Hypertherm MicroEdge User manual

Shape Cutting Control
Software Version 7.50
Making people and machines more productive through process Automation

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 may appear.
TRADEMARKS Hypertherm Automation is a wholly owned subsidiary of Hypertherm®, Inc.
ShapeWizard®and EDGE®are reg. trademarks of Hypertherm Automation.
Gemini™, Voyager™ and Mariner™ are trademarks of Hypertherm Automation.
HyperNest®, HyperCAD®and HyperNet®are reg. trademarks of Hypertherm
Automation.
Nester™, APC™ and Sensor™ THC are trademarks of Hypertherm Automation.
Command®THC and HT 4400®are registered trademarks of Hypertherm®, Inc.
HD3070®and HD4070®HyDefinition®Plasma are reg. trademarks of Hypertherm®, Inc.
HyPerformance™ and HPR130™ are trademarks of Hypertherm Automation.
Microsoft®and Microsoft logo are registered trademarks of the Microsoft Corporation.
Pentium®and Celeron®are registered trademarks of Intel Corporation.
NJWIN®is a registered trademark of NJStar Software Corporation.
Virus Scan®is a registered trademark of McAfee Associates, Inc.
Norton AntiVirus™ and Norton Ghost are Trademarks of Symantec™ Corp.
HASP®is a registered trademark of Aladdin Knowledge Systems Ltd.
SERCOS Interface™ is a trademark of SERCOS North America.
Indramat™ is a trademark of Bosch Rexroth.
Pacific Scientific™ is a trademark of Danaher Motion.
PATENTS Hypertherm Automation CNC products may be covered by one or all of the following
US Patents - US 6772040, US 6622058 or US6359251.
COPYRIGHT ©2007 by Hypertherm Automation. All rights Reserved
Printed in USA

Table of Contents I I
Table of Contents
SAFETY..................................................................................................................................................1
Read This Manual...............................................................................................................................1
Dangerous Machinery.........................................................................................................................1
High Voltages......................................................................................................................................1
Product Listings...................................................................................................................................2
MicroEdge and Voyager III..............................................................................................................2
Edge TI............................................................................................................................................2
OVERVIEW ............................................................................................................................................3
Introduction .........................................................................................................................................3
ShapeWizard.......................................................................................................................................3
Teach/Trace........................................................................................................................................3
Shape Libraries...................................................................................................................................3
Program Upload and Download..........................................................................................................4
SoftMotion...........................................................................................................................................4
Cutting Options ...................................................................................................................................4
Mirror function .................................................................................................................................4
Rotate function ................................................................................................................................4
Scale function..................................................................................................................................4
Repeat function ...............................................................................................................................4
Programming Features .......................................................................................................................4
Manual Data Input (MDI).................................................................................................................5
Communications Link......................................................................................................................5
Graphical program display ..............................................................................................................5
Built-in Parametric Shape Library....................................................................................................5
Teach/Trace ....................................................................................................................................5
Performance Features ........................................................................................................................6
Installation and Setup Features..........................................................................................................7
Hardware Specifications .....................................................................................................................7
Model Numbering System...................................................................................................................8
Front Panel Layout..............................................................................................................................9
PC Keyboard Layout.........................................................................................................................12
Screen Hierarchy...........................................................................................................................14
Key & Menu Functions......................................................................................................................15
Numeric Keypad................................................................................................................................17
Help Screen ......................................................................................................................................18
Show Bookmarks ..........................................................................................................................18
Main Screen......................................................................................................................................19
Preview Window............................................................................................................................19
Watch Window ..............................................................................................................................19
Shape Manager.............................................................................................................................19
Files...............................................................................................................................................19
Part Options...................................................................................................................................20
Setups ...........................................................................................................................................20
View Part/View Sheet....................................................................................................................20
Change Cut Mode .........................................................................................................................21
Change Consumable.....................................................................................................................21
Zero Positions ...............................................................................................................................21
Shape Manager Screen....................................................................................................................22
Shape Library................................................................................................................................22

Table of Contents II II
Text Editor..................................................................................................................................... 22
Shape Wizard ............................................................................................................................... 22
Teach Trace.................................................................................................................................. 22
Nester............................................................................................................................................ 22
HyperCAD..................................................................................................................................... 23
HyperNEST................................................................................................................................... 23
Evaluation Timer........................................................................................................................... 23
Files.................................................................................................................................................. 24
Load from Disk.............................................................................................................................. 24
Save to Disk.................................................................................................................................. 24
Download from Host ..................................................................................................................... 24
Upload to Host .............................................................................................................................. 25
Resume Last Part ......................................................................................................................... 25
Show Certain Files........................................................................................................................ 25
Show All Files ............................................................................................................................... 25
Setups Screen.................................................................................................................................. 26
Cutting........................................................................................................................................... 26
Process......................................................................................................................................... 26
Disable Control ............................................................................................................................. 26
Watch............................................................................................................................................ 26
Password ...................................................................................................................................... 26
Diagnostics ................................................................................................................................... 27
Change to Metric Units/English Units ........................................................................................... 27
Change Consumable........................................................................................................................ 28
New Torch Tip............................................................................................................................... 28
New Nozzle................................................................................................................................... 28
New Electrode............................................................................................................................... 28
Reset Database ............................................................................................................................ 29
Setups........................................................................................................................................... 29
Upload Database .......................................................................................................................... 29
Save Database ............................................................................................................................. 29
SETUPS............................................................................................................................................... 31
Cutting .............................................................................................................................................. 31
Cut Mode ...................................................................................................................................... 31
Kerf................................................................................................................................................ 31
Kerf Variable / Kerf Value ............................................................................................................. 31
Trial/Cut Speed............................................................................................................................. 32
Marker 1 / Marker 2 Speed........................................................................................................... 32
Plate Size...................................................................................................................................... 32
Vent Controls 1 - 50..................................................................................................................... 32
Marker Offsets 1 - 12.................................................................................................................... 32
Dwell Time.................................................................................................................................... 32
Arc Radial Error ............................................................................................................................ 33
Dwell Override .............................................................................................................................. 33
Optional Program Stop ................................................................................................................. 33
EIA I & J Codes............................................................................................................................. 33
EIA F-Code Override .................................................................................................................... 33
Speed +/- Affects F-Codes ........................................................................................................... 33
EIA Decimal Shift.......................................................................................................................... 33
Process Select Override............................................................................................................... 33
Station Select Override................................................................................................................. 33
Auto Torch Spacing Override ....................................................................................................... 33
G97 Loop Count Prompt............................................................................................................... 34
ESAB Multi Torch Support............................................................................................................ 34
Force G40 Kerf Disable ................................................................................................................ 34

Table of Contents III III
G40 Used in Simple Shapes.........................................................................................................34
Auto Start after APA......................................................................................................................34
EIA Code 2 Decimal Shift..............................................................................................................34
M17, M18 Used as Cut Codes......................................................................................................34
M76 Rotary Shortest Path.............................................................................................................34
Show Traverse Segments.............................................................................................................35
Retain Skew Adjustment...............................................................................................................35
THC Voltage Offset .......................................................................................................................35
Process.............................................................................................................................................36
Oxy Fuel............................................................................................................................................37
Ignition Time..................................................................................................................................38
Low Preheat ..................................................................................................................................38
High Preheat..................................................................................................................................38
Pierce Time ...................................................................................................................................38
Moving Pierce Time.......................................................................................................................38
Creep Time....................................................................................................................................39
Primary Torch Up Time .................................................................................................................39
Primary Torch Down Time.............................................................................................................39
Pierce Torch Up Time ...................................................................................................................39
Pierce Torch Down Time...............................................................................................................39
Cut Off Time..................................................................................................................................39
Bleedoff Time ................................................................................................................................39
Igniters...........................................................................................................................................39
Preheat During Cut........................................................................................................................39
Staged Pierce................................................................................................................................39
Plasma..............................................................................................................................................40
Purge Time....................................................................................................................................41
Pierce Time ...................................................................................................................................41
Creep Time....................................................................................................................................41
Cut Off Time..................................................................................................................................41
Torch Down Time..........................................................................................................................42
Arc Off Time ..................................................................................................................................42
Stop Time......................................................................................................................................42
Retract Delay.................................................................................................................................42
Set Arc Current..............................................................................................................................42
Corner Current Percent.................................................................................................................42
Retry Transfer Fail.........................................................................................................................42
Transfer Time................................................................................................................................42
Arc on Feedback ...........................................................................................................................43
Ignition...........................................................................................................................................43
Dual Grid/THC...............................................................................................................................43
Dual Grid/THC Start ......................................................................................................................43
Partial Raise..................................................................................................................................43
Torch Down During Cut.................................................................................................................43
Torch Down Between Cuts............................................................................................................43
Marker...............................................................................................................................................44
Marker Interface............................................................................................................................44
Ignition Time..................................................................................................................................45
Marker On Time ............................................................................................................................45
Marker Off Time ............................................................................................................................45
Marker Up Time.............................................................................................................................45
Marker Partial Up Time .................................................................................................................45
Marker Down Time........................................................................................................................46
Set Arc Current..............................................................................................................................46
Corner Current Percent.................................................................................................................46
Ignition...........................................................................................................................................46

Table of Contents IV IV
Cut Control Used for Marking ....................................................................................................... 46
Marker Down/Up With Each Marker On/Off.................................................................................. 46
Arc On Feedback.......................................................................................................................... 46
Partial Raise.................................................................................................................................. 46
Down On During Mark .................................................................................................................. 46
Down On Between Marks............................................................................................................. 46
Laser Overview................................................................................................................................. 47
Laser............................................................................................................................................. 48
Test Lifter...................................................................................................................................... 48
Purge Time ................................................................................................................................... 49
New Gas Purge Time.................................................................................................................... 49
Shutter Time ................................................................................................................................. 49
Power Ramp Time........................................................................................................................ 49
Pierce Time................................................................................................................................... 49
Pulse On Time.............................................................................................................................. 50
Pulse Off Time.............................................................................................................................. 50
Creep Time................................................................................................................................... 50
Beam Off Time.............................................................................................................................. 50
Postflow Time ............................................................................................................................... 50
Cut Height..................................................................................................................................... 50
Pierce Height ................................................................................................................................ 50
Lens Cut Position.......................................................................................................................... 50
Lens Pierce Position..................................................................................................................... 50
Pulse Laser Time.......................................................................................................................... 50
Pulse Laser Power........................................................................................................................ 50
Height Control Manual/Automatic................................................................................................. 51
IHS in Manual ............................................................................................................................... 51
Retract Full/Partial ........................................................................................................................ 51
Partial Retract Distance................................................................................................................ 51
Start IHS Distance ........................................................................................................................ 51
Preflow During IHS ....................................................................................................................... 51
Nozzle Contact IHS....................................................................................................................... 51
Nozzle Contact During Cut ........................................................................................................... 51
Pierce Control Manual/Automatic................................................................................................. 51
Pierce Mode Pulse/Blast............................................................................................................... 51
Pierce Complete ........................................................................................................................... 51
Next Pulse..................................................................................................................................... 52
Cut Chart....................................................................................................................................... 52
Laser Cut Chart ................................................................................................................................ 53
Material Type ................................................................................................................................ 53
Specific Material............................................................................................................................ 53
Process Power.............................................................................................................................. 53
Assist Gas..................................................................................................................................... 53
Material Thickness........................................................................................................................ 53
Focal Length ................................................................................................................................. 54
Nozzle........................................................................................................................................... 54
Test Gas ....................................................................................................................................... 54
Set Power ..................................................................................................................................... 54
Cut Speed..................................................................................................................................... 54
Kerf................................................................................................................................................ 54
Pierce Height ................................................................................................................................ 54
Lens Cut Position.......................................................................................................................... 54
Lens Pierce Position..................................................................................................................... 54
Resonator On Time....................................................................................................................... 54
Purge Time ................................................................................................................................... 54
Pierce Time................................................................................................................................... 55

Table of Contents V V
Pulse On Time...............................................................................................................................55
Pulse Off Time...............................................................................................................................55
Creep Time....................................................................................................................................55
Pierce Complete............................................................................................................................55
Next Pulse.....................................................................................................................................55
Start Corner Power........................................................................................................................55
Minimum Corner Power.................................................................................................................55
Save Process ................................................................................................................................56
Rest Process.................................................................................................................................56
Save Cut Charts............................................................................................................................56
Load Cut Charts ............................................................................................................................56
Pulse Laser Time ..........................................................................................................................56
Pulse Laser Power ........................................................................................................................56
Height Control Manual/Automatic..................................................................................................56
IHS in Manual................................................................................................................................57
Retract Full/Partial.........................................................................................................................57
Partial Retract Distance.................................................................................................................57
Start IHS Distance.........................................................................................................................57
Preflow During IHS........................................................................................................................57
Nozzle Contact IHS.......................................................................................................................57
Nozzle Contact During Cut............................................................................................................57
Pierce Control Manual/Automatic..................................................................................................57
Pierce Mode Pulse/Blast ...............................................................................................................57
Pierce Complete............................................................................................................................57
Next Pulse.....................................................................................................................................57
Cut Chart.......................................................................................................................................58
Water Jet...........................................................................................................................................59
Purge Time....................................................................................................................................60
Pierce Time ...................................................................................................................................60
Creep Time....................................................................................................................................60
Abrasive Off Time..........................................................................................................................60
Abrasive Charging.........................................................................................................................60
Watch................................................................................................................................................61
None..............................................................................................................................................61
Input/Output...................................................................................................................................62
Position..........................................................................................................................................62
Following Error ..............................................................................................................................62
Command Voltage.........................................................................................................................62
Temperature..................................................................................................................................62
Speedometer.................................................................................................................................62
Oxy Fuel Torch Tip........................................................................................................................62
Plasma Torch Tip ..........................................................................................................................62
Plasma Electrode ..........................................................................................................................62
Jog Keys........................................................................................................................................63
Process Data.................................................................................................................................63
Laser Nozzle..................................................................................................................................63
HPR Power Supply........................................................................................................................63
Multiple Watch Windows...............................................................................................................63
SHAPE MANAGER..............................................................................................................................65
Shape Library....................................................................................................................................65
Selecting a Simple Shape.............................................................................................................65
Text Editor.........................................................................................................................................66
Show Original Text........................................................................................................................66
Delete Part.....................................................................................................................................66
Shape Wizard....................................................................................................................................67

Table of Contents VI VI
Manual Line Edit........................................................................................................................... 67
Replace Segment ......................................................................................................................... 68
Insert Before Segment.................................................................................................................. 69
Insert After Segment..................................................................................................................... 69
Remove Segment......................................................................................................................... 69
Teach Trace ..................................................................................................................................... 69
Start Corner .................................................................................................................................. 70
Tracing Pitch................................................................................................................................. 70
Arc Radial Error ............................................................................................................................ 71
Auto Closure Detect...................................................................................................................... 71
Closure Over/Under Lap............................................................................................................... 71
Kerf Direction................................................................................................................................ 71
Traverse/Pierce............................................................................................................................. 71
Tracing a part................................................................................................................................ 71
Plate Remnant Trace.................................................................................................................... 72
Nester............................................................................................................................................... 74
Manual Nesting................................................................................................................................. 74
Main Screen Layout...................................................................................................................... 74
Add Part........................................................................................................................................ 75
Remove Part................................................................................................................................. 75
Cut Earlier..................................................................................................................................... 75
Cut Later ....................................................................................................................................... 75
View Sheet / View Part ................................................................................................................. 75
Arrow Key (Distance).................................................................................................................... 75
Clear Nest..................................................................................................................................... 75
Setup............................................................................................................................................. 75
Nester Setup..................................................................................................................................... 76
Arrow Motion................................................................................................................................. 76
Autoposition .................................................................................................................................. 76
Using Nester..................................................................................................................................... 76
Adding Parts ................................................................................................................................. 77
Saving a Nest................................................................................................................................ 79
HyperNest –CNC Automatic Nesting Software............................................................................... 80
Main Screen Layout...................................................................................................................... 80
Automatic Nesting Setup.................................................................................................................. 81
Automatic Nesting......................................................................................................................... 81
Part Spacing ................................................................................................................................. 81
Plate Edge Spacing ...................................................................................................................... 81
Program Origin.............................................................................................................................. 81
Cut Direction ................................................................................................................................. 82
Return to Nest Start...................................................................................................................... 82
Using HyperNest –CNC................................................................................................................... 82
Adding Parts ................................................................................................................................. 82
Remove Part................................................................................................................................. 85
Nest Summary.............................................................................................................................. 86
Main Screen View of Nest ............................................................................................................ 88
HyperCAD......................................................................................................................................... 89
HyperNEST ...................................................................................................................................... 90
FILES................................................................................................................................................... 93
Load from Disk ................................................................................................................................. 93
Load from...................................................................................................................................... 93
Files............................................................................................................................................... 93
File name/Diskette file name ........................................................................................................ 94
Preview ......................................................................................................................................... 94
Load to.......................................................................................................................................... 94

Table of Contents VII VII
Hard drive file name......................................................................................................................94
Resume Last Part..........................................................................................................................94
Show Certain Files ........................................................................................................................94
Show All Files................................................................................................................................94
Resume Last Part Features..............................................................................................................94
Rush Job Interrupt.........................................................................................................................94
Automated Power Loss Recovery.................................................................................................95
Save to Disk......................................................................................................................................96
Save to ..........................................................................................................................................96
File name/Diskette file name.........................................................................................................96
Save Original Text.........................................................................................................................96
Save from......................................................................................................................................96
Files...............................................................................................................................................97
Hard drive file name......................................................................................................................97
Preview..........................................................................................................................................97
Save KeyLog to Disk.....................................................................................................................98
Download from Host .........................................................................................................................99
Download from ..............................................................................................................................99
Files...............................................................................................................................................99
Remote file name ..........................................................................................................................99
Preview........................................................................................................................................100
Download to.................................................................................................................................100
Local file name............................................................................................................................100
Upload to Host ................................................................................................................................101
Upload to.....................................................................................................................................101
Remote file name ........................................................................................................................101
Upload from.................................................................................................................................101
Files.............................................................................................................................................102
Local file name ............................................................................................................................102
Preview........................................................................................................................................102
Loading Of Invalid Files ..................................................................................................................103
LIBRARY SHAPES............................................................................................................................105
Rectangle........................................................................................................................................107
Circle...............................................................................................................................................109
Triangle...........................................................................................................................................111
L-Bracket.........................................................................................................................................113
Trapezoid........................................................................................................................................115
Slant Rectangle...............................................................................................................................117
Gambrel Rectangle.........................................................................................................................119
Roofed Rectangle ...........................................................................................................................121
4 Sided Polygon..............................................................................................................................123
5 Sided Polygon..............................................................................................................................125
Oval.................................................................................................................................................127
Circle w/ Flat Side...........................................................................................................................129
Circle Slice......................................................................................................................................131
Straight Slots...................................................................................................................................133
Angled Slots....................................................................................................................................135
Horizontal Rip..................................................................................................................................137
Vertical Rip......................................................................................................................................139
Flange.............................................................................................................................................141
Circle w/ Rectangular Hole .............................................................................................................143
Gusset.............................................................................................................................................145
8 Sided............................................................................................................................................147
Rectangle w/ Convex Corners ........................................................................................................149
Rectangle w/ Concave Corners......................................................................................................151

Table of Contents VIII VIII
L-Bracket w/ Elbow Radii................................................................................................................ 153
Slant L-Bracket w/ Elbow Radii ...................................................................................................... 155
Trapezoid w/ Convex Corners........................................................................................................ 157
Flange Slice.................................................................................................................................... 159
Elbow.............................................................................................................................................. 161
Flange Repair Ring......................................................................................................................... 163
Rectangle w/ Rectangular Hole...................................................................................................... 165
Rectangle w/ Circular Hole............................................................................................................. 167
Rectangle w/ Circular Hole and Convex Corners........................................................................... 169
Rectangle w/ Tab............................................................................................................................ 171
Rectangle w/ Convex Tab .............................................................................................................. 173
Rectangle w/ Notch ........................................................................................................................ 175
Rectangle w/ Slant Notch............................................................................................................... 177
Rectangle w/ Radius Notch............................................................................................................ 179
Convex Rectangle .......................................................................................................................... 181
Concave Rectangle ........................................................................................................................ 183
Triangle w/ Concave Side............................................................................................................... 185
Polygon w/ Concave Side............................................................................................................... 187
Slant Rectangle with Radius .......................................................................................................... 189
Slant Rectangle with Circular Hole................................................................................................. 191
Slant Rectangle w/ Beveled Corners.............................................................................................. 193
Cross .............................................................................................................................................. 195
Cross w/ Circular Hole and Concave Inside Corners..................................................................... 197
4 Sided Convex Rectangle............................................................................................................. 199
4 Sided Concave Rectangle........................................................................................................... 201
Pipe Mount ..................................................................................................................................... 203
Bolt Hole Circle............................................................................................................................... 205
Bolt Hole Flange............................................................................................................................. 207
Bolt Hole Rectangle........................................................................................................................ 209
Bolt Hole Rectangle w/ Convex Corners........................................................................................ 211
Bolt Hole Rectangle w/ Center Hole............................................................................................... 213
Bolt Hole Rectangle w/ Center Hole and Convex Corners............................................................. 215
Rounded L-Bracket......................................................................................................................... 217
Horseshoe ...................................................................................................................................... 219
Convex Roof Trapezoid w/ Hole..................................................................................................... 221
Convex Roof Polygon w/ Hole........................................................................................................ 223
Convex Roof Polygon w/ Oval Hole and Concave Bottom ............................................................ 225
Pulley Cover ................................................................................................................................... 227
Paddle Blind ................................................................................................................................... 229
Water Pump Gasket....................................................................................................................... 231
Frame ............................................................................................................................................. 233
Pulley.............................................................................................................................................. 235
Sprocket.......................................................................................................................................... 237
Text................................................................................................................................................. 239
Test Pattern.................................................................................................................................... 241
PART OPTIONS ................................................................................................................................ 243
Scale Factor................................................................................................................................ 243
Rotate Angle ............................................................................................................................... 243
Mirror X/Mirror Y ......................................................................................................................... 243
Kerf.............................................................................................................................................. 244
Repeat............................................................................................................................................ 245
Straight Repeat........................................................................................................................... 245
Repeat Type ............................................................................................................................... 245
Start Corner ................................................................................................................................ 245
Number of Rows......................................................................................................................... 245

Table of Contents IX IX
Number of Columns ....................................................................................................................245
X Pattern Offset/Y Pattern Offset................................................................................................246
Scrap Clearance..........................................................................................................................246
X Nest Distance/Y Nest Distance................................................................................................246
Staggered Repeat .......................................................................................................................246
Nested Repeat ............................................................................................................................247
Pattern Offsets ............................................................................................................................247
Nest Distance..............................................................................................................................247
Align ................................................................................................................................................249
Corner to Align with.....................................................................................................................249
Scrap Clearance..........................................................................................................................250
Skew Adjustment.........................................................................................................................250
Skew Reference..........................................................................................................................250
At Corner.....................................................................................................................................250
At Skew Point..............................................................................................................................250
Automatic Plate Alignment (APA)...................................................................................................251
Five Point Align ...........................................................................................................................251
Three Point Align.........................................................................................................................253
Program Code.............................................................................................................................253
CUTTING............................................................................................................................................257
Speed Increase ...........................................................................................................................258
Speed Decrease..........................................................................................................................258
Repeats.......................................................................................................................................258
Cut Delay Timers.........................................................................................................................258
Extend .........................................................................................................................................259
Set Now.......................................................................................................................................259
Release .......................................................................................................................................259
Multitasking..................................................................................................................................260
PAUSE ...............................................................................................................................................261
Change Consumable ......................................................................................................................265
MANUAL ............................................................................................................................................269
Manual Options...............................................................................................................................275
Home Axes......................................................................................................................................277
DIAGNOSTICS...................................................................................................................................279
Control Information .........................................................................................................................279
Hardware.....................................................................................................................................279
Software Versions .......................................................................................................................279
Control Information......................................................................................................................280
Software Modules........................................................................................................................280
Voltage ........................................................................................................................................280
Fans.............................................................................................................................................280
Limited Version............................................................................................................................280
THC Revision ..............................................................................................................................280
System Diagnostics.....................................................................................................................280
I/O ...................................................................................................................................................281
Inputs...........................................................................................................................................281
Outputs........................................................................................................................................282
Expaned I/O.................................................................................................................................283
Analog Input Diagnostics ................................................................................................................284
Inputs...........................................................................................................................................284
Analog Inputs ..............................................................................................................................284
Oscilloscope....................................................................................................................................285

Table of Contents X X
Digital Inputs ............................................................................................................................... 285
Digital Outputs ............................................................................................................................ 285
Analog Inputs.............................................................................................................................. 285
Analog Outputs ........................................................................................................................... 285
Status.......................................................................................................................................... 286
Start............................................................................................................................................. 286
Stop............................................................................................................................................. 286
Rate............................................................................................................................................. 286
Record ........................................................................................................................................ 286
Stop............................................................................................................................................. 286
Pause.......................................................................................................................................... 286
Play............................................................................................................................................. 286
Fast Forward............................................................................................................................... 286
Load............................................................................................................................................ 287
Save............................................................................................................................................ 287
Serial Port....................................................................................................................................... 288
Port.............................................................................................................................................. 288
Test............................................................................................................................................. 288
Send............................................................................................................................................ 288
Received..................................................................................................................................... 289
Test Port ..................................................................................................................................... 289
Drives and Motors .......................................................................................................................... 290
Pulse Type.................................................................................................................................. 291
Pulse Direction............................................................................................................................ 291
Pulse Magnitude......................................................................................................................... 291
Pulse Duration ............................................................................................................................ 291
Test Transverse/Rail/Dual Gantry/CBH...................................................................................... 291
Test All........................................................................................................................................ 292
Speed.......................................................................................................................................... 292
SERCOS Drives & Motors.............................................................................................................. 292
Error Messages .............................................................................................................................. 294
Unable to Find HASP.................................................................................................................. 297
Norton Ghost Utility ........................................................................................................................ 298
Instructions for Ghost Recovery ................................................................................................. 298
PASSWORD SETUPS....................................................................................................................... 301
Machine.......................................................................................................................................... 302
X Axis Orientation....................................................................................................................... 302
Up Direction ................................................................................................................................ 302
Right Direction ............................................................................................................................ 302
Dual Gantry Installed .................................................................................................................. 302
CBH Installed.............................................................................................................................. 302
X and Y Motor/Encoder............................................................................................................... 303
Auto Torch Spacing .................................................................................................................... 303
Tilt Rotator Installed.................................................................................................................... 303
Dual Tilt Rotator Installed ........................................................................................................... 303
Auto Home at Power Up............................................................................................................. 303
Follower Initially .......................................................................................................................... 303
Dual Tilting Rotator Mode........................................................................................................... 303
Key Press Logging...................................................................................................................... 303
Table Size................................................................................................................................... 304
THCs Installed ............................................................................................................................ 304
THC Installed On Axis / Analog ................................................................................................. 304
Ignore Torch Collision During IHS.............................................................................................. 304
Command THCs Installed........................................................................................................... 304
SERCOS......................................................................................................................................... 305

Table of Contents XI XI
Drive Type...................................................................................................................................305
Update Rate ................................................................................................................................305
Baud Rate....................................................................................................................................305
Light Level...................................................................................................................................305
Drive I/O ......................................................................................................................................306
RECO/Beckoff I/O at Address 50...............................................................................................306
HPR/4070 at address 60.............................................................................................................306
HTA I/O at Address 70 ................................................................................................................306
Speeds............................................................................................................................................307
Speed 0 To..................................................................................................................................307
Acceleration Rate........................................................................................................................307
Fast Stop Deceleration Rate.......................................................................................................308
Maximum Machine Speed...........................................................................................................308
Limited Machine Speed...............................................................................................................308
High Jog Speed...........................................................................................................................308
Medium Jog Speed .....................................................................................................................308
Low Jog Speed............................................................................................................................308
Minimum Corner Speed ..............................................................................................................308
Fast Home Speed .......................................................................................................................309
Slow Home Speed.......................................................................................................................309
Creep Speed Percentage............................................................................................................309
Plasma Hi/Lo Speed Percentage................................................................................................309
Plasma Distance To Corner........................................................................................................309
Plasma Distance From Corner....................................................................................................309
CBH Speed Setups (Shown only when enabled) ...........................................................................309
CBH Acceleration Rate ...............................................................................................................309
Maximum CBH Speed.................................................................................................................309
CBH High Jog / Home Speed......................................................................................................310
CBH Low Jog / Home Speed ......................................................................................................310
THC Speed Setups (Shown only when enabled) ...........................................................................310
THC Acceleration Rate................................................................................................................310
Maximum THC Speed.................................................................................................................310
THC Jog Speed...........................................................................................................................310
THC Home/Fast IHS Speed........................................................................................................310
THC Slow IHS Speed..................................................................................................................310
Rotate Acceleration Rate ............................................................................................................312
Maximum Rotate Speed..............................................................................................................312
Rotate High Jog Speed...............................................................................................................312
Rotate Low Jog Speed................................................................................................................312
Tilt Acceleration Rate ..................................................................................................................312
Maximum Tilt Speed....................................................................................................................312
Tilt High Jog Speed.....................................................................................................................312
Tilt Low Jog Speed......................................................................................................................312
Torch Height Disable Feature.........................................................................................................312
Tangent Angle.............................................................................................................................312
Plasma Hi/Lo Speed Percentage................................................................................................313
Plasma Distance To Corner........................................................................................................313
Plasma Distance From Corner....................................................................................................313
Ports................................................................................................................................................315
Port Designation..........................................................................................................................315
Baud Rate....................................................................................................................................316
Parity ...........................................................................................................................................316
Data Bits......................................................................................................................................316
Time Out Delay ...........................................................................................................................316
Transmit Delay ............................................................................................................................316
Rewind.........................................................................................................................................316

Table of Contents XII XII
Dialog Start ................................................................................................................................. 316
Dialog Done ................................................................................................................................ 316
Dialog Prompt ............................................................................................................................. 316
Dialog Pause............................................................................................................................... 317
Dialog Acknowledge ................................................................................................................... 317
End of Transmission................................................................................................................... 317
Using Phoenix Link..................................................................................................................... 317
Show Host File Names ............................................................................................................... 317
File Dump Mode.......................................................................................................................... 317
Allow M65 Auto Reload............................................................................................................... 317
Auto Home before Auto Reload.................................................................................................. 317
ESSI Program Termination......................................................................................................... 317
Download Updates...................................................................................................................... 317
Control Monitoring....................................................................................................................... 318
Flow control................................................................................................................................. 318
During Jog on Path..................................................................................................................... 318
Retry on Time Out....................................................................................................................... 318
Time Out ..................................................................................................................................... 318
I/O................................................................................................................................................... 319
Input Logic .................................................................................................................................. 319
Logic Selection Box .................................................................................................................... 320
Input Selection............................................................................................................................ 320
Torch Collision Uses................................................................................................................... 320
Inputs Inverted ............................................................................................................................ 320
Drive Enables.............................................................................................................................. 320
Initial Feedback Delay................................................................................................................. 320
Speed Pot and Joystick Overview.................................................................................................. 321
Joystick Installed......................................................................................................................... 321
Speed Pot Installed..................................................................................................................... 321
Plasma Override %..................................................................................................................... 321
Oxy Fuel Override %................................................................................................................... 321
Trial Override %.......................................................................................................................... 321
Speed Pot Installed On............................................................................................................... 321
Analog Offset 1- 12..................................................................................................................... 321
Input Definitions.......................................................................................................................... 322
Output Logic................................................................................................................................ 327
Logic Selection Box .................................................................................................................... 327
Output Selection ......................................................................................................................... 327
Output Definitions ....................................................................................................................... 327
Axes................................................................................................................................................ 331
Transverse/Rail .............................................................................................................................. 331
Speed 0 To ................................................................................................................................. 331
Proportional Gain........................................................................................................................ 331
Integral Gain ............................................................................................................................... 332
Derivative Gain ........................................................................................................................... 332
Feedforward Gain ....................................................................................................................... 332
Velocity Gain............................................................................................................................... 332
Servo Error Tolerance................................................................................................................. 332
Encoder Counts per inch ............................................................................................................ 332
Fault Ramp Time ........................................................................................................................ 333
Drive Type................................................................................................................................... 333
DAC Polarity ............................................................................................................................... 333
Encoder Polarity.......................................................................................................................... 333
Encoder Decode Mode............................................................................................................... 333
Use Hardware Overtravels ......................................................................................................... 333
Backlash Compensation............................................................................................................. 333

Table of Contents XIII XIII
Home...........................................................................................................................................333
Absolute Home Position..............................................................................................................334
Home Offset Distance .................................................................................................................334
Home Switch Normally................................................................................................................334
Home Direction............................................................................................................................334
Use Marker Pulse........................................................................................................................334
Use Software Travel Limits .........................................................................................................334
Maximum Travel Limit.................................................................................................................334
Minimum Travel Limit..................................................................................................................334
SERCOS AXES...........................................................................................................................335
SERCOS Drive Address..............................................................................................................335
Emulated Encoder Counts/ motor rev.........................................................................................335
Dual Gantry.....................................................................................................................................336
Speed 0 To..................................................................................................................................336
Proportional Gain ........................................................................................................................336
Integral Gain................................................................................................................................337
Derivative Gain............................................................................................................................337
Feedforward Gain........................................................................................................................337
Velocity Gain ...............................................................................................................................337
Skew Error Tolerance..................................................................................................................337
Encoder Counts per inch.............................................................................................................337
Drive Type...................................................................................................................................338
DAC Polarity................................................................................................................................338
Encoder Polarity..........................................................................................................................338
Encoder Decode Mode................................................................................................................338
Use Home Limit Switch...............................................................................................................338
Switch Offset Distance ................................................................................................................338
Backlash Compensation..............................................................................................................338
CBH.................................................................................................................................................339
Proportional Gain ........................................................................................................................339
Integral Gain................................................................................................................................340
Derivative Gain............................................................................................................................340
Feedforward Gain........................................................................................................................340
Velocity Gain ...............................................................................................................................340
Servo Error Tolerance.................................................................................................................340
Encoder Counts per rev ..............................................................................................................340
Drive Type...................................................................................................................................340
DAC Polarity................................................................................................................................341
Encoder Polarity..........................................................................................................................341
Encoder Decode Mode................................................................................................................341
Follower Initially...........................................................................................................................341
Auto Home At Power Up.............................................................................................................341
Absolute Home Angle..................................................................................................................341
Home Offset Angle......................................................................................................................341
Use Home Limit Switch...............................................................................................................341
Home Direction............................................................................................................................341
Use Marker Pulse........................................................................................................................341
Rotate..............................................................................................................................................342
Absolute Home Angle..................................................................................................................342
Home Offset Angle......................................................................................................................342
Tilt ...................................................................................................................................................343
Absolute Home Angle..................................................................................................................343
Home Offset Angle......................................................................................................................343
Transverse 2 Axis ...........................................................................................................................344
Minimum Torch Spacing..............................................................................................................344
Mirrored Marker Offsets ..............................................................................................................344

Table of Contents XIV XIV
Station Configuration...................................................................................................................... 345
Stations 1-4 / 5-8......................................................................................................................... 345
Reset........................................................................................................................................... 346
Part Program Support................................................................................................................. 346
Station Selects............................................................................................................................ 346
Process Selects.......................................................................................................................... 346
Station Configuration Variables .................................................................................................. 346
Overview..................................................................................................................................... 347
Command®THC Support............................................................................................................ 348
HD4070®Support ....................................................................................................................... 348
FineLine 100 / 200 Support ........................................................................................................ 349
Special............................................................................................................................................ 350
Date............................................................................................................................................. 350
Time............................................................................................................................................ 350
Display Time ............................................................................................................................... 350
Mouse Pointer............................................................................................................................. 350
Keyboard..................................................................................................................................... 350
User Level................................................................................................................................... 351
File Extensions............................................................................................................................ 351
Adding Folders............................................................................................................................ 351
Deleting Folders.......................................................................................................................... 351
Deleting Files .............................................................................................................................. 351
Mapping Drives........................................................................................................................... 351
Configuring Watch ...................................................................................................................... 351
Adding Processes....................................................................................................................... 351
Removing Processes.................................................................................................................. 351
Force Simulation......................................................................................................................... 351
Temperature ............................................................................................................................... 351
Tools Installed............................................................................................................................. 352
Message Enables ....................................................................................................................... 352
Ready to Start Cutting Message................................................................................................. 352
Kerf Too Large Warning Message.............................................................................................. 352
Homing Must Be Performed Message........................................................................................ 352
Values Have been Changed Message....................................................................................... 352
Home Torch Height Control Message ........................................................................................ 352
Ready to Final Align Message.................................................................................................... 352
Part Larger than Plate Message................................................................................................. 352
Cut Chart Data Has Changed Message..................................................................................... 353
Save Part for Rush Job............................................................................................................... 353
Latched Manual Keys ................................................................................................................. 353
Auto Drop Down.......................................................................................................................... 353
Zero Positions............................................................................................................................. 353
Auto Size App. ............................................................................................................................ 353
Language.................................................................................................................................... 353
Tangent Angle............................................................................................................................. 353
Password .................................................................................................................................... 353
Special Password ....................................................................................................................... 354
Station Configuration Password ................................................................................................. 354
Auto Update Max Consumable Life............................................................................................ 354
Machine Position Resets ............................................................................................................ 354
Arc Speed Limit Check ............................................................................................................... 354
HD3070 Auto Gas....................................................................................................................... 354
Front Panel ................................................................................................................................. 354
Save Setups................................................................................................................................ 354
Load Setups................................................................................................................................ 355
Update Software ......................................................................................................................... 355

Table of Contents XV XV
Update Help.................................................................................................................................355
System Tools...............................................................................................................................355
Restore Last Version...................................................................................................................355
Make Link Disk............................................................................................................................355
System Tools –Windows®XP........................................................................................................356
System Tools...............................................................................................................................356
Automated Backup......................................................................................................................356
Backup Hard Drive ......................................................................................................................357
Scan Hard Disk ...........................................................................................................................357
Antivirus™....................................................................................................................................359
Defragment Hard Disk.................................................................................................................360
Format Floppy Disk .....................................................................................................................361
Reset Setups...............................................................................................................................361
Network and Remote Tools.........................................................................................................362
Windows XP®Remote Assistant.................................................................................................362
Network Connection....................................................................................................................363
Network System Requirements:..................................................................................................363
PHOENIX LINK ..................................................................................................................................365
Phoenix Link Overview ...................................................................................................................365
Phoenix Link................................................................................................................................365
Port..............................................................................................................................................365
Baud............................................................................................................................................365
Folder ..........................................................................................................................................366
Files.............................................................................................................................................366
Settings........................................................................................................................................366
Test..............................................................................................................................................366
Files.................................................................................................................................................367
Show All Files..............................................................................................................................367
Show Extension in Name............................................................................................................367
Add to Files..................................................................................................................................368
Remove from Files ......................................................................................................................368
Settings...........................................................................................................................................369
Allow M65 Auto Reload...............................................................................................................369
Use Multi Drop.............................................................................................................................369
Add Control..................................................................................................................................369
Remove Control ..........................................................................................................................369
Control Monitoring.......................................................................................................................370
Installation.......................................................................................................................................371
Minimum System Requirements .................................................................................................371
Software..........................................................................................................................................371
Change Master Folder.................................................................................................................372
Operating Multiple Links..............................................................................................................373
Hardware.........................................................................................................................................375
Operating Phoenix Link...................................................................................................................376
Common Errors...............................................................................................................................376
Error Messages...............................................................................................................................376
Unable to Open Port (control) .....................................................................................................377
Unable to Open Port (host) .........................................................................................................377
Unable to Initialize Port ...............................................................................................................377
Port Failed...................................................................................................................................377
Host Not Responding ..................................................................................................................377
Communication Failed.................................................................................................................377
Communications Time Out..........................................................................................................377
Checksum Error ..........................................................................................................................377
Warning: The Master Folder Selected does Not Contain any Folders ......................................377

Table of Contents XVI XVI
SENSOR THC.................................................................................................................................... 379
Sensor Torch Height Control Overview.......................................................................................... 379
Cut Setups...................................................................................................................................... 380
THC Voltage Offset..................................................................................................................... 380
Plasma Setups ............................................................................................................................... 381
Test Lifter.................................................................................................................................... 381
Retract Delay.............................................................................................................................. 382
Auto Voltage Set......................................................................................................................... 382
Set Arc Voltage........................................................................................................................... 382
Voltage Control ........................................................................................................................... 383
Ignition Output............................................................................................................................. 383
IHS in Manual ............................................................................................................................. 383
Retract Full/Partial ...................................................................................................................... 383
Skip IHS Within........................................................................................................................... 383
Preflow During IHS ..................................................................................................................... 383
Early Preflow if Skip IHS............................................................................................................. 383
Nozzle Contact IHS..................................................................................................................... 384
Nozzle Contact During Cut ......................................................................................................... 384
Offset IHS ................................................................................................................................... 384
Auto Kerf Voltage Change.......................................................................................................... 384
Kerf Detect Reacquire Time ....................................................................................................... 384
Marker Setups ................................................................................................................................ 385
Test Lifter.................................................................................................................................... 385
Purge Time ................................................................................................................................. 385
Start Time ................................................................................................................................... 385
Sample Voltage........................................................................................................................... 386
Set Arc Voltage........................................................................................................................... 386
Voltage Control ........................................................................................................................... 386
IHS in Manual ............................................................................................................................. 386
Retract Full/Partial ...................................................................................................................... 386
Skip IHS Within........................................................................................................................... 387
Preflow During IHS ..................................................................................................................... 387
Nozzle Contact IHS..................................................................................................................... 387
Process Watch ............................................................................................................................... 388
Input/Output ................................................................................................................................ 388
Position ....................................................................................................................................... 388
Plasma Process.......................................................................................................................... 388
Main Cut Screen............................................................................................................................. 389
Automatic THC Mode.................................................................................................................. 389
Sensor THC Setup ......................................................................................................................... 390
Analog Input ................................................................................................................................... 390
Sensor THC Axis Setups................................................................................................................ 391
THC I/O........................................................................................................................................... 394
COMMAND THC................................................................................................................................ 397
Clear Error .................................................................................................................................. 397
Purge Time ................................................................................................................................. 398
Pierce Time................................................................................................................................. 398
Creep Time................................................................................................................................. 399
Arc Off Time................................................................................................................................ 399
Stop Time.................................................................................................................................... 399
Accel Delay................................................................................................................................. 399
Retract Delay Time..................................................................................................................... 399
Ignition ........................................................................................................................................ 399
Voltage Control ........................................................................................................................... 399

Table of Contents XVII XVII
Retract Full/Partial.......................................................................................................................399
Retry On Transfer Fail.................................................................................................................399
Transfer Time..............................................................................................................................399
Set Arc Current............................................................................................................................400
Corner Current Percent...............................................................................................................400
Set Arc Voltage ...........................................................................................................................400
Homing Speed.............................................................................................................................400
Nozzle Ohmic Contact.................................................................................................................400
Preflow During IHS......................................................................................................................400
Main Cut Screen .............................................................................................................................401
Automatic THC Mode..................................................................................................................401
Extend .........................................................................................................................................401
Set Now.......................................................................................................................................401
Release .......................................................................................................................................401
Manual THC Mode ......................................................................................................................402
Extend .........................................................................................................................................402
Set Now.......................................................................................................................................402
Release .......................................................................................................................................402
Diagnostics......................................................................................................................................403
Command THC Machine Interface .................................................................................................403
Port Designation..........................................................................................................................403
RS-422 Connections to Command®THC with 25-pin D-type connector...................................403
MOTION OVERVIEW.........................................................................................................................405
General Motion Theory –Servo Loop Control................................................................................405
Motion Tuning Watch Windows...................................................................................................412
SERCOS Interface Overview..........................................................................................................414
ASCII CODES ....................................................................................................................................415
Control Codes .............................................................................................................................415
All Codes.....................................................................................................................................416
PROGRAM CODES...........................................................................................................................417
EIA RS-274D...................................................................................................................................417
Directly Supported EIA Codes.....................................................................................................417
Mapped EIA Codes .....................................................................................................................420
Unsupported EIA Codes..............................................................................................................421
EIA Comments ............................................................................................................................422
ESSI................................................................................................................................................423
Mapped ESSI Codes...................................................................................................................423
Unsupported ESSI Codes...........................................................................................................425
ESSI Comments..........................................................................................................................426
Advanced Feature Codes ..............................................................................................................427
Tilt / Rotator Part Codes..............................................................................................................427
Automatic Torch Spacing Program Codes..................................................................................427
Station Selects................................................................................................................................428
Process Selects...........................................................................................................................428
Station Configuration Variables...................................................................................................428
Automatic Torch Spacing................................................................................................................429
Automatic Torch Spacing Program Codes..................................................................................431
Automatic Torch Spacing I/O ......................................................................................................431
Sensor THC Part Program Support................................................................................................432
THC Index code ..........................................................................................................................432
Sub Parts ........................................................................................................................................433
Marker Font Generator ...................................................................................................................435
Internal Fonts ..............................................................................................................................436

Table of Contents XVIII XVIII
External Fonts............................................................................................................................. 436
Custom Fonts.............................................................................................................................. 437
Serial Messaging............................................................................................................................ 438
Overview..................................................................................................................................... 438
Baud Rate................................................................................................................................... 439
Parity........................................................................................................................................... 439
Data Bits ..................................................................................................................................... 439
Flow Control................................................................................................................................ 439
During Jog on Path..................................................................................................................... 440
Retry on Time Out....................................................................................................................... 440
Time Out ..................................................................................................................................... 440
Programming Code..................................................................................................................... 440
Message Information .................................................................................................................. 441
Message Command Type........................................................................................................... 442
Optional Format Value................................................................................................................ 442
Specialty Characters Supported................................................................................................. 442
Optional Format Character Assignments.................................................................................... 443
Optional Delay Time/Time Out Value ......................................................................................... 443
Message Text Content................................................................................................................ 443
Non –Printing Characters .......................................................................................................... 444
Exceptions / Additions................................................................................................................. 444
Non Printing Character Table ..................................................................................................... 445
AUTOMATED PLASMA INTERFACE .............................................................................................. 447
HPR and HD4070 Interface............................................................................................................ 447
Cut Chart..................................................................................................................................... 448
Material Type .............................................................................................................................. 448
Current Settings.......................................................................................................................... 448
Plasma / Shield Gases................................................................................................................ 448
Material Thickness...................................................................................................................... 448
Cut Speed................................................................................................................................... 448
Kerf.............................................................................................................................................. 449
Set Arc Voltage........................................................................................................................... 449
Preflow Setting............................................................................................................................ 449
Cutflow Settings.......................................................................................................................... 449
Preflow Time............................................................................................................................... 449
Purge Time ................................................................................................................................. 449
Pierce Time................................................................................................................................. 449
Creep Time................................................................................................................................. 449
Save Process.............................................................................................................................. 449
Reset Process............................................................................................................................. 449
Save Cut Charts.......................................................................................................................... 450
Load Cut Charts.......................................................................................................................... 450
Test Preflow................................................................................................................................ 450
Test Cutflow................................................................................................................................ 450
I/O and Diagnostics..................................................................................................................... 452
Information.................................................................................................................................. 452
HPR Diagnostics......................................................................................................................... 452
HD4070 Diagnostics................................................................................................................... 453
Test Preflow................................................................................................................................ 453
Test Cutflow................................................................................................................................ 453
Test HPR Gas Console............................................................................................................... 453
Coolant Override......................................................................................................................... 453
Update Software ......................................................................................................................... 453
Inputs .......................................................................................................................................... 454
Inputs .......................................................................................................................................... 455