues such as ring
distance. Low is the default setting for Voyager III

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Voyager III

Drive I/O
The user may select to use I/O options directly supported on the Drive Amplifier.
Options are None, Overtravel and Home Switches only or All I/O. Note: The Drive I/O
will populate the general purpose I/O (both analog and digital) in order from the lowest
SERCOS drive axis to the highest SERCOS drive axis. All I/O is the default setting for
SMCC / Voyager III interface.

RECO I/O at Address 50

This parameter is set to Yes if the Indramat RECO I/O module is being used to expand
the total number of I/O being used on the standard fiber optic ring. Note: The RECO I/O
will populate the general purpose I/O (both analog and digital) following all drive I/O.
The default setting for Voyager III is NO.

HTA I/O at Address 70

This parameter is set to Yes if one of the SERCOS to Analog cards is set to be used for
I/O expansion.

Common Status Messages

Starting Up Drives on SERCOS Ring. Phase 1 -4
This is a status message to indicate the SERCOS ring power up and will advance through
phases 1-4. Failure to reach phase 4 indicates a problem with power up. Cycle power to
initiate SERCOS phase up again. If the system repeatedly fails to enable the SERCOS
ring, contact your vendor for assistance.

SERCOS Ring not Running. Restart Ring?

This status message indicates the SERCOS ring is currently not running. You may see
this when a command such as a motion command is requested but the RING was not
enabled. Restart of the ring is recommended.

Updating SMCC software.....

After a control software update, the SERCOS to Analog card software may also be
updated at restart of SERCOS ring. It is important not to interrupt this update sequence.

SERCOS Ring Not Running. Please Check Power, Status of LEDs on

Drives and I/O Modules, Fiber Optic Ring Connections and SERCOS Baud
Rate.
This status message indicates the SERCOS ring is not running after power up. It is
recommended to check hardware and parameters then restart the ring by power cycle.

New Setups May Require Restarting SERCOS Ring to Take Effect. Restart SERCOS
Ring?
When changes are made to system configuration that affect the SERCOS ring operation,
you may be prompted to restart the ring. Restart of the ring is recommended.

564
 Voyager III

SERCOS Drives Not Enabled and Ready. Please Check Drive are Enabled
and Ready with No Errors.
This status message indicates the SERCOS ring is not running due to a missing enable
signal. First check that the Control Enable Disabled softkey is correct. The softkey
should read DISABLE CONTROL. Then check status of ring hardware or external
drives to ensure there are no errors displayed.

Machine Interface
I/O Configuration Type “V” ( Positive Logic Single Ended I/O )
Connecting single ended I/O to the control. The control provides +24V power on pins
22, 23 & 24 (+24 VDC) and pins 9, 10, 11 &12 (24 VDC Common) on the I/O
connector.

Output tied to external Cut On Input tied to Cut Sense Relay

Examples of possible circuits

Output

24 VDC
Com

565
Voyager III

Input

Single Ended I/O Pinout

The Single Ended I/O offers up to 48 outputs which are rated at 24VDC for up to 1-amp
loads and 32 inputs rated for 24VDC as standard

I/O Connector

Pin Description
1 Output 1
2 Output 2
3 Output 3
4 Output 4
5 Output 5
6 Output 6
7 Output 7
8 Output 8
9 +24 VDC Common
10 +24 VDC Common
11 +24 VDC Common
12 +24 VDC Common
13 Watchdog Contact
14 Input 1
15 Input 2
16 Input 3
17 Input 4
18 Input 5
19 Input 6
20 Input 7
21 Input 8
22 +24 VDC
23 +24 VDC
24 +24 VDC
25 Watchdog Contact
Note: Wiring pattern continues incrementally for I/O 9-16, 17- 24, 25-32, 33-40, 41-48

566
 Voyager III

Mating Connector
Connector: 25C D-Sub Amp # 207464-2 or equivalent
Backshell: Amp #748676-3 or equivalent
Pins: Amp #5-66506-9 ( 20-24 AWG ) or equivalent

Axes Connector Location* Axes Assignment

1 Axis 0 X- Transverse or Rail
2 Axis 1 Y- Transverse or Rail
3 Axis 2 Dual Gantry, CBH, Rotate or THC
4 Axis 3 CBH, Tilt or THC
5 Axis 4 Rotate or THC
6 Axis 5 Tilt or THC

Note: Markings on backdoor machine interface for Axes are zero based.

Drive/ Encoder Pinout

Pin Description
1 Channel A Input
2 Channel B Input
3 Channel Z Input
4 Encoder Power Output ( 5 VDC supplied as standard )
5 Field Common
6 Servo Output (± 10V)
7 Drive Enable In ( relay contact )
8 Field Common
9 Channel /A Input
10 Channel /B Input
11 Channel /Z Input
12 Field Common
13 Field Common
14 Servo Output Common
15 Drive Enable Out ( relay contact )

Note: Cable Shields should be connected to chassis ground.

Drive/ Encoder Input Mating Connector

Connector: 15C D-Sub Amp # 25206-3 or equivalent
Backshell: Amp #748676-2 or equivalent
Pins: Amp #5-66506-9 ( 20-24 AWG ) or equivalent

Note: Wiring pattern continues for additional Axes

567
Voyager III

Analog Connection Pinout

Note on analog connector: For opertional flexibility, inputs and outputs have a shared
logic and are provided in both positive logic (+24VDC) and negative logic (24VDC
common).

In this application shared I/O means that a single I/O assignment is offered at three
locations.

Example: Output 15 could be assigned as the I/O connector a Nozzle Contact Enable.
Once assigned in software, this output signal would be available as:

- A positive logic output on second I/O connector Pin 20

- A positive logic output on analog connector Pin 7
- A negative logic output on analog connector Pin 8

Analog 1
Pin # Designation Description
1 Analog 1 + Analog Input ( 0-10VDC)
2 Analog 1 - Analog Common
3 +24VDC
4 Duplicate Input 15 Positive logic shared input 15
5 Field Common
6 Alternate Input 15 Negative logic shared input 15
7 Duplicate Output 15 Positive logic shared output 15
8 Alternate Output 15 Negative logic shared output 15
9 Field Common

Note: Wiring pattern continues for Analog 2-6

Assignable shared I/O locations are 15, 16, 31, 32, 47, 48

Mating Connector
Connector: 9C D-Sub Amp # 205204-4 or equivalent
Backshell: Amp #748676-1 or equivalent
Pins: Amp #5-66506-9 ( 20-24 AWG ) or equivalent

568
 Voyager III

Sensor THC Interface

Analog 9C Divider J2
Pin # Description Pin #
5 24V Common 1
6 Nozzle Contact Sense 3
8 Nozzle Contact Enable 4
1 Analog In+ 6
2 Analog In– 7
Chassis Shield No Connection

Mating Connector
Connector: 9C D-Sub Amp # 205204-4 or equivalent
Backshell: Amp #748676-1 or equivalent
Pins: Amp #5-66506-9 ( 20-24 AWG ) or equivalent
Cable Belden #9505 or equivalent

Note: Wiring pattern continues for Analog 2-6

It is recommended that the Hold Ignition Input be wired to the Power Supply through an
external relay from the I/O connector. Please refer to instructions from supply
manufacturer for details on connection to the Hold Ignition Input.

Voltage Divider Card Pinout ( Series 3 )

Part # PBS-0061

Divider PCB - 2C Connector J1

Pin # Description
1 85 -265 VAC Power Input ( 47-63Hz )
2 85 -265 VAC Neutral Input

Mating Connector
2C Phoenix Connector – Phoenix Part # 1840366

Divider PCB - 8C Connector J2 to Control Analog Connector

Pin # Description
1 +24 VDC Common
3 Nozzle Contact Sense
4 Nozzle Contact Enable
6 Analog Out +
7 Analog Out –
8 E Ground

569
Voyager III

Mating Connector
8C Phoenix Connector – Phoenix Part # 1803633

Divider PCB - 5C Connector J3 to Plasma Supply / Table

Pin Number Description
1 Ground ( Chassis Ground )
2 Electrode ( Plasma DC – )
3 Work ( Plasma DC + )
4 NC
5 Shield ( Nozzle Contact )
SERCOS to Analog Conversion Card

I/O
indicator

Decimal Read

Status Indicator
Lights
RX Fiber

TX Fiber

Drive Address

Dip Switches

Programming
Port
Power Connector
` Axis Enable

Decimal Read Out

The 7 segment display indicates SERCOS ring phases status 1-4. Additionally, the 2
decimal points in the 7 segment display indicate phase condition for the SERCOS ring
and are on immediately after CNC boot up and reset. They remain on until the ring is
successfully phased up to phase 4. After that the decimal points remain off even if the
ring drops from phase 4. With this approach, if the SERCOS ring is not running, you can
determine if the ring has ever made it to phase 4 during that power on cycle. This
assumes the card has not been reset or lost power.

570
 Voyager III

Status Indicator Lights

A Red and Green light are provided to indicate status of the SERCOS ring. Red indicates
a Fault and Green indicates a RUN status.

Drive Address Rotary Hex Switches

Factory settings are as follows:
For Axes 1 and 2: SW1 = 0, SW2 = 1
For Axes 3 and 4: SW1 = 0, SW2 = 3
For Axes 5 and 6: SW1 = 0, SW2 = 5
For Axes 7 and 8: SW1 = 0, SW2 = 7
For Axes 9 and 10: SW1 = 0, SW2 = 9
For Axes 11 and 12: SW1 = 0, SW2 = B

Note: Markings on backdoor machine interface for Axes are zero based.

Address Rotary Hex Switches ( for I/O only )

For I/O Expansion Interface ( no Axes being used ): SW1 = 7, SW2 = 0

Programming Port
This is for factory use only.

Dip Switch Settings

Fiber Optic Light Level:

Location SW3
Low Level (0-15 meters): 1 = OFF, 2 = OFF ( Default setting )
Medium Level (15-30 meters): 1 = OFF, 2 = ON
High Level (30-45 meters): 1 = ON, 2 = OFF
Highest Level (>45 meters): 1 = ON, 2 = ON

Baud Rate:
Location SW3
16 MBAUD 3 = ON, 4 = ON (Default setting)
8 MBAUD 3 = ON, 4 = OFF
4 MBAUD 3 = OFF, 4 = ON
2 MBAUD 3 = OFF, 4 = OFF

Reserved:
Location SW3
5 = OFF, 6 = OFF, 7 = OFF, 8 = OFF

Flash Write Jumpers:

Location SW4
1 = ON, 2 = ON

571
Voyager III

Reset Button:
SW5 – Press to reset card

Error Codes:
E1 Display Code = "Voltage or Temperature Error Detected!"
Displayed if voltage or temperature sensors on Field Interface board indicate an error.
Please check power supply, wiring and connections.

E2 Display Code = "Bad Checksum for SMCC Software!"

Displayed if checksum for SERCOS Slave Flash Program is not correct. Program needs
to be reloaded using the Serial Port connection.

E3 Display Code = "Wrong Interface Board Detected for Selected SERCOS

Address!"
Displayed if the selected SERCOS Slave Address/SERCOS Slave mode does not match
the Field Interface functionality. For example, using an HPR Field Interface with a
SERCOS Slave card set to Drive Address 1-12 is not possible, since these are axes
SERCOS addresses only, not peripheral I/O SERCOS addresses.

572
Mariner
Overview

Mariner ™ offers motion control operation of

up to 12 axes with 1024 I/O signals with
SERCOS Interface, providing a high degree of
Mariner™
flexibility in operation and table configurations.
This control system supports Multiple Sensor
Torch Height Controls, Tilt/Rotate, Dual
Tilt/Rotate and Dual Transverse motion axes
along with direct communication to
Hypertherm’s HD3070 HyDefinition Autogas
Console, HD4070 HyDefinition and HPR
Plasma systems. A unique Laser process
screen directly integrates to Hypertherm’s
FASTLaser head. This product uses type “V”
software.
Touch Screen
The 15” display used in the Mariner control is a
patented IntelliTouch Surface Wave technology
which provides precise drift free touch accuracy
and unsurpassed clarity. Pure glass
construction with tiny transducers on the back
of the touch screen preserves color purity and
works even if scratched. There is no known
wear out mechanism as there are no layers,
coatings or moving parts. IntelliTouch
technology has been tested by the supplier for
more than 50 million touches in one location
without failure.
THC, Joystick and Speedpots
Features for Sensor THC, Joystick and
Speedpots are provided as standard.
Connection and operation information is
provided in the Operators and Installation
Guide provided with this product.

Note: Use of some devices such as USB

memory devices may require loading of a
device driver for operation. Many standard
device drivers are located in the C:\CABS or
D:\CABS\I386 folders.

573
Mariner

The Mariner Shape Cutting Control is designed with all machine interface connections
passing through the pedestal mount at the base of the enclosure. Motion and I/O are
supported via the fiber optic communication ring of the SERCOS Interface.

The information contained in this section is intended to provide the basic information for
connection of the Mariner Shape Cutting Control to the cutting table. Each machine
interface will vary slightly based on the cutting table configuration and features.

AC Input Pinout
TB connector Description
101 110VAC or 220VAC Input (Hot)
102 110VAC or 220VAC Input (Neutral)
AC Power Ground

Recommended Wire
14 AWG or greater

E-Stop
The E-stop Switch provides normally open contacts rated at 20VAC/500mA minimum to
250VAC/6A maximum.

TB connector Description
103 Contact Closure
104 Contact Closure

Diagram Location Din-02

SERCOS Motion and I/O

As noted previously, Motion and I/O are supported via the fiber optic communication
ring of the SERCOS Interface. Digital and Analog I/O are supported.

574
 Mariner

Motion is controlled through address assignments for the axes. Inputs and Outputs work
on a similar assignment in SERCOS and may be mapped at the I/O configuration screen.

Details for wiring the motion and /O are specific to the specific SERCOS hardware being
used. Please refer to the appropriate supplier for interfacing information.

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