MicroEdge Manual

HYPERTHERM SHAPE CUTTING CONTROL INSTALLATION & SETUP GUIDE MICROEDGE™ ADDENDUM 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. HD 3070® and HD 4070® 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 SECOS North America. Indramat™ is a trademark of Bosch Rexroth. Pacific Scientific™ is a trademark of Danaher Motion. COPYRIGHT ©2004 by Hypertherm Automation. All rights Reserved Printed in USA Table of Contents SAFETY ................................................................................................................................................1 Read This Manual .............................................................................................................................1 Dangerous Machinery .......................................................................................................................1 High Voltages.....................................................................................................................................1 Product Listings.................................................................................................................................2 Type “M” and “P” Controls ................................................................................................................2 MicroEDGE™ Shape Cutting Control .............................................................................................3 Model Numbering System.................................................................................................................4 OVERVIEW..........................................................................................................................................5 Keyboard Layout ...............................................................................................................................5 Keyboard Layout ...............................................................................................................................6 System Requirements .......................................................................................................................6 Monitor Requirements ( CRT or LCD ) ........................................................................................6 Keyboard Requirements ................................................................................................................6 Optional Mouse Requirements......................................................................................................6 THC, Joystick & Speedpots...........................................................................................................6 MACHINE INTERFACE ...................................................................................................................7 Serial Port ......................................................................................................................................7 I/O Configuration Type “P” ...............................................................................................................8 I/O Connector .................................................................................................................................8 I/O Configuration Type “P” ( Single Ended I/O ) .............................................................................9 Single Ended I/O Pinout..............................................................................................................10 Drive/Encoder Connector ............................................................................................................11 Axes Assignments ........................................................................................................................11 Drive/Encoder Pinout ..................................................................................................................12 Drive/Encoder Pinout (For 3 and 4 Axes units) .........................................................................12 I/O Configuration Type “M” ( Double Ended I/O ).........................................................................13 Double Ended I/O Pinout.............................................................................................................13 Drive/Encoder Connector ............................................................................................................14 Axes Assignments ........................................................................................................................14 Drive/Encoder Pinout ..................................................................................................................15 I/O Configuration Type “B”.............................................................................................................16 Oxy Fuel and Plasma Connectors...............................................................................................16 Oxy Fuel Pinout ...........................................................................................................................17 Plasma Pinout ..............................................................................................................................17 Drive Connector ...........................................................................................................................18 Axes Assignments ........................................................................................................................18 Drive Pinout .................................................................................................................................18 Encoder Connectors .....................................................................................................................19 Encoder Pinout.............................................................................................................................19 THC and Joystick Interface ............................................................................................................20 Series 1 PCI Analog Card............................................................................................................20 THC 1............................................................................................................................................20 THC 2............................................................................................................................................20 Joystick.........................................................................................................................................21 THC and Joystick Cable Grounding...........................................................................................21 Safety 1 Safety Read This Manual Read and understand this instructional manual, the cutting machine manuals, and your employer’s safety practices. Note: This product is not designed to be field serviceable. Please return to an authorized repair center for any required service. Dangerous Machinery Operation and maintenance of automated equipment involves potential hazards. Personnel should take precautions to avoid injury. Injury and entanglement may occur if hands and limbs come in contact with moving machinery. KEEP HANDS CLEAR of dangerous moving machinery. All control, including manual, can be effected using the remote interface. Loose fitting clothing or ties may become entangled in the machinery. These items should not be worn while operating or servicing the machine. High Voltages Electric shock can kill. Be sure this equipment is safely installed in accordance with enclosed procedures and specifications. Avoid contact with electrical wires and cabling while power is on. This equipment should only be opened by trained service personnel. Please refer to the appropriate appendix in the Installation Guide provided with your control for details on safety certification for that product. 2 MicroEDGE™ Addendum Product Listings Type “M” and “P” Controls Note: This product has been designed and manufactured in accordance with CE and UL Safety Standards. UL has successfully tested and listed the type “ M” and ”P” (with 10.4” display) control products in accordance with the applicable U.S. and Canadian Safety Standards. File number E178333. Note: Suitable for pollution degree 2 environment only. This appliance has been successfully tested and listed by CE under the following standards; EN 500081-2 1994, EN 61000-6-2 1999 and EN 55011:1998. Certificate number: Retlif R-3909N Overview 3 MicroEDGE™ Shape Cutting Control System Features* Operating System Microsoft Windows XP® - Embedded Version Processor Intel 2.4 Ghz or greater Memory 256 Megabytes RAM Hard Drive 40.0 Gigabyte Hard Drive or greater Communication 1 x RS232; Programmable to 230K Baud using Hypertherm’s communications software Floppy Drive 1.44 Megabyte Floppy Drive CD-ROM/DVD Drive Standard RFI/ EMI Shielding Machine side Opto-Isolation: grounding I/0 24 Lines of user definable Interface Signal ( 12 In / 12 Out ) Supportable Axes Standard 2; Optional expansion of up to 4 Axes SERCOS Interface™ Optional SERCOS Interface™ for expandable axis, I/O and analog inputs Motherboard Interface PS2 Keyboard & Mouse**, 5 – 2.0 USB, Parallel Port Optional Networking On-board RJ-45 Network Port Dimensions 14.38”W x 20.00”D x 9.35”H Weight 35 lbs Operating Environment 0 to 50C; 95% relative humidity (non-condensing) On-board Voltage and Temperature Monitoring Power Universal Input *Information subject to change without notice. ** User supplied Display and Keyboard required. SERCOS™ Interface is a Trademark of SERCOS North America 4 MicroEDGE™ Addendum Model Numbering System The control is available with the following hardware and software configurations. Features and control configuration options in software are based on the I/O configuration of the control. Generally, the information presented in this guide is based on the I/O configuration as outlined below. Please refer to your control I/O configuration for available features and product information. The specific configuration is determined by the Model Number, as shown below: -- Axis Configuration 2 = 2 Servo Axes 3 = 3 Servo Axes 4 = 4 Servo Axes 5 = 5 Servo Axes 6 = 6 Servo Axes 7 = 7 Servo Axes 8 = 8 Servo Axes 9 = 9 Servo Axes A = 10 Servo Axes B = 11 Servo Axes C = 12 Servo Axes S = Sercos I / O Configuration B = Burny 3 / 5 M = MicroPath P = PicoPath V = Voyager S = Sercos Power Supplies 0 = Standard Logic Supply 2 = Standard Logic Supply & Auxiliary Supply with +5, +/-12 & +24 vdc Pointing Device 0 = None 1 = Industrial Mouse LCD Type X = None 0 = 10.4" Dual Scan DSTN 1 = 10.4" Active Matrix TFT 2 = 15" Active Matrix TFT 3 = 15" Touch Screen Memory 0 = 16 MBytes 1 = 32 MBytes 2 = 64 MBytes 3 = 128 MBytes 4 = 256 MBytes 5 = 512 MBytes Processor Backup Hard Drive 0 = None 1 = Installed -H THC 0 = None 1 = 1 THC 2 = 2 THC's Speed Pots 0 = None 1 = 1 Speed Pot 2 = 2 Speed Pots Joystick 0 = None 1 = Joystick Operating System APC 0 = None 1 = 1 APC 2 = 2 APC's 0 = Windows 95 / 98 1 = Windows NT 2 = Windows XP 0 = 166 MHz 1 = 200 MHz 2 = 266 MHz 3 = 433 MHz 4 = 566 MHz 5 = 1.2 GHz 6 = 2.4 GHz Model Numbers You may wish to record your Model Number in the space provided below. Model Number Information Model Number: Serial Number: Overview 5 Overview The MicroEDGE™ CNC control is the latest PC based motion control offering from Hypertherm® Automation specifically for the metal cutting industry. This control package provides a unique combination of flexible table configurations, expandable features and an unparalleled ease of use. MicroEDGE™ utilizes our proprietary Graphical User Interface (GUI) and SoftMotion Technology with motion control operation of up to four axes with 24 I/O signals. This product offers a unique approach to the motion control market by allowing the table manufacturer / system integrator to customize the final package by adding their own Monitor, Keyboard and Mouse. Additional features such as Joystick, Speed Pots, networking, CAD / CAM Software, Nesting Software provide unlimited combinations of productivity options. Interface Options Type “M” ( 2 axes ) Type “P” ( 2-4 axes ) Please refer to the Operator’s and Installation manuals included with your control for additional information on this product. Operation and interface information will be based on the interface option selected (Type P or Type M). Disclaimer No warranty, expressed or implied, extends to this product beyond original hardware and software provided by Hypertherm Automation®. MicroEDGE™ Top View Front and Rear View 6 MicroEDGE™ Addendum Keyboard Layout Typical Keyboard Layout Keyboard Functions Function Keys F1-F8 are equivalent to the soft keys on the display screen. Function Key F9 is equivalent to the START key. Function Key F10 and Pause Key are equivalent to the STOP key. Function Key F11 is equivalent to the MANUAL MODE key. Function Key F12 is equivalent to the HELP key. Arrow direction keys are used for manual motion. The HOME key is equivalent to the PREV field key. The END key is equivalent to the NEXT field key. The [ key is equivalent to the purple arrow shift key. The ] key is equivalent to the blue arrow shift key. The Esc key is equivalent to the CANCEL key. To exit the control software press Alt F4. To switch between applications press Alt Tab. A color coded key cap sticker set is provided to allow easy reference to the keys used by the control software. System Requirements Monitor Requirements ( CRT or LCD ) Standard VGA capable 640 x 480 analog monitors or better with 15 pin High Density D-sub connector. Keyboard Requirements Standard 101/ 104 Key PS/2 or USB Compatible Keyboard Optional Mouse Requirements PS/2 or USB Compatible Mouse THC, Joystick & Speedpots Optional features for two Sensor THC, one Joystick and two Speedpots are offered. Connection and operation information is provided in the Operators and Installation Guide provided with this product. Note: Use of some monitors and other devices may require loading of a device driver for operation. Many standard device drivers are located in the C:\CABS or C:\CABS\I386 folders. Machine Interface 7 Machine Interface The MicroEDGE™ shape cutting control is an extremely versatile product offering up to four configurable axes of motion, configurable I/O locations and three different styles of external table interface for ease of installation. The control features may also be expanded through use of optional analog and network interface cards. The rear panel of the control has several cable connectors to connect the control to power, I/O and communication ports. These connectors are clearly labeled as to their function. The AC power cable is inserted into the AC power connector and plugged into a standard 3-way 110 or 220 volt outlet. The control has a universal AC input power module that allows the user to plug into either voltage without changing additional jumpers. In addition, the AC Power connector contains an integral fuse receptacle and line filter. A remote communications link can be connected to one of the two serial ports and an external ground (PE) lug for earth grounding of the unit is also provided. Serial Port Please refer to the Ports Information section of the Installation Guide for additional information on configuration of Serial ports for communication. Note: Serial ports for the MicroEDGE are not optically isolated. Appropriate grounding or after market port isolator or protocol converter to add optical isolation is recommended. 8 MicroEDGE™ Addendum I/O Configuration Type “P” The cables that connect the control to the cutting machine are attached to the I/O (Input/Output), and the DRIVE/ENCODER connectors. For the purposes of this guide Single Ended I/O is referred to as Type “P” configuration. The information provided here is the basic information for connection of the shape cutting control to the cutting table. Each machine interface will vary slightly based on the cutting table configuration and features. Additionally, I/O pinout information may vary slightly based on the configuration of the selected I/O and their locations. Changes to the I/O configuration may be made in the password protected I/O screen. All controls are shipped with the default selection of Inputs and interface locations for the selected control Interface (I/O) configuration. Installation and service should only be performed by a qualified service technician. I/O Connector The I/O connector is a standard sex circular CPC connector from AMP. This connector was specifically chosen for its rugged industrial design and its metal insulation characteristics for EMI/RFI noise immunity. In the single ended I/O scheme, a ground is provided on the I/O pin. In the double-ended approach, both the positive and negative pins for each I/O point are provided to the user. The advantage to single ended I/O is that it takes one pin for each point versus two for the double- ended I/O scheme, thus increasing the total number of I/O points available to the user. I/O Mating Connector Connector AMP #208470-1 Backshell AMP #208945-8 Sockets (16-18 ga) AMP #66101-3 Sockets (20-24 ga) AMP #66105-3 Machine Interface 9 I/O Configuration Type “P” ( Single Ended I/O ) Connecting single ended I/O to the control. These examples assume a +24V power supply has been connected across pins 34 and 36 of the control, or that the optional internal +24V power supply has been installed. Output tied to external Cut On Input tied to Cut Sense Relay Examples of possible circuits Output Input 10 MicroEDGE™ Addendum Single Ended I/O Pinout The Single Ended I/O offers 12 outputs which are rated at 24VDC for up to 1-amp loads and 12 inputs rated for 24VDC. Pin I/O Description 1 Input 1 Torch Up Sense 2 Input 2 Torch Down Sense 3 Input 3 Preheat Sense or X -Overtravel