Thermal Dynamics iCNC Performance User manual

Thermal-Dynamics.com
®
24V
DC
INPUT VOLTAGE
Revision: AB Issue Date: February, 2016 Manual No.: 0-5401
iCNC PERFORMANCE
CNC CONTROLLER
Service and
Installation
Manual

WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Dynamics product. We are proud to have you as our
customer and will strive to provide you with the best service and reliability in the industry. This
product is backed by our extensive warranty and world-wide service network. To locate your
nearest distributor or service agency call 1-800-752-7622, or visit us on the web at www.thermal-
dynamics.com.
This Service Manual has been designed to instruct you on the correct use and operation of your
Thermal Dynamics product. Your satisfaction with this product and its safe operation is our
ultimate concern. Therefore please take the time to read the entire manual, especially the Safety
Precautions. They will help you to avoid potential hazards that may exist when working with this
product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products.
We distinguish ourselves from our competition through market-leading, dependable products
that have stood the test of time. We pride ourselves on technical innovation, competitive prices,
excellent delivery, superior customer service and technical support, together with excellence in
sales and marketing expertise.
Above all, we are committed to developing technologically advanced products to achieve a safer
working environment within the welding industry.

!
WARNING
Read and understand this entire Manual and your employer’s safety practices before installing, operat-
ing, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s best judgement, the
Manufacturer assumes no liability for its use.
iCNC Performance
Service Manual No. 0-5401
Published by:
Thermal Dynamics Corporation.
2800 Airport Rd.
Denton, Texas 76207
www.thermal-dynamics.com
© Copyright 2015, 2016 by
Thermal Dynamics Corporation.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any er-
ror or omission in this manual, whether such error results from negligence, accident, or any other cause.
Publication Date: September 25, 2015
Revision Date: February, 2016
Record the following information for Warranty purposes:
Where Purchased: ___________________________________
Purchase Date:______________________________________
iCNC Performance Serial #:_______________________________

Be sure this information reaches the operator.
You can get extra copies through your supplier.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting equipment, we urge
you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging,” Booklet 0-5407. Do NOT permit untrained persons to install, operate, or maintain
this equipment. Do NOT attempt to install or operate this equipment until you have read
and fully understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read the Safety Precautions before
installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or
inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be
checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn,
distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufac-
turer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was
purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this
equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage,
improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.
!
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR
OPERATING.
PROTECT YOURSELF AN D OTHERS!

ASSUREZ-VOUS QUE CETTE INFORMATION EST DISTRIBUÉE À L’OPÉRATEUR.
VOUS POUVEZ OBTENIR DES COPIES SUPPLÉMENTAIRES CHEZ VOTRE FOURNISSEUR.
ATTENTION
Les INSTRUCTIONS suivantes sont destinées aux opérateurs qualiés seulement. Si vous
n’avez pas une connaissance approfondie des principes de fonctionnement et des règles
de sécurité pour le soudage à l’arc et l’équipement de coupage, nous vous suggérons de
lire notre brochure « Precautions and Safe Practices for Arc Welding, Cutting and Gouging,
» Brochure 0-5407. Ne permettez PAS aux personnes non qualiées d’installer, d’opérer ou
de faire l’entretien de cet équipement. Ne tentez PAS d’installer ou d’opérer cet équipement
avant de lire et de bien comprendre ces instructions. Si vous ne comprenez pas bien les
instructions, communiquez avec votre fournisseur pour plus de renseignements. Assu-
rez-vous de lire les Règles de Sécurité avant d’installer ou d’opérer cet équipement.
RESPONSABILITÉS DE L’UTILISATEUR
Cet équipement opérera conformément à la description contenue dans ce manuel, les étiquettes d’accompagnement et/ou les
feuillets d’information si l’équipement est installé, opéré, entretenu et réparé selon les instructions fournies. Vous devez faire une
vérication périodique de l’équipement. Ne jamais utiliser un équipement qui ne fonctionne pas bien ou n’est pas bien entretenu.
Les pièces qui sont brisées, usées, déformées ou contaminées doivent être remplacées immédiatement. Dans le cas où une répa-
ration ou un remplacement est nécessaire, il est recommandé par le fabricant de faire une demande de conseil de service écrite ou
par téléphone chez le Distributeur Autorisé de votre équipement.
Cet équipement ou ses pièces ne doivent pas être modiés sans permission préalable écrite par le fabricant. L’utilisateur de l’équi-
pement sera le seul responsable de toute défaillance résultant d’une utilisation incorrecte, un entretien fautif, des dommages, une
réparation incorrecte ou une modication par une personne autre que le fabricant ou un centre de service désigné par le fabricant.
!
ASSUREZ-VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D’UTILISATION AVANT
D’INSTALLER OU D’OPÉRER L’UNITÉ.
PROTÉGEZ-VOUS ET LES AUTRES!

This Page Intentionally Blank

Declaration of Conformity
We Thermal Dynamics
of 2800 Airport Road
Denton, TX 76207 U.S.A.
in accordance with the following Directive(s):
2006/95/EC The Low Voltage Directive
2004/108/EC The Electromagnetic Compatibility Directive
hereby declare that:
Equipment: Plasma Cutting CNC Controller
Model Name/Number: iCNC Performance
Market Release Date: August 19, 2015
is in conformity with the applicable requirements of the following harmonized standards:
Conforms to requirements of IEC 61326-1:2012
IEC 61000-4-2: 2008, Electro Static Discharge Immunity
IEC 61000-4-3:2006 +A1:2007 +A2:2010, Radiated, Radio-Frequency, Electromagnetic Immunity
IEC 61000-4-4:2012, Electrical Fast Transient/Burst Immunity
IEC 61000-4-6: 2008, Conducted Radio-Frequency Electromagnetic Immunity
IEC 61000-4-8:2009, Power Frequency Magnetic Field Immunity
CISPR 11:2009 +A1:2010, AC Mains Conducted Emissions
CISPR 11:2009 +A1:2010, Radiated Emissions
Meets IEC 61010-1:2010 Safety requirements for electrical equipment for measurement, control, and
laboratory use - Part 1: General requirements
Classification: The equipment described in this document is Class A and intended for industrial use.
!
WARNING
This Class A equipment is not intended for use in residential locations where the electrical
power is provided by the public low-voltage supply system. There may be potential difficul-
ties in ensuring electromagnetic compatibility in those locations, due to conducted as well
as radiated disturbances.
Manufacturer’s Authorized Representative
Steve Ward V.P. Europe and General Manager
Address:Victor Technologies International Inc.
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
Date: August 19, 2015
Steve Ward
Full Name
V.P. Europe and General Manager
(Position)
(Signature)

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

TABLE OF CONTENTS
SECTION 1: SAFETY........................................................................................ 1-1
1.01 Safety Precautions - ENGLISH........................................................................ 1-1
1.02 Précautions de sécurité - FRENCH CANADIAN ............................................... 1-6
SECTION 2: SPECIFICATIONS............................................................................. 2-1
2.1 System Description......................................................................................... 2-1
2.2 Specification ................................................................................................... 2-1
2.3 Dimensions..................................................................................................... 2-2
2.4 Basic System Layout ...................................................................................... 2-3
2.5 Grounding and Cable Routing......................................................................... 2-4
2.5.1 Low Cost Ground Rod Tester ......................................................................... 2-4
2.6 Connector Locations....................................................................................... 2-6
SECTION 3: I/O DESCRIPTIONS .......................................................................... 3-1
3.1 General ........................................................................................................... 3-1
3.2 J45 Inputs....................................................................................................... 3-1
3.2.1 Input Pin Arrangement.................................................................................... 3-1
3.2.2 Input Example................................................................................................. 3-2
3.2.3 Input Naming.................................................................................................. 3-2
3.3 J46 Outputs .................................................................................................... 3-3
3.3.1 Output Pin Arrangement ................................................................................. 3-3
3.3.2 Output Example .............................................................................................. 3-4
3.3.3 Output naming................................................................................................ 3-4
3.3.4 Wiring Multiple Oxyfuel Lifters ....................................................................... 3-5
3.3.5 Wiring Multiple Stations ................................................................................. 3-6
SECTION 4: MOTION ....................................................................................... 4-1
4.1 Motion in General ........................................................................................... 4-1
4.1.1 Motion Signal Characteristics ......................................................................... 4-1
4.2 J47 Servo Connector ...................................................................................... 4-2
4.2.1 Servo Pin arrangement ................................................................................... 4-2
4.3 J48 Encoder Connector .................................................................................. 4-3
4.3.1 Encoder Pin Arrangement............................................................................... 4-3
4.4 Servo Connection Examples ........................................................................... 4-4
4.4.1 Analog Speed Signal with Yaskawa SGDV ...................................................... 4-4
4.4.2 Step/Dir Signal with Yaskawa SGDV ............................................................... 4-4
4.4.3 Analog Speed Signal with Panasonic A5......................................................... 4-5
4.4.4 Step/Dir with Panasonic A5 w/o Encoder Feedback........................................ 4-5
4.4.5 Step/Dir Signal without Encoder Feedback ..................................................... 4-6
SECTION 5: INPUT POWER ............................................................................... 5-1
5.1 Power Supply ................................................................................................. 5-1
5.2 Power Connector ............................................................................................ 5-1
5.2.1 Power Connector Pin Arrangement................................................................. 5-1
SECTION 6: iHC............................................................................................. 6-1
6.1 Lifter Specifications ........................................................................................ 6-1
6.1.2 Voltage Divider Dimensions............................................................................ 6-2
6.2 Connector Locations....................................................................................... 6-2
6.3 IO Example Connections................................................................................. 6-3
6.4 J54 Lifter ........................................................................................................ 6-4
6.5 J55 Plasma..................................................................................................... 6-5
6.6 J53 CNC.......................................................................................................... 6-6

TABLE OF CONTENTS
6.7 iHC Software................................................................................................... 6-7
6.7.1 Pierce/Cut Sequence....................................................................................... 6-7
6.7.2 IO Bits Tab ...................................................................................................... 6-8
6.7.3 Service Tab ..................................................................................................... 6-9
6.7.4 Installation Tab.............................................................................................. 6-10
6.7.5 Parameter Limits .......................................................................................... 6-11
SECTION 7: iCNC SETUP .................................................................................. 7-1
7.1 Initial Checks .................................................................................................. 7-1
7.2 Starting iCNC Setup........................................................................................ 7-2
7.3 Motion, STEP/DIR........................................................................................... 7-3
7.3.2 Drive and Encoder Polarities Step/Dir............................................................. 7-4
7.3.3 Encoder Values Step/Dir ................................................................................. 7-5
7.3.4 Max Speed Adjustment Step/Dir..................................................................... 7-6
7.3.5 Motion Parameters ......................................................................................... 7-6
7.4 Motion, Analog Speed..................................................................................... 7-8
7.4.1 Drive Configuration Analog Speed .................................................................. 7-8
7.4.2 Drive and Encoder Polarities Analog Speed .................................................... 7-9
7.4.3 Encoder Values Analog Speed ...................................................................... 7-10
7.4.4 Drift Adjustment Analog Speed..................................................................... 7-11
7.4.5 Max Speed Adjustment Analog Speed .......................................................... 7-11
7.4.6 Max Speed Test Analog Speed...................................................................... 7-12
7.4.7 Min Speed Test Analog Speed....................................................................... 7-12
7.4.8 Motion Parameters ....................................................................................... 7-13
7. I/O................................................................................................................. 7-15
7.5.1 I/O General.................................................................................................... 7-15
7.5.2 I/O and Delay ................................................................................................ 7-17
7.5.2.1 I/O and Delay Plasma Cutting ....................................................................... 7-17
7.5.2.2 Advanced...................................................................................................... 7-19
7.5.2.3 I/O and Delay Gas Cutting............................................................................. 7-20
7.5.2.4 Custom ......................................................................................................... 7-21
7.5.2.5 Advanced...................................................................................................... 7-22
7.5.2.6 I/O and Delay Line Marking........................................................................... 7-22
7.5.3 Custom ......................................................................................................... 7-23
7.5.4 Advanced...................................................................................................... 7-24
7.5.5 I/O Point Marking.......................................................................................... 7-25
7.5.6 I/O Outbit Names .......................................................................................... 7-26
7.5.7 I/O Inbit Names............................................................................................. 7-26
7.6 Cutting Table Data......................................................................................... 7-27
7.6.1 Homing / Limits............................................................................................ 7-27
7.6.2 Down Draft ................................................................................................... 7-31
7.7 Others........................................................................................................... 7-32
7.7.1 General ......................................................................................................... 7-32
7.7.2 THC/Plasma Settings ................................................................................... 7-33
7.7.3 Teach In ....................................................................................................... 7-34
7.7.4 Get Serial Number ........................................................................................ 7-34
7.7.5 Diagnostic Information ................................................................................. 7-34
7.7.6 Advanced Diagnostics................................................................................... 7-34
7.7.7 Update Software ........................................................................................... 7-34
7.8 Backups........................................................................................................ 7-34
7.8.1 Backup Machine Settings.............................................................................. 7-34
7.8.2 Restore Machine Settings............................................................................. 7-35