KAR CNC

Operation Manual

Manufactured by ProMotion Controls Document v1.01

Koike KAR CNC

Table of Contents Part I Warranty

1

1

Warnings ................................ ................................................ ................................. ................................ ............... 1

2

Contact ................................ ............... Info ................................. ................................. ................................ ............... 2

Part II Overview 1

3

Main Screen ................................ ................................................ ................................. ................................ ............... 4 Info (System Status) ............................................................................ 4 ProMotion Cut - Next............................................................................ Job 5 Current Job

2

............................................................................ 7

KAR CNC ............................... ............... Operating ................................. Control ................................. Panel................................ ................ 10 Emergency Stop - Off ............................................................................ Button 11 Input Power Switch............................................................................ 11 Drive Enable Switch............................................................................ 12 IHS Switch

............................................................................ 13

Floating Head Switch ............................................................................ 13 Plasma Switch

............................................................................ 14

Torch Raise / Lower............................................................................ Switch 15 Speed Potentiometer ............................................................................ 15 Eight Direction Jog ............................................................................ Keys 16 Manual Mode Button ............................................................................ 16 Zero Button

............................................................................ 17

Start Button

............................................................................ 18

Torch On/Off Button............................................................................ 19 Speed Up & Speed Down ............................................................................ Buttons 20 Move Ahead Button............................................................................ 20 Stop / Backup Button ............................................................................ 21

Part III Setup of KAR CNC 1

22

Starting ............................... ............... and Turning ................................. off the ................................. Controller ................................ ................ 22 Starting Procedure ............................................................................ 22 Shutting Off / Removing ............................................................................ Power 22

2

Homing ............................... ............... Procedure ................................. ................................. ................................ ................ 22 I

© 1997 - 2005 Robotronic Oy

Koike KAR CNC

3

Jog

................................................................................ 23

4

Parameter ................................................................................ Quick View 24 Advanced Setup

............................................................................ 26

Plate Alignment

............................................................................ 29

Part IV ProMotion® Nest 1

30

File Menu ................................................................................ 32 New Plate

............................................................................ 32

Open

............................................................................ 32

Trash

............................................................................ 34

Save As

............................................................................ 34

Macro

............................................................................ 34

Print

............................................................................ 38

DNC

............................................................................ 38

Import

............................................................................ 39

Export

............................................................................ 39

Exit

............................................................................ 39

2

View Menu ................................................................................ 39

3

Tools Menu ................................................................................ / Toolbox 40 Move Shape

............................................................................ 40

Rotate Shape

............................................................................ 40

Mirror

............................................................................ 41

Remove

............................................................................ 41

Change Piercing Point ............................................................................ 41 Change Compensation ............................................................................ Side 41 Change Cutting Direction ............................................................................ 42 Change Cutting Order ............................................................................ 42 Split Element

............................................................................ 44

Join Profiles

............................................................................ 44

Leadins

............................................................................ 44

Zoom In / Out

............................................................................ 45

Reset View

............................................................................ 45

Pan View

............................................................................ 45

Ruler

............................................................................ 46


II

Koike KAR CNC

4

Copy

............................................................................ 46

Cut

............................................................................ 46

Paste

............................................................................ 47

Undo

............................................................................ 47

Options ................................................................................ Menu 47 Handling Options ............................................................................ 48 EIA Options

............................................................................ 51

Language Options ............................................................................ 53

5

Help Menu ................................................................................ 54

6

Toolbar................................................................................ 54

7

8

MicroCAD

............................................................................ 55

NestInfo

............................................................................ 57

List Windows ................................................................................ 58 Plate List

............................................................................ 58

Part List

............................................................................ 59

Miscellaneous ................................................................................ 60 Terminology

............................................................................ 60

DXF

............................................................................ 60

Improving DXF Loading ............................................................................ Times 61 CNC-2

............................................................................ 65

Line and point marking ............................................................................ 65

Part V Monograph Training Guide

66

1

Introduction ................................................................................ 66

2

Independent ................................................................................ Systems 66 ATC - Arc Voltage Controller ............................................................................ 66 Trouble Shooting AVC ............................................................................. 69 Other Issues Which Influence Proper Arc Voltage............................................................................. Control 71 Torch Lifter/ Linear ............................................................................ Slide 72 Lifter Check Out / Setup Procedure ............................................................................. 73 Koike HS-5 Lifter Technical Information ............................................................................. 75

III


Koike KAR CNC

Lifter Sequencing Conditions ............................................................................. 77 Sequence of Operation Manual mode ............................................................................. 78 Sequence of Operation Auto mode ............................................................................. 79 State of Lifter Motion Trajectory ............................................................................. 80

3

IHS (Initial ................................................................................ Height Sensing) 81 IHS Checkout Procedure ............................................................................ 82 Initial Height Sensing ............................................................................ Troubleshooting Guide 83

4

Process ................................................................................ Controller 85 Plasma Cutting (Tab............................................................................ 0) 86 Plasma Cutting (Tab............................................................................ 1) 87 MNM Model Plasma............................................................................ Cutting Sequence of Operation 87 BASIC SETUPS

............................................................................ 89

ADVANCED SETUPS ............................................................................ 90 Show Delay Names ............................................................................ In Readjust Field 93 Aux Parameters

............................................................................ 95

Floating Head Setup............................................................................ Tables 97

5

Plasma................................................................................ Power Supply 99 General Information............................................................................ 99

Part VI Connector Review

101 108

Index


IV

Warranty 1

Koike KAR CNC

Warranty ProMotion Controls Inc. warrants to the purchaser that products shall be free from defects in materials and workmanship, under normal and proper use, for a period of one (1) year from shipment date from seller's factory. Labor expenses are covered for a period of 90 days on equipment installed by ProMotion Controls, from date of installation. The warranty shall not extend beyond this time for any reason. Improper use, modification, mishandling, or incorrect installation by others will exclude ProMotion Controls from warranting this product. ProMotion Controls, at its option, shall repair or replace free of charge any product covered by this warranty, which has been returned with prior authorization. The product must be properly packaged and returned with all costs, freight and insurance prepaid and is subject to inspection of proper use as noted above. Replacement or repaired parts will be sent standard ground delivery and insured, at no charge, to the end user. The warranty on replacement or repairs shall expire on the same date as the warranty on the originally purchased product. Shipment costs and insurance when expedited services are required will not be covered. Under no event will this warranty obligate ProMotion Controls for any amount exceeding the price of the goods upon which liability is based. The applicable warranty expressed in this section constitutes the only warranty of Promotion Controls, Inc. and no other warranty or condition statutory or otherwise shall be implied.

1.1

Warnings DO NOT CONNECT the controller directly to a computer through the RJ45 or RS232 port! Connections must be made with fiber optic devices, wireless LAN, short haul modems or other approved devices which provide galvanic isolation, due to ground loops, electrical noise, or high frequency which can destroy electrical components in the controller or host computer. Failure to follow these rules will VOID THE WARRANTY!

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Koike KAR CNC

1.2

Warranty

Contact Info Koike Aronson, Inc. Eastern Region Divisional Headquarters, Arcade NY 1 585-492-2400 Southern Region Houston, TX 77055 1 713-682-9645 www.koike.com ProMotion Controls 780 W. Smith Rd. Unit F Medina, Ohio 44256 Tel: +1 330 721 1464 Fax: +1 330 721 1463 E-mail: [email protected] www.promotioncontrols.com International Office Robotronic Oy Sammonkatu 66 B FIN-33540 Tampere Finland Tel: +358 3 276 0500 Fax: +358 3 222 5967 E-mail: [email protected] www.robotronic.fi


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Overview 2

Koike KAR CNC

Overview Introduction The KAR CNC controller is a two axis servo controller specifically designed for the Monograph Millennium plasma cutting machine by Koike Aronson, Inc. The system includes two microprocessors to offer TRUEMULTITASKING functions, download or prepare your next job while the machine is cutting. With a 12.1 inch TFT color screen you can graphically see your current job being cut and look at your next job simultaneously. The KAR CNC controller is designed to be user friendly and simple to use. Please review the functionality of the screens and the operational of the front panel keys to take full advantage of the KAR CNC controller.

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Koike KAR CNC

2.1

Overview

Main Screen The main screen is divided in three parts. Info (Systems Status) Promotion Cut –Next Job Current Job · · ·

2.1.1

Info (System Status)

This is located on top of the screen. The info screen shows information to the operator and used for diagnostics and troubleshooting.

· · ·

Speed IPM (or metric) indicates machine speed. X & Y readouts indicates position of cutting torch. Speed Bar in %. This is interfaced directly with the Speed


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Overview

·

·

·

2.1.2

Koike KAR CNC

Potentiometer. If the speed pot is turned completely 100% CW the Speed Bar will show 100%. Jogging direction indicator. Monitors and shows which direction jogging key is pressed. Operational Panel – Interfaced with the 8 push buttons. Monitors which button is pressed or activated. System Running – Indicates that the second CPU is activated and functionally properly.

ProMotion Cut - Next Job

Located on the left hand side of the screen, the Promotion Cut Screen is the starting point to navigate through out the different screens.

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Koike KAR CNC

Overview

Selecting the Shapes button will automatically open the Macro Shape Library in ProMotion Nest.


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Overview

Koike KAR CNC

The Download button opens the Windows Open File to select a stored program from the internal drive system or external device.

'The Setup button opens the Parameter Quick View Screen to allow you to change values for Kerf, Speed etc.

Selecting rows & columns button will ask you how many rows and columns of the shape currently shown.

Opens to the jog screen dialog box. Functions like Drive machine to and Rip cut are located under this jog dialog box.

Selecting on the Act button will allow you to do a trial run of the program, select on board manual, and the options to open the menu bar on Promotion Cut - Next Job Screen. HINT: To perform a trial run properly the manual mode button must not be activated.

2.1.3

Current Job

The current job screen located on the right hand side of the screen. This screen displays the current job being cut with real time tracking.

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Koike KAR CNC

Overview

Normally this button is grayed out. Activated when a cutting program is stopped by pressing the torch on/off and or the Stop–Backup buttons located on the front panel of the controller. Selecting the cancel program will suspend the current job program.


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Overview

Koike KAR CNC

Normally this button is grayed out. Activated when a current program is stopped and the manual mode button is activated. When confirming if a program fits on a plate i.e. in trial mode it will reposition the program the same distance as the torch movement.

Normally this button is grayed out. Activated when a current program is stopped and the manual mode button is activated. Selecting Cut Path Recovery will re-start the pierce cycle at the point the torch is located and will find the program path at the point the torch existed in manual mode.

Selecting the readjust cut parameters button will allow the operator to change certain parameters i.e. cutting speeds, creep speed, creep time and pre-stop distance to the cutting program on the fly. This will eliminate the need to stop the machine to make these changes.

Refresh the current job screen.

Selecting the next job preview allows the transfer of next program from the next job preview screen with out activating the cutting sequence. This is grayed out during cutting.

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Koike KAR CNC

Overview

Selecting the view track during cutting will zoom in on the cutting path.

The Cut again box allows the opportunity to suspend and save a job and restart a saved job. Show new start point – Selecting this function allows the mouse pointer to automatically change to a cross hair when a pierce point is identified on a part. Restart- After locating a new pierce point , select restart to start cutting cycle. Zoom – Expands on the save job screen Save job – Will store existing suspended program in temporary file Reload saved job – Brings back the suspended saved program from the temporary file. Cancel – Cancel any selected functions under the cutting again box. ·

·

· ·

·

·

2.2

KAR CNC Operating Control Panel The KAR CNC operating controls functions are locate below the LCD graphic screens. Most of all the machines motion and cutting are initiated using the operating control panel.


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Overview 2.2.1

Koike KAR CNC

Emergency Stop - Off Button

The emergency stop –off button is used to remove power from the entire system in case of an emergency. It supplies power to the servos, and cutting controls. The power to the CNC is not removed. Motion and cutting will stop immediately when the Emergency stop is pushed in. Turn the E-stop button clockwise and release to apply power to the servos and cutting controls. 2.2.2

Input Power Switch

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Koike KAR CNC

Overview

The power switch is a momentary switch. Toggle the switch up and hold two seconds will turn on power to the CNC and the system. The proper way to switch power off is using Windows shutdown. This will switch off all power in the controller. In case Windows shutdown is not available, it is possible to force power off by pressing down this switch for 20 seconds. This method is not recommended, unless there is no other way to shutdown the system. Note: After switching off the controller it is advisible to wait at least 25 seconds to allow the capacitors to discharge before switching on again. 2.2.3

Drive Enable Switch

This is a two position switch on or off. In the off position it disables the servo drives. When the drive switch is in the on position it enables the servo drives allowing the machine to move when commanded to do so.


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Overview 2.2.4

Koike KAR CNC

IHS Switch

This is a two positions switch In the Auto mode the inital height sense will automatically be turned on by the controller to locate the initial height before cutting. In the manual mode the initial height can be turned on manually and controlled by the UP/DOWN switch or by the ARC voltage control height system. 2.2.5

Floating Head Switch

This is a three position switch ON/OFF/AUTO. In the On position the floating head will lower on the surface of the material. In Auto mode

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Koike KAR CNC

Overview

the floating head will lower automatically commanded by the controller. In the OFF position the floating head will be disabled and stays in the up position. 2.2.6

Plasma Switch

This is a three position switch ON/OFF/AUTO. In the On position the plasma can be turned on manualy using the torch on/off button. In Auto mode the plasma will be turned on automatically commanded by the controller. In the OFF position the plasma is disabled and cannot be operated.


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Overview 2.2.7

Koike KAR CNC

Torch Raise / Lower Switch

This is a momentary two position switch to raise or lower the torch. 2.2.8

Speed Potentiometer

Turning the potentiometer counter clockwise decreases the actual speed in comparison with the programmed speed. This potentiometer is only for special cases, it used to temporarily slow down the cutting speed. Turning down the speed below 100 % the Torch Hold / Corner signal will be activated on, which freezes the automatic torch height control at that height. In most case the speed

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Koike KAR CNC

Overview

potentiometer is set at 100% clockwise. 2.2.9

Eight Direction Jog Keys

The manual mode must be activated before using the jog function. Press and hold a directional button and the machine will move in that direction, releasing the button will cause the machine to stop. Pressing and holding two adjoining directional buttons will move both axes in a 45 degree direction. 2.2.10

Manual Mode Button


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Overview

Koike KAR CNC

Pressing the MANUAL MODE button activates the capability to jog and reposition the machine. Pressing it again will turn off the manual mode and will return the machine to the last know parked position. HINT: When locating a new starting point on the table (using the jog function keys) press the Zero button to reset X & Y counters to zero, this will automatically turn off the manual mode and the machine will stay at this new zero, zero point location. 2.2.11

Zero Button

Resets the X & Y counters to zero after locating a new starting point on the table using the jog function keys. HINT: Pressing the zero button will automatically will turn off the manual mode button if it was activated on.

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Koike KAR CNC

2.2.12

Overview

Start Button

Sends the cutting program from the next job preview screen to the current job screen to be executed and starts the cutting cycle sequence. The light of the START-button is on during the entire execution of the program. No programs can be transferred to current job screen if the the START button button is on. HINT: If this button is pressed during a programmed delay the delay is terminated at once without memorising the interrupted time of the delay in cutting parameters.


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Overview 2.2.13

Koike KAR CNC

Torch On/Off Button

Pressing the torch on /off button when the manual mode is activated will start or turns off the plasma arc manually When the start button is activated the cutting sequence is initiated the TORCH ON/OFF button will go on automatically indicating the torch is on and has started to cut. At the end of the program the light on the TORCH ON/OFF will go out automatically indicating end of cut. Press and release the TORCH ON/OFF button during the cutting, the machine motion and cutting stops . Pressing this button again starts the machine motion and the cutting sequence with the programmed delays.

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Koike KAR CNC

2.2.14

Overview

Speed Up & Speed Down Buttons

Short pushes increase or decrease the actual and set speed in small steps. Long lasting push changes the speeds at a faster rate The lights will come on the buttons on during the automatic corner deceleration and acceleration respectively. 2.2.15

Move Ahead Button

The MOVE AHEAD button is illuminated when a program is cutting. Pressing the Torch on/off button will stop the machine and cutting and the Move Ahead button will turn off. At this stage pressing the


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Overview

Koike KAR CNC

MOVE AHEAD button the program will move forward on programmed path with out cutting, pressing the MOVE AHEAD button again will stop machine motion. HINT: Turn speed potentiometer counter clockwise when using the Move Ahead feature for more precise control. 2.2.16

Stop / Backup Button

Press and release the STOP BACKUP button once durring the cutting process stops cutting sequence and machine motion. Press and release the STOP BACKUP button again will move the machine in reverse on path. Pressing STOP BACKUP button again will stop motion. HINT: Both the Stop-Backup and Torch on/off buttons work identical the same when a cutting program is on and you would like to stop cutting.

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Koike KAR CNC

3

Setup of KAR CNC

Setup of KAR CNC

3.1

Starting and Turning off the Controller

3.1.1

Starting Procedure

Make sure that the red Emergency Stop button is pressed in and the drive enable switch is in the off position. Switch on the system by toggling up the power switch located on the far right hand side. When power is applied, the KAR CNC controller will take approximately 2-3 minutes to go through the internal diagnostics and boot up procedure to the Promotion Work Screen displaying Promotion Cut next job preview and current job screen along with Info (System Status). In addition, you will see the yellow Zero button start flashing, this will stop automatically. HINT: The flashing Zero button indicates that the second CPU used for motion has booted up correctly. Release the red E-Stop button by turning it clockwise and external stop limit dialog warning box will disappear on the screen. Switch the drive enable switch to the on position to enable the drives. A dialog box will appear START HOMING PROCEDURE, see section 2.2 for detail information.

3.1.2

Shutting Off / Removing Power

After locating a safe parked position, disable the drives by switching the drive enable switch to off. Turn off computer by clicking on Start (bottom left hand corner) on window's task bar and click on Turn off computer and Turn off. After the controller goes through a proper cycle down procedure the controller will turn off. Press in the Emergency stop button.

3.2

Homing Procedure During initial power up the KAR CNC controller displays a Start Homing procedure dialog box. If you select Yes, the machine will automatically locate the (factory set) absolute zero home location. Normally this is at the bottom left corner of the cutting table - the


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Setup of KAR CNC

Koike KAR CNC

same corner where the KAR CNC controller is. If you select No, the dialog box disappears and no movement is executed.

3.3

Jog When selecting the Jog Button, the Jog dialog box will appear.

You can use Jog tool only when a cutting program is not running and the controller is not in the manual drive mode. Use this tool to drive the machine to the position (X,Y) or to drive a distance (X,Y) from the current position. Driving is usually done in rapid speed. It's also possible to cut with this tool, if you have checked the Rip Cut box. If Use program rotation is checked, the coordinates where you

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Koike KAR CNC

Setup of KAR CNC

drive, are corrected according to the program rotation. The program rotation is set in the parameter quick view screen. It is possible to define several different home positions. These can be used to define the home positions of different plates, which are on the cutting table. Select the number of the table from the list and click the Drive to button. The machine drives to the defined home position of the selected table. If there is a need to drive the same distance often (for example plasma torch to the same position where gas torch was), it's useful to save these kind of distances as default offsets (offset 1 and 2). This way you can drive the default offset just by clicking a button once. Set absolute zero (home) position by clicking the Set absolute 0,0 here button. This tool is needed, if the programmed working area limits are in use. Those limits force the machine to stop before it hits the electrical limit switches. Setting absolute zero position can also be automatic, when the machine is driven to the predefined zero position every time the controller is turned on. Absolute zero position is also needed, if there is a need to set several home positions.

3.4

Parameter Quick View The parameter quick view screen opens automatically when a program is sent to cutting from Promotion Nest or when the Setup button is clicked. The quick view screen allows the operator to change the most comely used and variable parameters quickly. It also provides options for plate alignment and advance set up.


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Setup of KAR CNC

Koike KAR CNC

Kerf Specifies the amount of kerf (compensation) that will be applied to the cutting program. Caution should be taken when selecting the amount of kerf, to high of a value can cause the program to be altered especially when a radius of an arc is smaller than the kerf value. Cutting Speed This is the speed of the cutting process. Program Rotation Any value (degree) will rotate the cutting program. When a plate alignment is performed the rotation of the skewed plate is automatically enter here. Also, by clicking on the +/- 90 the part program will rotate at 90 degrees intermittent. Clicking on the zero box will clear any value of rotation to zero degree. Pierce Height It is the distance from the plasma tip to the work piece at initial pierce. Note this is a time based value (in seconds) from the point the plasma tip contacts the work piece and retracts to the initial

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Koike KAR CNC

Setup of KAR CNC

pierce height. Pierce Time This is a move delay after the pierce has started. Parameter Set (Plasma) If selected in the advanced set up screen the material, thickness and tool used will appear here to guide the operator on the current parameter selection.

3.4.1

Advanced Setup

The advanced set up screen allows the operator the flexibility to change more parameters if needed. On the 1 Parameters tab the parameter quick view settings are shown again, along with creep speed, mirror and tool location. In addition a cutting process database can be set up by selecting material, thickness and tool.

Kerf, Cutting Speed, Pierce Height, Pierce Time, Program Rotation


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Setup of KAR CNC

Koike KAR CNC

These settings are identical as described in the parameter quick view screen. Changing the setting here will also change in the parameter quick view screen automatically. Creep Speed This is the process cutting speed at beginning of the cutting program. The duration of this speed is determined by the setting of the creep time in Tab 6 Cutting parameter. After the creep time is completed, the controller accelerates up to the set cutting speed. Tool Location If a laser pointer is installed to the machine, it is best to define tool locations relative to the laser pointer. This way you can position and set the zero point using the laser pointer and the system knows the location of all the tools and can automatically handle them while cutting a program. Adding tool offset in your cutting program is not required. Mirror Checking the mirror box will mirror your program in the X axis. Gas and Plasma 2 Tabs Not used. General If this button is clicked on a dialog box will appear regarding kerf compensation loops. In most case the box is checked. On small occasions the kerf compensation calculation adds an extra loop which it may be undesirable on certain parts with very small radius. Un-checking this box will remove the loops created. OK Clicking on the OK button is a temporary change only to the cutting program in Promotion Cut Next Job screen. SAVE Clicking on the Save button after a change has been made a password box will automatically appear. After the password the changes will become permanently per that settings. Close Clicking on this button will close this screen.

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Koike KAR CNC

Setup of KAR CNC

Process Data Base The KAR CNC has a unique feature that allows building a data base for specific cutting parameters based on material, thickness and tool.

Based on material, thickness and tool selected the cutting parameters will change automatically, for example kerf and cutting speeds. Once a data base is built up with all the correct information, the guessing work where to set the cutting parameters will be minimized. This would be helpful when a new operator is trained to operate a cutting machine and maintain consistent cut quality. Note: It is not necessary to use all three fields to set the data base e.g. use material and thickness only and leave tool at Default. Set up Data Base A) Click inside Add/Remove box to activate the new box. Click new for material and a new material dialog box opens up. Click on other than ok. Type in your description for material. Repeat steps for thickness and tool. B) Select the wanted material, thickness and tool and enter all correct corresponding values for cutting speed, kerf, pierce height and pierce time. Review the entire screen that every field is correct, click on the save button and enter password to lock it in. C) Repeat steps A &B to re-enter new parameter settings for new material, thickness and too.


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Setup of KAR CNC 3.4.2

Koike KAR CNC

Plate Alignment

When plate alignment is activated it allows a quick way to pick two points on the edge of a skewed plate. Performing this exercise will automatically rotate a part or nest program the same amount so that it will fit precisely onto the plate without running of material at the edge of the plate.

To use the plate alignment find the first corner and click on Set point 1 here. Select which direction the next point is relative to the first location, travel to the second point and click on confirm point here.

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Koike KAR CNC

4

ProMotion® Nest

ProMotion® Nest What is it? ProMotion® Nest is a software, which converts CAD pictures (DXF format) to cutting programs. It is also possible to modify existing cutting programs (EIA, ESSI or CNC-2 format) by ProMotion® Nest. Nest. Basics When ProMotion® Nest loads a CAD picture, it adds cutting technology (kerf side, piercing points, cutting order, etc.) to shapes automatically. If you want, you can easily change any of those settings. Copy shapes to a plate, nest, set cutting order, etc. When ready, send your cutting program to ProMotion® Cut or save it for later use. ProMotion® Nest user interface ProMotion® Nest's user interface is a collection of several small windows, buttons and bars. Below is a brief description of all of them.


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ProMotion® Nest

Koike KAR CNC

1. Title bar Title bar is at the top of the ProMotion® Nest window. It contains the version number, the name of the registered user and the name of the active job. 2. Menu bar Menu bar lies just below the title bar. Menu bar has following menus: File Menu View Menu Tools Menu Options Menu Help Menu 3. Toolbar Toolbar lies just below the menu bar. Toolbar contains buttons for quick access to most important tools of ProMotion® Nest (like load, save, macros). See more from chapter Toolbar . 4. Work window Work window is the large white area in the middle of the screen. Active job is displayed displayed here and and editing is also done here. 5. Coordinates Y-coordinates are displayed displayed on the left side of the work window and X-coordinates just below of the work window. 6. Status bar Status bar lies at bottom of the ProMotion® Nest window. Status bar displays messages and hints from ProMotion® Nest. It also displays the current coordinates of the mouse cursor, when it is on the work window. 7. Toolbox Toolbox is located at the top right corner of the ProMotion® Nest window. It contains buttons for most editing tools. 8. Plate list Plate list is located just below of the toolbox. Plate list contains a list of all plates loaded to ProMotion® Nest. See Plate list for list for more information. 9. Part list

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Koike KAR CNC

ProMotion® Nest

Part list is located at the bottom right corner of the ProMotion® Nest window. Part list contains a list of all shapes loaded to ProMotion® Nest. See Part list for list for more information.

4.1

File Menu The File menu provides provides tools tools for opening existing files, saving files and exiting the application. ProMotion® Nest can read files which are in DXF-, EIA- or ESSI-format.

4.1.1

New Plate

When you activate this tool, a window appears asking the length and width of the new plate.

Insert the values and click the "Ok"-button and a new empty plate appears. The name of the plate appears in the Plate List. You can also create round plates, if you check the round plate option. Then you only need to enter the diameter of the circle. This is handy option, if you are nesting on a circular remnant plate.

4.1.2

Open

Loads an existing file and reconstructs it for further use. If the file contains lots of elements, reconstruction may take a while.


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ProMotion® Nest

Koike KAR CNC

DXF-files:

If you load a file, that is in DXF-format and that file includes more than one layer, then ProMotion® Nest asks you to select which layers are loaded to the nesting. If there are line and/or point markings in the DXF-file, they must be in their own separate layers. Line and point marking layers are chosen in the same dialog as the profile layers. In the example above the layer "PROFILES" is selected for containing the profiles. The layer "POWDER" is selected as line marking layer and there is no selected point marking layer. Select all button loads all layers to the nesting. Normally ProMotion® Nest starts to load elements from DXF file, after it has found a certain keyword from the file. This is for speeding up the loading process and to cut off all auxiliary elements (like measure lines). Sometimes however, there is a need to load elements before that keyword. Raw Load is made for cases like this. It loads every possible element from the DXF file to your nesting.

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Koike KAR CNC

ProMotion® Nest

Other files: ESSI and EIA files don't have any layers to choose. Just make sure that your options are set correctly. See also Line and point marking.

4.1.3

Trash

Closes the current nesting, which is seen at the work window. If there are more than one nesting open, then next one will be displayed at the work window.

4.1.4

Save As

Saves the current nesting (the one in the work window).

4.1.5

Macro

When you select this tool, the macro list window (picture 1) opens. This window displays small images of the available macros. There are only 20 macros displayed in any time, but you can see more macros, if you click the "Next" and "Previous" buttons.


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ProMotion® Nest

Koike KAR CNC

Picture 1. Creating a new shape with macros Select the macro you want by double-clicking it. The window below (picture 2) opens. Enter all the measures to the measure list. In the picture on the left side of the window you can see the shape and red lines. Those red lines are measure lines and they show you, what is the actual measure you are entering to the measure list. When you have entered all the measures, you can preview the shape by clicking the "Preview"-button. If you want to change some of the measures after preview, click the "Back"-button and change the measures. When you are satisfied, click "Ok"-button and the shape appears in the ProMotion® Nest's work window. Note: You can use the number pad of this window or the wheel of your mouse to input numbers.

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Picture 2. Editing the macrolist Click the button "Edit macrolist" in the first window (picture 1) to open the macrolist edit window (see below). The list "Current macros" shows the macros currently in the list. The list "Available macros" shows all the macros, which you can add to the macrolist. The dashed line in the "Current macro" list shows, where is the page break. There can be only 20 macros visible in any time in the macro list (see picture 1).


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Picture 3. How to change the order of macros in the macro list: Select one of the macros in the list "Current macros". The macro you selected is displayd in the little picture box just below the list. Click the button "Up" to move the selected macro one step towards the beginning of the list. Click the button "Down" to move the selected macro one step towards the end of the list. ·

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How to remove a macro from the macro list: Select one of the macros in the list "Current macros". The macro you selected is displayd in the little picture box just below the list. Click the button "Remove" and the macro you selected is removed from the list. ·

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How to add a macro to the macro list: Select one of the macros in the list "Available macros". The macro you selected is displayd in the little picture box just below the list. Click the button "Add" and the macro you selected is added to the end of the list. ·

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Koike KAR CNC

4.1.6

ProMotion® Nest

Print

This tool prints the current nesting to the default printer.

4.1.7

DNC

Use this tool to load files from DNC connection. There must be ProMotion® iLink running on the PC from where you download files.

Next Use this button to browse the files available in ProMotion® iLink working directory (folder). Available filenames are displayed in the text field just below this button. Load Click this button, when you want to start DNC download. The file currently displayed in the tect field starts loading. If you know the file you want to download, you can just type it's name to the text field and click Load button. Abort Click this button to abort DNC download Load Previous If you have previously downloaded a file and you want to use that same file again, you don't need to download it again. Just click "Load Previous" button and the last file, you have downloaded will be loaded. File Open Click here to change to normal File Open dialog. Use this if the file you want to use locates in the KAR CNC's hard drive or some where in the network, where you have access.


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ProMotion ® iLink LT There is a free copy of ProMotion® iLink LT in your KAR CNC's hard drive at "C:\Program Files\ProMotion Nest\iLink\iLinkLT.exe". There are also instructions how to use ProMotion® iLink LT.

4.1.8

Import

This tool imports a nesting created by ProMotion® Cut. 4.1.9

Export

This tool exports the current nesting to ProMotion® Cut. Please note, that the exported nesting won't open automatically in ProMotion® Cut. To open it, you must use the import tool of ProMotion® Cut. 4.1.10

Exit

Exits the ProMotion® Nest application. Important! All nestings will be closed and all data they contain will be lost. If you want to save one or more of those nestings, you should save them before exiting. 4.2

View Menu Black and White view This turns drawing color to black. Outbits If this option is checked, then ProMotion® Nest displays special outbits, if there are any in a nesting. See more info from ProMotion® Cut manual. Transferlines Hide All Transferlines can be toggled on or off by selecting this option. Show Cut When this is selected, you can see transferlines between cutting profiles. This is the default setting. Show Powder When this is selected, you can see transferlines between powder marking profiles. ·

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4.3

ProMotion® Nest

Show Drill When this is selected, you can see transferlines between drill marking points.

Tools Menu / Toolbox The Tools menu / Toolbox provides tools to edit a nesting.

4.3.1

Move Shape

By using this tool you can manually change the position of a shape. Move cursor over a shape and press the left mouse button down. Now the shape will follow the movement of the mouse as long as you press the button.

4.3.2

Rotate Shape

Rotates a shape counter clockwise, if the left mouse button is pressed and clockwise if right mouse button is pressed. Rotation angle can be changed in options menu.


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ProMotion® Nest 4.3.3

Koike KAR CNC

Mirror

This tool let's you mirror shapes in X or Y axis. If you move the mouse cursor over a shape and click the left mouse button, the shape will be mirrored in Y axis. If you click the right mouse button, the shape will be mirrored in X axis.

4.3.4

Remove

The left mouse button activates area deletion. Keep the left mouse button pressed down and move the mouse. A rectangle will follow the movement of the mouse. When you release the left mouse button, all the profiles that are completely inside the rectangle will be deleted. If you click the right mouse button, then a single element will be deleted. 4.3.5

Change Piercing Point

To change the piercing point move the mouse cursor over that element where you want to place the piercing point. If you click the left button, the piercing point will be the first point of the element. If you click the right button, the piercing point will be that point, where your mouse cursor is. This action can only be done on complete profiles.

4.3.6

Change Compensation Side

The compensation side can be changed by pointing a profile with the mouse cursor and clicking the left button.

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4.3.7

ProMotion® Nest

Change Cutting Direction

The cutting direction can be changed by pointing a profile with the mouse cursor and clicking the left button.

4.3.8

Change Cutting Order

When this tool is activated, the following dialog will appear.

By using this dialog you can choose the type of objects, whose cutting order will be changed, and the method of changing the


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cutting order. The cutting order can be changed between parts (shapes), holes, line marking profiles and point marking points. There are five methods which can be used to change the cutting order: show order , swap, move one step, line and free select. In the Show order method you just click the objects in that order they are about to be cut or marked. When you click an object, it will change its color to indicate that it is selected. If the color of the object will not change, then you cannot change its order (it's probably of wrong type). Selections can be removed by clicking the unselect button in the "Change cutting direction" dialog. The option Lock first object can be used with this method. If "Lock first object" is selected, then you cannot change the cutting order of the objects, which are before the first selected object in the cutting order. When you are ready, click the Apply button to create the new cutting order. This is the only method, that you can use on powder and drill markings. In the Swap method you click two objects and their positions in the cutting order will be changed between them. When you click the first object, it will change it's color to indicate selection. When you click the second object, the first object will become unselected and the cutting order will change. In the Move one step method you just choose the object, which cutting order you want to change, and then use the Step arrows to change the cutting order. If you click the left "Step" arrow, the selected object will be cut earlier and if you click the right arrow, it will be cut later. In the Line method you draw a line over the parts or holes, which cutting order you want to change. The cutting order of the first part/hole, that the line overlaps, won't change. The rest of the overlapped parts/holes will come immediately after the first one. In the Free select method you just click the profiles in that order you want to cut them and then click the apply button. This method is named free select, because you can select any cutting order between parts and holes (e.g. you can first cut all the holes in your

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ProMotion® Nest

nesting and then all the parts). This method may disarrange the internal data structures of ProMotion Nest, which may cause automatic nesting and some other tools to fail. For this reason, it's recommended, that you use this method only, if you can't set the cutting order with the other methods. If you decide to use this method, use this when you have done everything else for your nesting. So this is the final thing to do for a nesting. Close button closes the dialog. Apply button is used in combination with the "Show order" and the "Free select" methods. Unselect button removes all selections.

4.3.9

Split Element

An element can be splitted by pointing it and clicking the left mouse button. The element will be splitted in two at the clicked point.

4.3.10

Join Profiles

Use this tool to close an open profile or join two open profiles. Follow these steps: Press down the left mouse button. Drag a rectangle around two start/end points of open profile(s). Release the mouse button. · · ·

Note! If you draw the rectangle around more or less than two points, this tool does nothing.

4.3.11

Leadins

Use this tool to change all leadins and leadouts in your nesting. When you activate this tool, the following window opens.


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ProMotion® Nest

Koike KAR CNC

Select leadin and leadout types and length. Then click apply button to apply new leadins and leadouts to the nesting.

4.3.12

Zoom In / Out

View can be zoomed in by moving the mouse button over the work window and pressing the left mouse button down. A rectangle will appear. This rectangle shows the area to be zoomed in. While the left mouse button is pressed down, the area of the rectangle can be changed by moving the mouse. If the right mouse button is clicked the view will be zoomed out. 4.3.13

Reset View

This tool will reset the view. Which means that the view will be resized in a way that all shapes and a possible plate will be seen as large as possible. 4.3.14

Pan View

View can be panned by moving the mouse cursor to the editing area

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and pressing the left mouse button. The picture will follow the mouse movement until the left mouse button is released. 4.3.15

Ruler

Use this tool to measure distances. Move the mouse cursor over some point A and press down the left mouse button. Move the cursor over some point B while you keep the left mouse button down. You can see the distance between points A and B at the top left corner of work window in a yellow box.

4.3.16

Copy

This tool allows user to copy different objects to the clipboard from where she/he can paste them to any nesting. The object type, that is to be copied, can be chosen from the "Options"-menu. There are two kinds of objects that can be copied: shapes and nestings. An object can be copied by pointing it with the mouse cursor and clicking the left mouse button.

4.3.17

Cut

Use "Cut" to move shapes to the clipboard. You can paste shapes from the clipboard to nestings. Follow these steps: 1. Activate the "Cut" tool by clicking button. 2. Press the left mouse button and keep it down. A focus rectangle appears. 3. Surround the shapes you want to cut with the focus rectangle and release the left mouse button.


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Paste

Use this tool to paste the copied/cut objects to a nesting. When you click button, a dialog window appears (see below). If you want more than one copy, change the paste multiplier in the dialog window. The paste multiplier tells how many times the copied objects are to be pasted. Now, click the editing area and the objects are pasted.

4.3.19

Undo

Last editing can be undone by clicking the undo button.

4.4

Options Menu The Options menu provides tools to configure the ProMotion® Nest software.

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4.4.1

ProMotion® Nest

Handling Options

Measurement Measurement is either in millimeters or inches. This option defines which. DXF Options Point Distance If two points are this close to each other, then they are assumed to be the same point. Important! Change the point distance before loading a file. Ignore unit info from file When reading DXF-files, ProMotion® Nest tries to detect which measurement is used in the file. This detection is ignored, if "Ignore unit info from file" is checked. If detection is ignored, the DXF-file is read in millimeters or inches depending on the measurement setting. Move Shapes to Origin If this option is selected, then the shape in DXF file is moved so, that it's minimum coordinates are at 0,0 point. If the DXF file contains a nesting (more than one shape), then the nesting is moved so that it's minimum coordinates are at 0,0 point. All the shapes in the nesting are moved exactly the same distance, so their relative position to each other do not change. Convert text to marking and Extended text search are advanced features, which are only available in ProMotion® iCNC® ·

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ProMotion® Nest

Koike KAR CNC

units. Scrap Cutting Only available in ProMotion® iCNC® units. Rotation Angle Defines the rotation angle, that the Rotate tool uses. The angle is in degrees. Copy/Paste Target Type Defines the target type of Copy/Paste tools. CNC Options These options are for older ProMotion® controls. KAR CNC is state of the art and these options are not needed in KAR CNC. Marking Options If "Skip Marking" is checked, then none of the markings are saved. This is an useful option, if you just want to print the part names (on paper), but not to really mark them. If "Do all markings first" is checked, then all the markings are saved first and after them the parts to be cut. "Go to origin after marking" moves the machine to the zero point of the plate, when all the markings are done. If "Stop after marking" is checked, then the machine stops after markings. Show Crosshair If this box is checked, a crosshair will be drawn at the current cursor position. Vertical-Horizontal Bridging, Use Wide Bridges and Max number of torches These are advanced features, which are only available in ProMotion® iCNC® units. No area calculations This option is useful only with some advanced features of ProMotion® Nest, which are not available in KAR CNC units. Torch on right Usually the origin is in the bottom left corner of the plate. If you

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ProMotion® Nest

select this option, then it will be in the bottom right corner. Software keyboard If you don't have a keyboard, you can always use software keyboard for text input. If you set this option, then the software keyboard is automatically displayed, when text input is needed. Please note, that you can use the mouse wheel for numerical input in ProMotion® Nest. DNC enabled This option sets the default download behaviour of ProMotion® Nest, when requested from ProMotion® Cut. If this option is set, then DNC download automatically activates, when you click DOWNLOAD in ProMotion® Cut. See more info about DNC in chapter File Menu. Default Leadins In this section you can define, what kind of leadins and leadout are automatically added to all profiles, when loading DXF or creating macros. If you load EIA or ESSI files, no leadins or leadouts are added, because they usually have programmed leadins and leadouts.


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EIA Options

These are options which affect the reading of EIA files. Note: "Coding" and "I and J codes" affect to the nesting only when they are not defined in the read EIA file.

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ProMotion® Nest

EIA Codes: These codes indicate some special action. For example code M09 means (in this case) that line marking is turned on. Coding: If coding is set to absolute, then all the X and Y coordinates are absolute. Otherwise they are incremental. I and J codes: I and J codes are the coordinates of the center point of an arc or a circle. If set to absolute, all I and J codes are absolute. Otherwise they are incremental. If X and Y codes are set to incremental, then I and J are also incremental. Unit / Scale: These options set the default units and scale used in EIA files. If an EIA-file has unit definition, then that overrides this setting. The scale is always defined here. Program Rotation: If the rotation is selected, all the new nestings, which are read from EIA files, will be rotated 90 degrees counter clockwise. Null G is linear: This option sets ProMotion® Nest to read those EIA-code lines, which have no G-codes, but have some coordinates, as linear cutting or rapid movement. If this option is not set, those lines are considered as the same type, what the last given G-code indicates. Ignore F codes If this option is set, then all F codes (feed rate, speed) are ignored. Ignore K codes If this option is set, then all K codes (kerf) are ignored. If this is not set, then you need to select, what does those codes mean. Are they kerf width or kerf compensation.


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ProMotion® Nest

Koike KAR CNC

Advanced EIA codes These settings define, which codes set outbits on and off. For more info about outbits, see ProMotion® Cut manual.

4.4.3

Language Options

Change the language used in the user interface of ProMotion® Nest.

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4.5

ProMotion® Nest

Help Menu Help menu has following items: · ·

4.6

Contents opens the help file on your screen. About... shows you version info of your ProMotion® Nest software.

Toolbar ProMotion® Nest's toolbar looks like this:

Here is a list and short description of each tool: Send to cutting This tool sends the current nesting to ProMotion® Cut and activates it. File open This tool let's you open a file from KAR CNC's hard drive or disk drive or from the network. Save as This tool saves the current nesting for later use. Macro This button starts the macro tool. See more info from topic Macro under File Menu. MicroCAD This button starts the MicroCAD tool. See more info from topic MicroCAD. New Plate This tool creates a new plate. See more info from topic New Plate under File Menu. Trash This tool trashes the current nesting. Undo This tool undos the last editing you made for the current


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ProMotion® Nest

Koike KAR CNC

nesting. Reset View If you have zoomed or panned your view, this tool restores the default view. NestInfo This button activates the NestInfo window. See more info from topic NestInfo. Help This button opens the help file.

4.6.1

MicroCAD

Use this set of tools to edit profiles. The tools are described below.

Add Circle Type the diameter and the coordinates of the center point to the corresponding text fields. Click the "Apply" button and the circle is

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ProMotion® Nest

added to the shape. The new circle will be the first one in the cutting order. Add Rectangle First select if you are going to use the center point or the bottom left corner of the rectangle. Type length, width and the coordinates to the corresponding text fields. Click the "Apply" button and the rectangle is added to the shape. The new rectangle will be the first one in the cutting order. Round Corner Insert the radius of the rounding to the "Radius" text field and click the "Apply" button to verify the radius. When you move the mouse cursor over a corner, the cursor changes to cross. Click the corner and it will be rounded with the radius you just set. Remove Rounding This tool changes arcs to two lines. Move the mouse cursor over an arc and it changes to cross. Click to remove rounding. Add Point This tool adds points (lines) to a shape. If the shape conatins open profiles, the line is drawn from the last point of the first open profile to the point you added. If there are no open profiles, then new line (and profile) is created from the 0,0 point to the point you added. Adding new points is simple. Just type in the coordinates and click the "Apply" button. Remove Point This tool removes single points from a profile. Move the mouse cursor over a point. The cursor changes to cross. Click and the point is removed. If the point was the last or the first point of the profile, then the whole element is removed. Other wise the previous and the next point are connected with a line. Move Point This tool moves a point to another location. Click a point to select it (a small box appears over the point). Enter the new coordinates to the coordinate fields and click the "Apply" button. The point moves to it's new location.


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NestInfo

NestInfo displays information about the current nesting. NestInfo contains following information: Plate Plate name - the name of the current plate. Area - the area of the plate. (square foot or square meters) Plate width (inches or millimeters) Plate height (inches or millimeters) Collar width - this is defined in Nesting options, which is not available in KAR CNC. (inches or millimeters) Net usage (%) - the relation between the parts area and the plate area in percentage. Part Parts nested - the number of parts in the nesting. Nest width - the width of the nesting. Nest height - the height of the nesting. Parts area - the total area of all parts. (square foot or square meters) Piercings - the number of the piercing points in the nesting. Nominal Areas Parts - the total of all parts' nominal sizes. Used Plate - nominal size of used plate. This is exactly (nest width + 2 x collar width) x (nest height + 2 x collar width). Nominal Usage (%) - the relation between nominal size of all parts and used plate. Real Usage (%) - the relation between real area of all parts and used plate. · · · · ·

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ProMotion® Nest

There is no data in the fields "Area", "Parts Area", "Real Usage" or "Net usage". If you want to know these areas, click the "Calculate Area"-button. Area calculation may take a while - depending on the size of your nesting. 4.7

List Windows There are two list windows on the right hand side of ProMotion® Nest user interface. Those windows are Plate List and Part List. They both offer you several tools for your use.

4.7.1

Plate List

This window contains a list of all plates, which are opened. The list is sorted alphabetically. The active plate has a blue bar on it (it is selected). These tools are available in the plate window: Activate - Click the name of the plate to activate it. Popup menu - Right-Click the window to open a popup menu. The menu contains following commans:


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ProMotion® Nest · · · · ·

Koike KAR CNC

New Plate Change plate changes the plates size. Trash Rename, which renames the active plate. Move Nesting to (see below)

Move Nesting to This tool changes the position of the whole nesting. When you select this tool, the window below appears.

Left is the nestings distance to the left side of the plate. If this number is negative, it means that the nesting is over the plate's edge. Right, bottom and top work in the same way. You can change left and bottom values. When you click Apply button, the nesting moves and the values (right and top) in this window are updated. Ok is like Apply, but it also closes this window.

4.7.2

Part List

This window contains a list of all parts, which are opened. The list is sorted alphabetically. The active part has a blue bar on it (it is selected). These tools are available in the part list window: Activate - Click the name of the part to activate it. Copy to the active plate - Double-Click the name of the part. Popup menu - Right-Click the window to open a popup menu. The menu contains following commans: Open Trash · ·

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Koike KAR CNC

· · ·

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4.8

ProMotion® Nest

Rename, which renames the active part. Copy to nesting, which copies the active part to the active plate. Move shapes to origin moves the nesting so that it's minimum x and y values are equal to zero. Add plate creates a plate, puts the nesting on that and moves the job to the plate list (plate window).

Miscellaneous

4.8.1

Terminology

Nesting Nesting is divided in the following way: Element is the atom of a nesting. Element is the smallest part that can be edited. There are three different kinds of elements: lines, arcs and points. Profile is a combination of one or more elements, which are connected to each other. At the start point of a profile the sheet is pierced and cutting starts. At the end point of a profile the torch is raised up and cutting stops (for a while at least). Shape contains one or more profiles. Shape is a logical part, which has a boundary and possibly has some holes too. Nesting contains all the shapes, but can also be an empty one.

Transferline Transferline is a path, that the torch follows, when it is not cutting.

4.8.2

DXF

DXF format is supported by most of the present day CAD-softwares. DXF files are an interface between CADs and ProMotion® Nest. There are some points in creating DXF to ProMotion® Nest, which should be noticed: It is useful to put geometries on their own separate layer and name that layer so that it is easily recognized (for example PROFILES). ProMotion® Nest detects different layers and lets the ·


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user to choose which ones will be loaded. Line and point markings must be placed on their own layers. Use POINT objects for point marking. Use DXF version 12. Most CADs let you choose, which version of DXF to export.

Splines and ellipses Current version of ProMotion® Nest does not support splines or ellipses. The reason for this is, that they are not circular arcs and KAR CNC can cut only lines or circular arcs. Same is true with any CNC controller. If you think about EIA or ESSI cnc programs, there are no codes for non circular arcs. Some CAD softwares allow you to convert those curves to short lines. The result is not perfect, but it's good enough in most cases. Future ProMotion® Nest will also have this feature, but before that, you just need to convert your splines and ellipses to lines in your CAD software.

4.8.3

Improving DXF Loading Times

To improve the loading times of DXF files, keep your files simple. If possible, use ProMotion® Nest to make nestings. If you make the nesting in your CAD software, that will increase the number of parts in the file and will increase the loading times. We recommend, that you put only part per DXF file. Please read below, what are the differences between making the nesting in CAD software or making it in ProMotion® Nest. Method - Nest in ProMotion® Nest 1. Create the part(s) using a CAD software. 2. Load the DXF file(s) to ProMotion® Nest. 3. Nest the parts in ProMotion® Nest. Method - Nest in CAD 1. Create the part(s) using a CAD software. 2. Nest the parts in CAD. 3. Load the DXF file to ProMotion® Nest. Comparison of methods If you compare these two methods, you can see, that the first step is the same in both methods. So you don't save any time during the first step.

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ProMotion® Nest

If you can't use automatic nesting tools, then the manual nesting process takes about the same time in CAD and ProMotion® Nest. However it's probably faster to do it in ProMotion® Nest, because it's a nesting software and thus has all the necessary tools quickly available. Where you can save lots of time, is loading the DXF file. If you nest in CAD, you have all the parts in one file - it's a ready nesting. If you are going to do the nesting in ProMotion® Nest, then your DXF file contains only one part. It's clear, that the loading times are faster when you have only one part compared to many parts, but they are actually faster, than you can imagine. Please see the following examples. Examples The load times used in these examples have been measured by using a Koike KAR CNC controller. Part 1

Part 2

Example 1 Let's assume, that we need to create a nesting of 100 copies of part 1. Please see the flowchart below. There you can see the different paths you can take to do that. Please note, that there are two processes, which are the same for all paths and thus their time consumption is not counted here. Those processes are Create part and Prepare for cutting.


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If we do the nesting in CAD, let's say that it takes 10 minutes (600 seconds) to do it. In addition, it takes 407 seconds more to load it to ProMotion® Nest (in KAR CNC). That makes total of 1007 seconds. If we just send the part to ProMotion® Nest, it takes only 1 second to load it. After that we have two different paths we can take. We can use rows & columns nesting, which takes only 10 seconds. That makes total of only 11 seconds. We can also do the nesting manually in ProMotion® Nest, which takes 400 seconds and total of 401 seconds. If we do the nesting at office with a nesting software, let's say that it takes 100 seconds (You can do this with ProMotion® Nest office version in 40 seconds). After that reading the ready cutting program to KAR CNC takes 78 seconds. Total is 178 seconds. Please note, that you can do all processes after and including the process Read to CNC while the machine is cutting previous job.

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Thinking like that leaves you zero seconds of wasted time, when you read the single part directly to KAR CNC and do the nesting there. If you use office nesting software, you waste 100 seconds and if you use CAD for manual nesting, you loose 600 seconds! Example 2 Let's take 15 copies of part 2. Load time for all parts is 352 seconds and for a single part it is 5.5 seconds. There are only 15 parts, so you can do the manual nesting quite fast - even with CAD. We can say, that the major time loss in this case is the loading time, if you try to load a DXF file containing all the parts. Conclusion As you can see, you can save lots of time by making the nesting in KAR CNC and that is why we highly recommend that. Download times DXF (All parts)

DXF (Single part)

CNC-2 (All parts)

EIA (All parts)

Part 1

407 s

1.0 s

78 s

98 s

Part 2

352 s

5.5 s

38 s

44 s

Size of the DXF file versus loading time Accurate loading time cannot be given based on DXF file size. Reason for this follows. In KAR CNC ProMotion® Nest can read in roughly 50 kilobytes of data per second. So it takes 20 seconds to read in a file of 1 Megabyte. Unfortunately that is just the beginning, because all the shape entities (lines and arcs) are in random order in the DXF file. These entities must be organized in logical order before they are usable for something else than just to be drawn on the screen. When the data is read in, ProMotion® Nest starts to process it and how long that takes, depends on how many parts there are in the file. Some large DXF files may contain only one simple part and lots of other data, which is not used by ProMotion® Nest. That kind of data could be font definitions, drawing colors, etc. That data is useful, if you read the file to CAD, but ProMotion® Nest is only interested about parts. If you have a file, which size is less than 20 kilobytes, you can be pretty sure, that it loads quickly. If the file size is 200 kilobytes, it can take anything from 10 seconds to couple of minutes. The time range increases, when the file size


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increases. So you can estimate the load time, but the estimation is not accurate. Note: These guidelines only apply to DXF files. Other file types (EIA, ESSI, CNC-2) fully support premade nestings and there are no restrictions on how or where they should be nested. Naturally the bigger your file is the longer it takes to load. In the table above you can see load times for files of different types containing the same nestings as used in above examples.

4.8.4

CNC-2

We have developed a new advanced CNC-language - Robotic CNC2. CNC-2 is more accurate than old Robotic CNC-, ESSI- or EIAlanguages. CNC-2 is an excellent choice for making backup copies. It does not save only the nesting, but the the plate too, if there is one.

4.8.5

Line and point marking

If a nesting contains line or point markings, they are merged to the shapes of the nesting. You cannot add, move or alter the markings, unless you also move the shapes. The only thing you can do to the markings themselves is to remove them. The line marking profiles are drawn in black color. The point marking points are encircled by a black crossed circle.

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5

Monograph Training Guide


5.1

Introduction The Koike Monograph plasma-cutting machine consists of a highly intelligent process controller, a stand-alone open loop arc voltage controller and a programmable high-speed linear slide. The torch lifter (linear slide) is integrated to the CNC. The CNC directly commands raising and lowering of the slide until the plasma power supply is started and the cutting process commences. The arc voltage controller (torch height control) provides a means of maintaining torch to work standoff distance during the actual cutting process. The linear slide is integrated to the CNC through an interface box located on the main rail behind the CNC. This interface combines the functions of the CNC, height controller and linear slide to work as one complete system. In addition this system includes an IHS (initial height sensing) system to detect when the torch is in contact with the material. The IHS system and arc voltage controller are two completely independent systems. The only function of IHS system is to initially sense the material and conversely the arc voltage control system only maintains the torch to work distance during the cutting process. The following details each independent system separately.

5.2

Independent Systems

5.2.1

ATC - Arc Voltage Controller

The Arc Voltage Controller is commonly referred to as the height control. It simply monitors the arc voltage potential between the work (material being cut) and the electrode within the torch body. The work is the positive or return ground path and the electrode serves as the negative. Due to current flow between the positive and negative a voltage potential will exist. The open circuit voltage (OCV) of the power supply is reduced or divided proportionally to produce a smaller overall voltage range that the height control utilizes. The range is typically 3-13 volts DC. Dividing the actual arc voltage by a 20:1 ratio produces this voltage. This in done on the voltage divider printed circuit board (VD PCB) located within the interface box. It is the board mounted on standoffs in front of the Koike interface PCB. The voltage divider PCB (printed circuit board) has two terminal


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connections for connecting to the OCV within the power supply. They are labeled PS+ and PS-. It is important that these are correctly connected. PS+ is the work or ground return and PS- must connect to the electrode. Two terminals are provided on the VD PCB for the divided output voltage to the height controller circuitry. These are labeled signal + and signal -. This voltage is very important. The height control functions based upon an input from the thumbwheel on the ATC unit. The thumbwheel allows the operator to set the desired arc voltage related to a specific torch standoff distance above the material. A dial setting of 100 through the 20:1 divider will produce a signal input of 5 VDC to the logic control board. There are two terminals labeled 115VAC. These terminals have a continuous supply of 115VAC to enable the logic functions of the VD PCB. This voltage is supplied from the Koike interface PCB and is fused at 2 amps. The next two terminals are labeled logic + and logic -. This logic output is activated when the material is sensed. The output activates when the torch nozzle or tip becomes shorted to the work (material). This is accomplished in two ways. First, a direct nozzle connection is made from the power supply to the pilot arc terminal on the VD PCB through a HV (high voltage) relay. The current state of the normally open HV relay is energized, and therefore closed, making this connection. The HV relay on the Koike interface PCB is used to open this connection once the material has been sensed and before the main arc has been established. This method only works when non-shielded torch parts are used where the nozzle or tip can directly contact the material. Secondly, when shielded torch parts are used the sensing is done via means of an ohmic wire attached to the shield cap on the torch. This signal is also connected to the pilot arc terminal on the Koike interface PCB. The Hypertherm Powermax G3 series units have the ability to use both means of plate sensing. The Thermal Cutmaster units can only sense via means of the ohmic wire connection due to its limitation to shielded torch parts. The height control only responds based upon three inputs and a common reference to earth ground. The inputs are enable, THD (torch height disable) and arc voltage signal level. The reference

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signal must reference the power supply work connection to the plate. 1.

2.

3.

Enable/ Start: The enable signal is a contact closure supplied by the Koike interface PCB once a main arc has been established. The only time the height control becomes activated is if the plasma cut has been initiated. The contact closure is between pins 8 and 9 of the CNC connector. The unit sends out 24VAC, and it is returned through the contact closure, once the main arc transfers starting the height control. There is a potentiometer on the front of the unit which delays height control activation after the main arc has been established. It is intended for machines without CNC controls or machines, which are sluggish or have response while cutting corners. The pot is adjustable from 0-6 seconds. After a main arc transfer is detected the timer begins and the height control is not enabled until the timer expires. The use of this pot is not required with the Koike MNM model due to the responsiveness of the machine. Set to minimal value. THD (freeze height): This contact closure is supplied directly from the CNC when the machine speed has been reduced by a percentage of the actual cut speed used to process the plate. This contact activates during acceleration/deceleration motion profiles when entering or exiting corners. As actual machine speed decreases the natural process of the plasma arc will remove more material due to increased kerf width. If the speed slows too much a loss of material will occur causing a sudden reduction in arc voltage. This sudden reduction results in a quick torch adjustment downward. The purpose of the THD contact is to only allow the height control to be activated when at full cut speed, thus preventing the torch from diving toward the material while cutting in corners or tight radius. The activation of the input is indicated on the unit by illumination of the AVC lamp. When the AVC lamp is illuminated the height control is on and functioning. When the lamp is off the lifter is frozen in its current position by the CNC or a main arc has not been transferred. The THD inputs are on pins 4 and 5 of the CNC connector. Signal (arc voltage input): The signal input is taken from the voltage divider PCB to the height control unit via a separate control cable. This control cable must be shielded and of conductor gauge no larger than 22 AWG. The cable must be routed independently of other control cables, especially AC line power supply cables. The signal cable cannot be joined with the


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CNC cable connections due to the 24VAC present for the enable signal. The signal cable is the most important aspect of a properly operating height control system. In the majority of cases the signal input is the root cause of the problem. The torch is raised or lowered based solely on this input from the power supply. Work Reference: The wire should be at minimum of 10 AWG wire connected to the ground stud on the back of the ATC unit to the star ground connection of the cutting table. The unit must have a solid reference to the work piece and power supply return in order for the arc voltage to be properly referenced. This reference establishes the signal input to the unit. If the reference is not solid and consistent the unit will not work correctly.

The torch height controller simply raises or lowers the torch positioning mechanism to a set point based upon the actual arc voltage between the nozzle and the plate. The operator using the thumbwheel on the front of the unit dials the set point in prior to initiating the cut. In most cases the ability to control and maintain proper torch to work distance is not the result of a faulty unit itself. In most instances it is due to incorrect signal input being supplied to the unit. Remember the unit only knows what to do based upon the signal input it receives. It will process and adjust for bad information just as well as good information with corresponding results. Many things can impact the operation of the height controller and the following trouble shooting section outlines the majority of those issues. Also reference the ATC operator and technical reference guide shipped with your equipment.

5.2.1.1

Trouble Shooting AVC

Problem 1: The torch to plate distance varies up and down as the part is being processed. Solution(s): 1.

2.

The signal input to the unit is unstable. RF noise may be attenuating the signal. Use shielded cable. Tie external shields to case grounds at both ends and internal shields only to earth ground within the Koike interface box. DO NOT coil the signal cable. The signal is a very low voltage

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3. 4.

5. 6. 7.


level and drives no current. Coiling this causes inductance and will adversely vary the signal input entering the unit. DO NOT coil extra torch lead. Lay extra torch lead out flat back and forth on the floor and place under the table. DO NOT coil the work cable. This will greatly affect the arc voltage at the torch and therefore affect the signal input to the unit. Loose connection on the PS + or PS- terminals of the VD PCB or the signal + or signal - terminals. Ensure terminals have not loosened from the VD PCB. Phase loss on primary input power connection to power supply. Poor or missing connection of the work reference connection from the ATC unit to table star ground.

Problem 2: The height control works, but I have to increase the AVC set point reference much higher than the manual states. Solution(s): 1.

DO NOT coil up the power supply work cable. This creates an inductor and reduces the actual arc voltage between the nozzle and the plate causing less output from the VD PCB therefore commanding the torch to lower. Increasing the set point allows it to work but with poor response. This can cause the torch to wander or vary.

Problem 3: As soon as the arc transfers and the AVC lamp (located on the front of the ATC) illuminates and the torch drives into the plate. Solution(s): 1. 2. 3. 4. 5. 6. 7.

Arc voltage set point set too low on ATC. Signal + and - reversed on the VD PCB (Located in Interface Box) Incorrect consumables or current setting for consumables used. The nozzle orifice is not round (Bad Nozzle). Poor work reference connection Look for loose terminal connections on the VD PCB or broken solder joints of terminals into board. Check air pressure on Plasma Power Supply. Set to parameters established in the Plasma Power Supply manual.


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Problem 4: As soon as the arc transfers and the AVC lamp illuminates the torch goes up. Solution(s): 1.

If the enable signal to the unit is closed, and THD signal contact is open the lifter will raise immediately. This is normal. Lack of arc voltage or signal input to the ATC unit will cause it to rise.

Refer to the ATC operator's manual supplied with the equipment and perform the Voltage Divider checkout procedure. Problem 5: The torch can't be raised or lowered from the up/down switch on the ATC unit, but torch raises and lowers from the CNC. Solution(s): 1.

Replace 3-amp motor fuse on rear of ATC unit.

Problem 6: The power on LED on the ATC unit is not illuminated: Solution(s): 1.

5.2.1.2 1. 2.

3. 4.

Check and replace 1 amp fuse on rear of unit. Check and replace 2-amp fuse on the Koike interface PCB located in the interface box mounted on the main rail. Power to the ATC unit comes from the plasma interface box.

Other Issues Which Influence Proper Arc Voltage Control Plasma gas quality. If the plasma arc is varying the arc voltage control will follow the arc. Clean, dry air is a must to maintain a consistent arc. Machine grounding. A poor connection will cause arc voltage controller variations. Do not create grounding loop. Ground your machine according to Koike recommendations. Ensure paint is removed prior to connection to the cutting table. Coiling of cables. Do not coil cables. Bad consumables in torch. The arc voltage changes drastically when the nozzle becomes distorted. The orifice of the nozzle must be round for the arc voltage to remain consistent.

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5. 6.

5.2.2


Cutting speeds incorrect. Ensure that speed is correct for material thickness and amperage selected. To slow or loss of material under the torch will cause the torch to lower. Leak in gas supply lines. This will usually cause the arc voltage to wander.

Torch Lifter/ Linear Slide

The lifter consists of a linear slide and ball screw. The slide is actuated by the DC brushless amplifier and motor, which mounts to the top of the slide. A spring coupler connects the motor shaft to the lead screw. The motor/amplifier is programmable. A program, which resides within the motor, is initiated each time the machine is powered on. Upon powering the machine, the lifter is commanded upward at a preset torque limit. Once the upper limit of the slide is reached the motor is stopped and commanded downward a preset distance. After this move the lifter is considered to be at absolute home reference. The lifter has 5 inches of travel from the home position and always knows its position from home. The motor does not incorporate a holding brake. The screw itself serves as the brake once power is removed, however due to reduced friction the lifter may drift down when powered off. Always make sure the torch is over an open area of the cutting table when the machine is powered off. Functionality of the lifter is based on fail-safe input/output logic commanded by the CNC through the plasma interface box. The motor I/O is isolated from the CNC through the plasma interface PCB. All I/O is 5VDC sourcing and is held at a logic high level. The following I/O is supplied to the lifter from the CNC as stated below. Each I/O is in the off state when 5VDC is present. 1. 2.

3.

Torch Up: Can be commanded by the CNC or ATC by automatic function or by use of the manual raise/lower switches. Torch Down: Can be commanded by the CNC or ATC by automatic function or by use of the manual raise/lower switches. Cut: Is initiated by the CNC control through program execution or by the manual plasma enable switch being placed in the on


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position. IHS Auto/Man: The IHS switch located on the CNC control panel selects the state of this input. If IHS is in the auto position the lifter will retract to the full upper position of the slide between each and every cut. When placed in the manual position the user time for ED1 (end delay) will determine how far the lifter is to retract in-between cuts.

The lifter itself is a preassembled unit, which should not be disassembled. Disassembling of the slide will void all warranty. The lifter needs to be lubricated from time to time to ensure maximum life of the unit. This can be done without disassembly. The spring coupling should also be checked on occasion to ensure that the motor shaft is securely coupled to the lead screw. Slippage will cause lifter and height control problems. The recommended lubricant information was shipped with the documentation for your specific equipment. The lubricant is recommended directly from the supplier of the unit.

5.2.2.1 Lifter Check Out / Setup Procedure The following procedure should be performed during initial setup of the equipment, and each time the torch is removed from the torch holder or any time the lifter is suspected of having a problem. It is important that the initial torch to work distance be set properly. LIFTER CHECKOUT: 1.

2. 3.

Power-up the machine and observe the lifter homing sequence. The lifter should move upward to the upper limit and move down a short distance. After this move the lifter is considered to be at absolute home reference. To test the lifter hold down and maintain the raise or lower switch to ensure that the lifter stops at the upper and lower limits. Lower the lifter to the lower limit position. Place the IHS switch in the auto position. The lifter should rise to the home position. With the IHS switch in the auto position and the torch positioned over an open section of the cutting table between table slats, hold down and maintain the torch lower switch. The lifter will traverse at high speed for approximately 3 inches then drop into slow speed. When the lifter reaches the lower limit turn off the

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4. 5.

6. 7.


drive enable switch on the CNC and apply the E-stop to remove power to the lifter. Note the lifter will not fall due to the lead screw pitch. Remove the torch from the torch holder. Check to ensure that the spring coupler, which joins the lead screw to the motor shaft, is secure. This is done by tightening the two 2 mm socket head screws in located the coupler. Make sure the coupler is centered between lead screw shaft and motor shaft. Manually rotate the spring coupler to lower the slide until it reaches the lower limit of travel. Place the torch into the torch holder. Move the torch down in the holder until the shield cap or nozzle is level with the table slats. It is imperative that the torch always makes contact with the thinnest and the thickest materials being cut during the slow portion of the lifter cycle. This slow speed portion of the lifter cycle is required for detection of the material. Proper adjustment of the torch position for material thickness to be processed will insure the slow speed portion of the cycle is achieved. Adjusting the torch to a lower position in the holder can reduce cycle times, however the slow speed portion of the cycle must be achieved to obtain proper ATC function. Secure the torch in the holder. Example: With the lifter in its lowest position and the torch adjusted as described in step 7 the lifter will drop into slow sensing speed and travel approximately 2.0" before a 24 gage plate is detected. This increases cycle time between cuts. If you set the torch 1 inch below the table surface the lifter will only need to travel .5 inch at slow speed before detecting the material. This will decrease cycle time by 1-second in-between cuts. In other words by increasing the torch set height below the table top you decrease the slow speed travel distance. Note: Increasing the distance below the plate will reduce the slow speed portion of the cycle. Reducing the slow portion of the cycle too much will affect proper functioning of the ATC. The slow speed portion of the cycle must be achieved to obtain proper ATC function. Important: The torch is installed at a preset distance of 7.5 inches from the top of the gear rack, on the torch body, to the top of the torch holder. This distance always ensures


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Koike KAR CNC

that the torch will properly detect materials that range is thickness from 24 gage to 5/8 inch thick A label is attached to the torch body which identifies this distance. This distance however does not minimize torch cycle time between cuts. Adjust torch accordingly to minimize cycle times. 8. 9.

Remove the E-stop to apply power to the lifter motor. The lifter will rise to the upper limit of the slide. The motor will stop when the physical mechanical limit of the slide is reached and the preset homing torque limit of the motor is exceeded. The lifter will then automatically lower for a short distance. The lifter is now considered to be at absolute home position. Once homed the lifter has five full inches of travel. 10. Position the carriage so that once lowered the torch will travel in-between two table slats and reach the lower limit of the slide. Place the IHS Auto/Man switch on the CNC switch control panel into the manual position and maintain (hold down) the torch lower switch. With the switch maintained the lifter should lower to the lower lifter software limit and stop. If the raise switch is maintained the lifter will go back to IHS sensing speed for the remaining 2 inches. Once the lower limit is reached the lifter will rapidly rise for two inches then begin to slowly lower again. This sequence will continue until the lower switch is released. Upon release, the lifter will return to home position. Important: If the lower limit is reached before the torch is able to contact the material, the lifter will reach the lower limit, retract to the home position and the torch will fire in the air. This condition requires lowering the torch within its holder. Follow the Example in step 2.3.1 step 7.

5.2.2.2

Koike HS-5 Lifter Technical Information

Components/Devices:

Koike H5 Lifter / Linear Slide Programmable Motor Interface Height Control w/ Plate Sensing Logic

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System Overview: The complete system consists of stand-alone arc voltage controller (AVC), a high-speed linear slide and a programmable lifter for positioning and setting of the initial pierce height. The arc voltage controller and the intelligent lifter are integrated to act as a complete system although each operates independently. The intelligent lifter provides the initial height sensing ability, referred to commonly as IHS, while the automatic voltage controller maintains torch to work distance during the cutting process. CNC Functionality: When a plasma start cycle is started, the torch first raises for the duration of torch up timer. This time is set in a user parameter within the CNC. This time is used to delay motion until the torch is fully retracted. This prevents the torch from contacting any parts, which may have tipped up, when traversing to next pierce location. This output will only activate when a time value in seconds is present in the primary plasma torch up time parameter field located in the plasma setups and the IHS auto/man selection switch is placed in the auto position. The timer value is overridden when IHS switch in selected in the manual position. Torch Up = typically.25-.5 seconds. Allows lifter to retract to full upper position before traversing between parts. If the timer is not set the torch will raise during the traverse to the next pierce location. The timer is used to delay motion to next pierce location, until the torch is partially or fully retracted. Not required with KAR CNC controller. As soon as the Torch Up timer elapses the Torch Down Timer starts. The lifter is commanded down at a high speed (700ipm). After a specific travel distance is reached the lifter slows to a lower speed (30ipm) at which the initial height sensing takes place. The torch down timer is initially set for a time, which exceeds the limits to completely cycle the lifter for the full stroke. When TDS, Torch Down Sense, input to CNC is activated and the Torch Down Timer has expired the start sequence advances within the CNC. Once TDS input to the CNC becomes activated, the downward motion stops. TDS input is activated by shorting the torch nozzle or tip directly to the material to be processed. When shielded consumables are


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Koike KAR CNC

used, where the nozzle or tip is prevented from directly contacting the material, an ohmic wire connection must be provided and attached to the shield cap. The torch shield is then used as the sensing means, directly contacting the material. Torch Down = typically 2-3 seconds The lifter is then raised for Plasma Pierce Up Time. This timer is user settable within the CNC and determines the height of the torch above the material when the torch is started. Once TDS input activates, torch down output deactivates and torch up output activates once again for the duration of the Plasma Pierce Up Timer . Typically set for .08-.2 seconds. Default is .15 seconds, which equates to approximately 1/8 inch of travel. Minimal value allowed is .08 seconds, which prevents the torch from firing when in contact with the material. After the Plasma Pierce Timer expires the CNC plasma start output is activated. This starts the actual torch. Once the main arc transfers to the material the Cut Sense input to the CNC is activated and motion along the programmed path is started. The Arc On Feedback parameter must be set to on or enabled for this to take place. If Arc On Feedback is set to off the machine motion will take place immediately following the Pierce Time timer. Following expiration of the user adjustable delay timer (0-6 seconds) on the ATC height control, arc voltage control takes over and maintains torch standoff to material based on arc voltage generated from the electrode to the plate. See ATC instruction manual for detailed use of ATC height controller.

5.2.2.3 1.

2.

Lifter Sequencing Conditions If during the IHS sequencing the CNC stop key is pressed the lifter will raise to home or position = zero based upon certain events (top of the stroke). During a trajectory the state of torch up, torch down, ignition (cut) and IHS select inputs to the lifter motor are therefore continuously being monitored. Once the CNC ignition output (cut on input to lifter) is activated, and then de-activated the lifter will return to home after one second. This one-second allows the plasma arc to fully

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Koike KAR CNC

3.

4.


extinguish before the torch is raised preventing the arc from extending from the material. When the IHS switch is in manual position it sends an input to the motor placing the lifter in manual mode. This is a contact closure from CNC. The contact is closed in manual mode and the operator can manually raise and lower the torch at a preset velocity or the height control can output to raise or lower the torch when necessary. In manual mode the lifter will retract to operator specific height at the end of the current cut cycle. If the IHS switch is placed in the Auto (on) position the lifter will retract to home position if the ignition output is lost. IHS sequencing selection can only be selected when the torch is not actually cutting. Lifter always returns to home upon selection of the mode of operation.

5.2.2.4 Sequence of Operation Manual mode When the IHS Auto/Man switch is placed in manual selection the lifter operates at two defined speeds. Speed range 1 is at a slow inching speed of 30 IPM. Speed range 2 is at the maximum lifter speed of 700 IPM. When the lifter manual lower switch is first activated the lifter moves at speed range 2 for a specific distance, then switches to speed range 1. If the raise or lower switch is released during motion at speed range 1 or speed range 2, the motion is immediately stopped. When the lifter manual raise switch is first activated the lifter moves at speed range 1 for two seconds, then switches to speed range 2. Further upward motion is prevented when the home position is reached. 1. 2. 3. 4. 5.

Operator selects IHS in manual using selector switch. Operator lowers torch to desired height above material. Operator presses cycle start (on the CNC) to execute desired program. Torch lowers from current position, detects plate, retracts to pierce height and fires. This occurs just as it does in automatic mode. After the main arc transfer occurs, motion along the programmed path begins.


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Monograph Training Guide 6.

Koike KAR CNC

The operator or the height controller if selected active, can raise or lower the torch as required.

NOTE: If cut sense is lost, safety device tripped, or cycle stop is activated the arc extinguishes and lifter motion freezes unless commanded by the operator using the manual raise/lower switch. The lifter will rise for the programmed torch up time set prior to initiating the cut cycle. NOTE: The lifter responds only to torch up or torch down commands by manual raise/lower switch or up/down commands from the height control. NOTE: At any time if the IHS selector switch is placed in the auto mode from the manual position, the torch will rise to the full upper or home position. Auto mode therefore cannot be selected during a cut, which was initially started with the IHS in manual mode.

5.2.2.5

Sequence of Operation Auto mode

Note: IHS selection switch placed in the auto position. 1.

2. 3.

4.

Operator selects IHS auto mode using selector switch. Lifter immediately moves to home position or holds if currently at home. This occurs 1 second later if ignition/cut output is currently on and then switched off, ensuring that the arc has extinguished prior to raising the torch. Operator initiates a cycle start command. Lifter rises for torch up time or until position equals 0 (full up). No actual lifter motion occurs since position is currently the home position. After torch up timer elapses torch lowers for the torch down time or until TDS becomes activated. Note: Torch initially lowers at rapid speed (speed 2) for 2/3rds of the stroke of the lifter, and then changes to a slower speed (speed 1) for sensing of the material. Ohmic Contact Plate Sensing: If during the slow speed portion of the IHS sequencing the torch nozzle or shield cap directly contacts the material, the TDS input is immediately

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activated. The torch down output is then de-activated and the torch up output is activated. 5. 6. 7.

Torch up output activates for Plasma Pierce Up Time Ignition on. Plasma torch started. After main arc transfers and the cut sense input is activated, motion begins along the path. 8. ATC height control amends torch standoff if auto mode is selected. If manual mode is selected, the operator using the manual raise/lower switch on the ATC or CNC operator panel amends the torch height.

5.2.2.6

State of Lifter Motion Trajectory

State 1/ IHS Switch: Lifter always responds to current state of the IHS selection switch when placed in auto mode from the manual position and vise versa. When the IHS selection switch is placed in the manual mode the lifter can only be raised or lowered by use of the manual raise/lower switches. Switch #1 is located on the CNC control panel and will only function when the plasma torch station select switch is enabled. Switch #2 is located on the height control console and will only function when the auto/man switch is placed in the manual position. If the switch is in the manual position and then switched to auto mode position, the lifter will return to home position or top of stroke. If the lifter is currently at home position and the mode is switched from manual to auto, no motion will take place. If the switch is in the auto position the lifter will be at the home position. Switching to manual mode will enable manual motion. If the switch is in auto position, the machine is in the cutting process and the manual position switch is selected, the lifter will return to home position after 1 second. State 2/Manual Mode: Manual motion of the lifter is allowed when the IHS selection switch is placed in the manual mode. The lifter can be commanded to move using two defined speeds. Speed 1 is slow inching speed (30 IPM) and speed 2 is rapid speed (700 IPM).


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When commanding manual motion using raise/lower switch the lifter moves at speed 1. After the switch is maintained for 1 second the speed is increased to the speed 2. Whenever the raise/lower switch is released the lifter motion stops immediately. When the lifter is at the home position no further motion can be commanded of the lifter upward. Home is therefore the upper limit of the lifter. The lifter position relative to the home position is being constantly monitored. The lower limit of the lifter is therefore set based upon the overall length of the slide. The lower limit cannot be exceeded in manual or auto modes of operation. The lower limit is set approximately .25 inches before end of slide. State 3/Lifter Homing: When control power to the CNC is first applied the lifter homing routine is immediately implemented. The lifter is commanded upwards at a predefined torque and speed towards the linear slide upper limit. Once the end limit (physical hard stop) is reached the motor is reversed and commanded off the end limit 1/8 inch. This point then becomes lifter home or absolute position 0,0. The lifter has a 5-inch stoke from the home position.

5.3

IHS (Initial Height Sensing) The IHS is the means for detecting when the torch nozzle or tip is in direct contact with the process material. When the torch is fired with the torch nozzle or tip in direct contact with the plate the consumables are almost always destroyed. Once this occurs problems relating to height control begin to occur and the cut quality diminishes. All it takes is one occurrence to destroy the consumable set. The Koike system implements automatic ohmic contact plate sensing to prevent this from happening. With the MNM model machine the feature is always active. The procedure below ensures that the system is functioning properly. The system works by detecting a short circuit between the torch

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nozzle and the work lead of the power supply. Circuitry is then actuated on the VD PCB and Koike plasma interface card, which stops further motion downward and commands the CNC to advance to the next instruction in the plasma starting sequence. Detection occurs in two ways. First, a direct connection is utilized from the nozzle connection, directly off the control board, within the power supply. With this connection the use of non-shielded consumables is allowed. This includes such consumable sets as the new Finecut for use with the Hypertherm G3 series units. Certain consumables sets are not offered non-shielded, where the nozzle is exposed. With these consumables a special ohmic cap or clip is attached to the shield cap. The clip contacts the shield used to protect the nozzle. One end of a high voltage wire is attached to the ohmic cap by a tab, while the other end connects the sensing input to the voltage divider PCB. When the shield contacts the plate, the plate is sensed in the same manner as if the nozzle directly contacted the plate. The IHS system and the ATC systems are completely independent of one another. The IHS is used to sense the material and the ATC is used to maintain a constant torch to work distance above the plate during the cutting process.

5.3.1 1. 2. 3.

4.

5.

IHS Checkout Procedure

Verify proper lifter functionality. See lifter checkout procedure. Place a piece of slightly crowned 16-20-gauge material under the torch with the crown facing upwards. Place the IHS Auto/Man switch in the manual position and lower the torch into the material. The lifter speed must decrease before the material in encountered. If not, see section 2.3.1 step #7 of the lifter checkout procedure. Once the material is contacted the lifter will stop and no further downward motion can be commanded. Remove the cover from the plasma interface box located on the main rail behind the CNC. Observe the RED LED on the voltage divider PCB. The LED should not be illuminated when the torch is contacting the material. Raise the torch to break contact and observe that the LED is now illuminated. Repeat item #4 using both shielded and non-shielded consumables installed within the torch. Note that Thermal


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6.

7.

Dynamics systems do not have the ability to sense the nozzle directly and will always require the use of the ohmic clip and wire to the torch body. See Plasma section for complete details for your system. Place the IHS Auto/Man switch in the auto position. Maintain the plasma lower switch in the lower position. The torch will rapid traverse from the home position, then drop into slow speed prior to detecting the plate surface. Once the plate is detected the torch will immediately retract back to the home position. The cycle will repeat as long as the lower switch is maintained. Turn the Plasma power supply off. Place material on table under the torch. On the CNC control select setup, then advanced setup, cutting table #6. Ensure that the torch down (SD2) and plasma start (SD4) timers are set for at least 5 seconds. Program a small part to perform cut signal test. ·

· ·

·

·

·

5.3.2

Koike KAR CNC

Place the plasma on/off/auto switch in the lower or auto position Press green program start button to start the program After torch contacts the material and retracts to the pierce height the torch is started and the plasma start timer begins to count down. The torch should remain at this position while the plasma start timer counts down. Press the torch on/off button to stop the sequence before the timer expires. If you do not stop the start sequence before the time expires the external stop input may activate. This depends on if the parameter Main Arc Lost During Cut was set to activate if the main arc is lost during a cut. Repeat the same starting sequence except place the on/off/auto switch in the center off position. With the cut switch in the off position the torch will retract to the piercing height and should then immediately retract to the home position. Cut sequence is fully functional.

Initial Height Sensing Troubleshooting Guide

Problem 1: The torch lowers to the plate, but then retracts back towards the home position. At some point the torch fires on its way back home.

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Koike KAR CNC


Solution: The torch has never actually contacted the material. The lower limit of the slide has been reached prior to the torch contacting the material. The torch has to be lowered within the holder or the spring coupling joining the motor shaft to the lead screw is slipping. Reset the torch in the holder per instruction in section 2.3.1 step #7. Check coupling screws per instruction in section 2.3.1 step #5. Problem 2: The torch lowers and senses the material then retracts to piercing height. As soon as the pierce height timer expires the torch retracts back to the home position. The torch does not fire. Solution: The plasma on/off/auto enable switch is placed in the off position. Place the plasma on/off/auto switch in the auto position. Problem 3: The torch contacts the material hard and pushes the material down. Solution: The material can only be sensed when the motor speed is reduced to the IHS sensing speed. The torch is contacting the material in high speed. Re-adjust the torch in the holder. Torch is too low for material being processed. See instruction in section 2.3.1 step #7. Problem 4: I am using non-shielded parts in my G3 torch, but the IHS is not working. Solution 1: The work cable from the power supply is not connected to the table or the plasma interface cable is not plugged into the unit. Check these cable connections. Solution 2: The HV (high voltage) relay has failed on the Koike Plasma Interface PCB. Replace the PCB or relay. Problem 5: I am using shielded consumables and the IHS is not working, but the torch raises and lowers fine. Solution: 1. The ohmic wire connection from the torch shield cap to the pilot arc connection on the voltage divider PCB may be broken or loose. 2. Remove the cover of the plasma interface box located behind the CNC control mounted on the main rail. Confirm that the


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3.

4. 5.

Koike KAR CNC

RED LED on the VD PCB is illuminated. Locate the terminal labeled pilot arc on the voltage divider PCB. It will have a colored wire attached to it labeled nozzle. Using a jumper wire short this pilot arc terminal to the key stock on the main rail or to other good ground point. Observe the RED LED on the VD PCB. The LED should go out when pilot arc terminal is shorted to power supply work connection. If LED goes out when shorted replace or correct the problem with the ohmic wire. Check for poor connection at torch or at terminals TB2- 20 and 21 of the Koike Plasma Interface PCB located behind the VD PCB in the interface box.

Problem 6: The torch will not lower, but raises fine. Solution: Check the status of the red LED on the VD PCB. If the LED is out remove the connection from the pilot arc terminal. If the LED illuminates then the ohmic wire is shorted to ground or the torch shield is shorted to the nozzle. Replace the ohmic wire or consumables.

5.4

Process Controller The Koike KAR CNC through its user switch control panel and sequential I/O platform is the executive control of the machine. It executes the sequence of events once the operator commands a program start. The I/O logic is sequential and interrupt bits can be set to override a set output bit. An interrupt bit is used to cancel the remaining time of a timed output. If an output bit is activated for a specified time an input bit is therefore used to advance the sequence by interrupting the current function. The Koike KAR CNC process controller incorporates a user defined graphical sequential timing chart. This allows the user to determine exactly what will occur once the program start button is pressed (Execution of the program). The KAR CNC utilizes the plasma process control-timing chart. The timing chart is illustrated below. The timing starts at SD1 once the program start button is pressed. A SD stands for a program start delay time and an ED stands for a program end delay time. A move delay is simply a delay in which no output is activated. It is just a time delay before the next event is

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Koike KAR CNC


commanded to begin. A start move delay is generally used for the plasma piercing time and an end move delay is used to ensure the arc has extinguished before rapid traversing to the next piercing location. Cutting represents when the actual cutting is taking place and rapid is the torch off move to the next pierce point location.

5.4.1

Plasma Cutting (Tab 0)

All inputs and outputs are sinking to 24VDC supply common. This means a 0 volts potential is present on the output pin when an output is turned on and a 0 volt reference must be supplied on an input pin to activate and input. In Tab 0 (table 0) only output 7 is required. SD1 is not required and the starting sequence begins at SD2. At the beginning of SD 2, output 7 of the controller is turned on. This output is the Plate Down output and remains on for the entire duration of the cut. This is indicated by the highlighted red bar graph. All other sequencing is set in table 1. As with the Plate Down output the Torch Down and Hold outputs also activate at the beginning of SD2. The Torch Down


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Koike KAR CNC

output starts the lifter lowering cycle and the HOLD output simply disables the height control. At the start of SD2 you will also notice that an inbit (input) interrupt is set by the check mark in the box at SD2. A bit number dialog box prompts you for the desired input number and the interrupt value which is the current state of the input. 1 represents waiting for input to be activated or 0 representing waiting for input to be deactivated. This input 10 becomes activated once the nozzle of the torch is shorted to the work lead and tells the controller that the torch is in contact with the plate.

5.4.2

Plasma Cutting (Tab 1)

5.4.3

MNM Model Plasma Cutting Sequence of Operation

· ·

·

Program start is executed by operator Torch lowers for SD2 (start delay #2 time) or until input 10 activates. SD2 is the torch down timer and must be set to a minimum value of 3- 4 seconds. Once input 10 (torch down sense) activates the torch down timer

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Koike KAR CNC

·

·

·

·

·


immediately expires and the sequence advances to SD3 (start delay #3 timer). The torch then rises for SD3 time. SD3 time is the pierce height up time for the pierce height and is determined by the operator based on material thickness. Once SD3 expires the torch is now at the pierce height, the plasma start output 9 is activated. It activates for time SD4 or until input 4 (main arc input) activates interrupting SD4 timer. Input 4 is the main arc transfer input from the power supply and indicates that the main arc has transferred to the plate. Once input 4 activates the sequence advances to the move delay (pierce timer). The move delay is used for the plasma pierce time and causes the machine to hold position with arc on until the time expires. After the move delay expires motion along the programmed part path begins. If input 4 is lost during the cutting process the external stop is activated stopping the machine motion and turning off output 9 (plasma start). This is determined by the state of a parameter in the advanced setups. After the cutting has finished the torch is raised for ED1 (torch up) time. This allows the operator the ability to select how far the torch raises after each cut. This timer only functions when the IHS switch is placed in the manual position prior to initiating the cut cycle. In the automatic position the lifter is retracted to the home position in-between cut cycles. After the torch up timer ED1 expires and the torch has retracted to the specified height, the machine rapid traverses to the next piercing position. The entire cycle then is repeated starting at SD2.

Plasma Default Timing Parameters for MNM Model Machine: The basic plasma setup parameters are displayed when the SETUP software key on the KAR CNC is activated. In the menu the basic parameters that are most frequently required to change are displayed.


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Monograph Training Guide 5.4.4

Koike KAR CNC

BASIC SETUPS

Kerf Width: The width of the cutting tool. This will be the amount of material, which is removed by the cut process. The amount must be offset to have the part be the correct dimension once processed. The kerf is the orifice size of the nozzle. Typically the kerf is .040 for 40 amps nozzles and .070 for standard tips. The Hypertherm Finecut nozzles have an orifice diameter of .032. Cutting Speed: The actual speed when processing the part program. Rapid speed is the speed when the torch is off and cutting speed is the speed when the arc is on. Trial speed is simply a dry run speed without actuating any I/O. Program Rotation: Indicates if any rotation was assigned to the part program. Any rotation caused by the plate alignment feature will appear in the window. Pierce Height: This is the height to which the torch will retract after the plate is sensed. The range is in seconds from .1 to .2 seconds, typically .15 seconds. The lower the time the closer the torch will be to the plate once the piercing begins. The time is SD3.

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Koike KAR CNC


Pierce Time: This is the time that the torch will stand still during the plate piercing before machine motion begins. This time is the start move delay.

5.4.5

ADVANCED SETUPS

The top of the window will display the current process, which will be performed. This is shown as Parameters (Plasma). The Koike MNM will only function in plasma mode. Select the Plasma software key from the Gas /Plasma/ Plasma 2 selection window. A bitmap of Parameter group 1 is currently displayed. The parameters are as follows: Kerf: Orifice diameter of nozzle or tip. Cutting Speed: Actual cutting speed. Creep Speed: A reduced cutting speed for the creep time value specified in parameter group #6. After time expires machine


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Koike KAR CNC

proceeds at the cutting speed. Not required with MNM machine. Make creep time minimum value of .01 seconds. Creep speed will default to 5 IPM or minimum based on maximum machine speed. Pierce Height: This is the distance based on time in which the torch will retract once the material in sensed. It is SD3 in parameter group six and is set, so it can be displayed in parameter group 2 Aux Parameters. Pierce Time: Hold time before motion with arc on. The value is the start move delay set in parameter group #6 and marked for display in parameter group 2. Program Rotation: Displays current rotation after performing a plate alignment function or allows operator to rotate the plate manually. +90 will rotate the plate at 90-degree increments and zero will return the rotation. Mirror: Flips the part creating a mirror of the original. Tool Location: Tool location prompts for and X and Y value. This tool location would be in reference to a laser pointer device used for orientation of the torch to the corner of a plate. The values are from the laser device to the plasma torch. It wants to know the location of the cutting tool relative to the lasers fixed position. The MNM is not offered with a laser pointer. A battery powered laser pointers may be used if so desired. Gas/ Plasma/ Plasma 2: The Koike MNM only supports the plasma mode of operation. MTT Tables: The MTT tables allow operator to establish preset parameters based upon the material, material thickness and the tool used in the process. Once the tables are created the operator simply selects the material, thickness and tool and all relevant parameters to process the plate are automatically recalled. To access the MTT tables and configure data the ADD/REMOVE dialog box must first be checked. When the ADD/REMOVE window is checked the NEW software keys are highlighted and therefore enabled for use in data entry. When the new button is selected a dialog box will be displayed and OTHER is displayed. When you

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Koike KAR CNC


click on OTHER a command line will appear. Type is the text you wish for the material, thickness or tool. Once the new MTT dialog has been prepared use the dropdown arrow for the material, thickness or tool to select and highlight you new data entry. Once the desired material, thickness and tool are highlight enter all relevant data required for the new MTT and SAVE the new MTT. Once new MTT sets, other than the default set, have been created the REMOVE button will become activated allowing user to delete unwanted data. Once all MTT data has been created the ADD/REMOVE window should be unchecked before the final save is implemented. The next time the controller is restarted the system will prompt for the password to save this data permanently. Enter the password "rbtc" in lower case when prompted to do so. Caution: The default MTT parameter group must remain. This group must not be removed or the controller will not function correctly. It is very important to recognize that each time the material, thickness or tool is changed the system will considered a change to become a brand new MTT group set. Each time a new MTT group set is created all relevant data must be updated for the new group set. Any parameter field highlighted in red requires data input. Such fields will be the creep time field. This includes sequence timing in parameter group #6, all cutting and rapid speeds, kerf values, etc. Once all data has been created for the new MTT group set the SAVE software key must be applied. The system will prompt for the password Edit Delay Names: This check box allows user to edit the name of the delay set in parameter group #6 cutting parameters. A bitmap of parameter group #6 cutting parameters is displayed below. The parameters are as follows: Cutting speed: Desired cutting speed. Rapid speed: Traverse speed between cut cycles. Usually set to the maximum speed of the machine. Creep speed: Reduction of actual cut speed for time allocated by creep time. Creep speed will have a minimal allowed default value


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Koike KAR CNC

based on machine maximum speed. Creep time: Time in which the reduction of cutting speed will occur at the creep speed. Prestop distance: This parameter is used with power supplies, which ramp down the current at the end of a cut cycle. It allows the plasma to shut off just prior to the program completing motion. As the power supply ramps down the arc remains on long enough to finish the cut. This prevents dimpling when the plasma ramps down normally after the motion has ended. It is not usually required with Inverter Type power supplies such as the Powermax G3 series and Thermal Cutmaster installed on the MNM machine. The parameter must be set in the Advanced Plasma Setups through the KAR CNC Setup Parameters, before it will function. Typical values range from .040 to .1 inches. Piercing Up/Down Routine Window: The plasma pierce up and pierce down feature is not implemented for use with the MNM model of machine. The MNM model uses a more advanced method of starting the torch cycle. The Start should be set for not activated. Start: Selects at which start delay the sequence is to begin. Piercing up: Time to raise the torch for piercing. Stay up: Time torch remains at piercing height. Piercing down: Time to lower to cutting height after stay up time has expired.

5.4.6

Show Delay Names In Readjust Field

This check box simply allows the name assigned to each delay to be displayed in the On-The-Fly parameter readjust window dialog window when prompted.

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Koike KAR CNC


Sequential Event Timing: When the checkbox for a particular delay is checked, this delay will be shown in the readjust parameter window for changing "On-The-Fly", during the cutting process. SD#1 (Start delay 1): Not required SD#2 (Start delay 2): Starts torch down for SD2 time or until torch is sensed making contact with the plate. Once plate contact is made torch down output time immediately expires. Minimum value is 3-4 seconds. SD#3 (Start delay 3): Raises torch for time duration to piercing height. SD#4 (Start delay 4): Output to start the power supply. Allows time for plasma to fire and receive arc transfer input to begin motion. If start timer expires before the main arc transfer is received the external stop input will activate. Move delay: Time to expire with arc on and before motion begins. Used for piercing of the material.


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Koike KAR CNC

CUTTING: Actual cutting of the part or program nest. The height control AVC LED indicator should be illuminated if placed in the auto mode of operation. The up/down LED indicators should blink at random as the torch requires amendment to the standoff between electrode and work. The AVC LED should blink briefly as the machine accelerates /decelerates to and from corners. At very slow cutting speeds, where the actual machine speed remains constant during cornering, this LED may remain illuminated. Amendment to the standoff can be made at any time using the thumb dial on the height control unit. Increasing the threshold voltage will increase the standoff from the plate. ED#1 (End delay 1): Turns on the torch up output after the cut to raise the torch before traversing. The distance the torch raises is determined by this time value. More time allows more distance. 2.5 seconds is the maximum value before the lifter will switch into high speed and traverse back to full upper home position. The IHS switch must be placed in the manual mode for this timer to be functional. ED#2 (End delay 2): Not required. Move delay: Not required.

5.4.7

Aux Parameters

A bitmap of parameter group #2 cutting parameters is displayed below. The parameters are as follows: Scale: This parameter allows the part to be scaled larger or smaller than the size originally created. 100 percent is actual size as created. A scale factor of 200 doubles the size. A scale factor of 50 will reduce the size by half. If a part is scaled a message window will appear stating that the scale is not at 100 percent before running the part. Delay nr 1: This allows the operator to display by name one of the most common delays, that requires frequent changing, on the basic setup screen. This delay is set to display the pierce height time. Delay nr 2: This allows the operator to display by name one of the most common delays, that requires frequent changing, on the basic setup screen. This delay is set to display the pierce time.

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Koike KAR CNC


Parameter group #7(Information) is simply a notepad. It allows a place for the operator to save information he deems important to the process. Plate Alignment: This feature allows the operator to align parts on a plate, which is not parallel to the main rail. It corrects for skewed plate. See KAR CNC operation manual for detailed instructions. General: Checking this check box allows system to correct for kerfing error's created when program contains small arc segments. OK: This button applies the current data to the process but does not retain the data permanently. It is a temporary save. SAVE: This button applies the current data to the process and prompts for the password to permanently save this new data. Password is lower case "rbtc". CLOSE: Simply closes the window and makes no changes.


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Monograph Training Guide 5.4.8

Koike KAR CNC

Floating Head Setup Tables

Floating Head: Tab 0

Floating Head: Tab 1

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Koike KAR CNC


Floating Head Plasma Advanced Parameters:


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5.5

Koike KAR CNC

Plasma Power Supply

5.5.1

General Information

Only inverter output contact start type power supplies are equipped on the Koike MNM plasma-cutting machine. The available power supplies are the Hypertherm 1000, 1250 and 1650 rated at 100 amps. A one hundred amp unit is the largest available on the MNM model. This MNM can also be equipped with the Thermal Dynamics Cutmaster 101, which is rated up to 80 amps. The table is rated up to 5/8-inch plate over the perimeter of bed.

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Koike KAR CNC

Hypertherm 1250 Cut Chart for 25-55 Amp Fine-cut nozzles: KAR CNC parameter setup MILD STEEL Thickness (Inch)

Amps

Speed (IPM)

Kerf (Inch)

Pierce T (sec)

Pierce H (sec)

Arc V (Volts)

.25

50

36

.032

.3

.18

85

.187

50

52

.032

.2

.17

80

.125

50

63

.032

.2

.16

75

12 Ga.

50

75

.032

.2

.15

75

14 Ga.

50

80

.032

.17

.15

75

16 Ga.

40

85

.032

.15

.15

75

24 Ga.

45

300

.032

.1

.12

75

T = Time in seconds H = Height based on time in seconds. ARC = Arc voltage (torch to work distance during the cutting process)


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Connector Review 6

Koike KAR CNC

Connector Review

Main Supply Power Input: Supply power to KAR CNC CONN J1: 1. Line 115VAC only. 2. Neutral 3. PE-Ground

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Koike KAR CNC

Connector Review

MOTOR: Motors connections using DC amplifiers will use a 4pin amp circular AMP connector. AMP mating PN# 206429-1 Plug, 4 Pin, CPC Backshell PN# 0868-8756-00 Koike PN# 0866-6068-00 CONN-J7/J8: 1. Motor – 2. Motor + 3. Tach + 4. Tach –


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Connector Review

Koike KAR CNC

ENCODERS: Encoder will use a 9-pin circular amp. AMP mating PN# 206708-1 Plug, 9 socket, CPC, Backshell PN# 9948-6721-00 Koike PN# 9948-6720-00 CONN-H10 X/Y: 1. Enc power supply. 5 VDC using HS CMC 250 Line count encoder. 2. Enc. Power supply common. 3. CHA-A 4. CHA-A Compliment 5. CHA-B 6. CHA-B Compliment 7. Not Used 8. Not Used 9. Enc Shield wire termination.

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Koike KAR CNC

Connector Review

J16 Limits: Amp 211768-1 Koike PN 9948-9874-06 (9-Pin large connector) Backshell PN# 0866-6331-00 1.

2. 3. 4. 5. 6. 7. 8. 9.

Input 0 to FET card. Actual signal to indicate limit switch trip. Fail-safe NC or activated through limit switches placed in series circuit. Jumpers to pin 3 internally. Jumpers to pin 2 internally. Connects to logic ground of FET card. Common reference for limit input. Not used. Not used. Not Used. Not Used. Keying pin.


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Connector Review

Koike KAR CNC

J25 I/O: Mating Connector: AMP PN# 206305-1 Plug 37 Pin (reverse sex) CPC Koike PN# 0866-6339-00 Backshell PN# 0866-6340-00 1. 2. 3.

C supply for user C user supply neutral PE Ground for user supply

4. 9.

THD (hold) signal. Dry contact closure from CNC. THD user common.

5. 6. 7.

Floating head lower 115VAC output Neutral for floating head valve PE ground for floating head valve

8.

Not Used

10. C torch down output for G-lifter 11. Neutral for G-lifter

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Koike KAR CNC

Connector Review

12. PE Ground for G-lifter 16. C torch up output for G-lifter 13. User DC Common for supply. 14. +24VDC user supply rated at 2 amps. To Interlogic VD PCB. 20. Collision detection/safety mount device sense reference (DC Common) 21. Collision sense input. 15. Plasma enable normally open set of contacts RL5 22. Plasma enable common N.O Contact RL5 17. IHS Switch. Outputs 24VDC in manual mode. Used with Smartmotor interface only. 18. Keying Pin 19. Keying Pin 23. 24. 26. 28. 31.

+37VDC user supply rated at 3.3 amps. +37VDC Common Torch up sense input Not Used Not Used

25. Torch up sense common. 27. 24VDC spare common. 29. Plasma enable +24VDC output. Used with Smartmotor Interface. 30. Plasma enable DC Common. 32. Arc Transfer (CSR) input. Contact closure from outside world required. 33. Arc Transfer DC Common. 34. +24VDC user supply at 2 amps. 35. User supply common. 36. Torch Down Sense Common. (DC Common for 24VDC supply) 37. Torch down sense input to CNC. From VD PCB SEN Relay output. NOTE: Activates pierce height timer to raise to pierce height.


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Connector Review

Koike KAR CNC

RS232 Keyboard Mouse LAN These connectors are from left to right: RS232, Keyboard (PS2), Mouse (PS2), LAN (RJ45) · · · ·

RS232 is for DNC data transfer. Keyboard connector is a standard PS2 connector. Mouse connector is a standard PS2 connector. LAN connector is a standard RJ45 connector.

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Koike KAR CNC

holes

Index

-I-

-C-

iLink 38 import 39

change compensation side 41 change cutting direction 42 change cutting order 42 change piercing point 41 cnc2 65 copy 46 cut 46

-Ddnc dxf

42

-J join profiles

44

-Llanguage 53 leadin 44 leadout 44 list windows 58 lock first object 42

38 60

-E-

-M-

eia 51 element 60 ellipse 60 exit 39 export 39

macro 34 marking 65 MicroCAD 55 mirror 41 move one step 42 move shape 40

-F-

-NFile menu

32 Nestinfo 57 nesting 60 new plate 32

-Hhandling options

48


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KAR CNC

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