operating manual plasma turn-key solution - power automation · 1.7 glossary cnc - computerized...

PlasmaTurn-key Solution

Operating Manual

HMI-Documentation

Original document

© 2017 Power Automation GmbH

Power Automation GmbH

CNC-Automatisierungstechnik

Gottlieb-Daimler-Str. 17/2

74385 Pleidelsheim

Germany

Telephone: +49-7144-899-0

Fax: +49-7144-899-299

E-mail: [email protected]

Internet: www.powerautomation.com

Version 2

2 18.04.2017

Table of contents1 General information................................................................... 5

1.1 Information on this manual................................................ 5

1.2 Explanation of symbols...................................................... 5

1.3 Limitation of liability............................................................ 6

1.4 Copyright........................................................................... 6

1.5 Warranty terms.................................................................. 7

1.6 Customer service............................................................... 7

1.7 Glossary............................................................................. 8

2 Main screen................................................................................ 92.1 Main control bar............................................................... 10

2.2 Status bar......................................................................... 11

2.3 Menu bar.......................................................................... 12

2.4 Error window.................................................................... 14

3 Path graphics........................................................................... 174 Machine control....................................................................... 21

4.1 Machine control - left side................................................ 21

4.2 Machine control - right side.............................................. 23

5 Job control............................................................................... 255.1 Job control cycle off – left side......................................... 25

5.2 Job control cycle off – right side...................................... 35

5.3 Job control cycle on - left side......................................... 40

5.4 Job control cycle on - right side....................................... 41

5.5 JobControl Cycle Stop - left side..................................... 43

5.6 JobControl Cycle Stop - right side................................... 46

6 File transfer.............................................................................. 497 Heads........................................................................................ 51

7.1 IHT & Hypertherm Head.................................................. 51

7.1.1 Hypertherm panel.......................................................... 52

7.1.2 IHT panel....................................................................... 53

7.2 Spindle Head................................................................... 57

8 Machine setup.......................................................................... 638.1 General Options............................................................... 65

8.2 Basic Settings.................................................................. 69

Plasma Turn-key Solution

Table of contents

18.04.2017 | 3

9 Service and return process..................................................... 779.1 Service............................................................................. 77

9.1.1 Service addresses......................................................... 78

9.2 Spare parts...................................................................... 79

9.3 Return policy and procedure............................................ 80

9.4 Training............................................................................ 82

10 Proof of change........................................................................ 8311 Index.......................................................................................... 85


Table of contents

18.04.2017 | 4

1 General information1.1 Information on this manualThis operating manual deals with the operation of the CNC controllerPA8000 with the technology package for plasma cutting machines andspindle heads.

1.2 Explanation of symbolsWarnings are identified by pictures. These warnings are introduced bysignal words, which express the severity of a danger.

Pay attention to these warnings and act cautiously in order to avoidaccidents, personal injuries and damage to property.

… indicates an imminently hazardous situation which, if unavoid-able, will result in death or serious injury.

… indicates a potentially hazardous situation which, if unavoid-able, could result in death or serious injury.

… indicates a potentially hazardous situation which, if unavoid-able, may result in minor or moderate injury.

… indicates a potentially hazardous situation which, if unavoid-able, may result in property damage.

… emphasizes useful hints and recommendations as well as informa-tion for efficient and trouble-free operation.

The following symbols are used in connection with the safety notes tohighlight particular dangers:

… highlights hazards caused by electric current. There is adanger of serious injury or death if the safety notes are not com-plied with.

The following symbols and highlights are used to distinguishinstructions, descriptions of results, cross-references and other ele-ments inside this manual.

.. Highlights a step as part of a procedure of instructions.

ð .. Highlights a state or an automatic process as a result of aninstruction.

n .. Highlights single or unordered instructions and lists.

Content

Warnings

L DANGER

L WARNING

L CAUTION

NOTICE

Special Safety Notes

L DANGER

Additional symbols and high-lighting


General information

18.04.2017 | 5

Ä “Additional symbols and highlighting” on page 5.. Highlights cross-references to chapters or sections of this manual.

[Key].. Highlights captions of buttons, fields and other elements of thesoftware's graphical user interface.

“Menu è Submenu è ”.. Highlights a path to access a menu or sub-menu in the software's graphical user interface.

Example/Extract.. Highlights verbatim examples and extracts fromconfiguration files.

1.3 Limitation of liabilityAll information and notes in this operating manual were compiledunder due consideration of valid standards and regulations, thepresent status of technology and our years of knowledge and experi-ence.

Power Automation can not be held liable for damage resulting from:

n disregarding this operating manualn unintended usen employment of untrained personneln unauthorized conversionsn unauthorized modifications to the softwaren technical modificationsn use of unapproved spare partsn use in conjunction with machines not deemed compatible by

Power Automation

In case of customized versions the actual scope of delivery can varyfrom the explanations and representations in this operating manual,because of the utilization of additional options or due to latest technicalchanges.

Apart from this, the obligations agreed upon in the delivery contract,the general terms and conditions, and the delivery conditions of PowerAutomation and the legal regulations valid at the time of contract doapply.

We reserve the right to make technical modifications in order toimprove usability.

1.4 CopyrightThis installation manual is protected by copyright law.

Passing this installation manual on to third parties, duplication of anykind – even in form of excerpts – as well as the use and/or disclosureof the contents without the written consent of Power Automation is notpermitted.

Liability

Copyright


General information

18.04.2017 | 6

Violations oblige to compensation. The right for further claims remainsreserved.

1.5 Warranty termsThe material warranty terms are provided in Power Automation's termsand conditions as well as inside the sales documents.

1.6 Customer serviceOur Customer Service is always available for technical information.

For information on whom to contact by phone, fax, e-mail or via theinternet, see Power Automation's address on page 2.

Additionally, Power Automation staff is always interested in receivingnew information and experiences resulting from the use of our prod-ucts, which could be of great value for future improvements.

Material Warranty

Service


General information

18.04.2017 | 7

1.7 GlossaryCNC - Computerized Numerical Control

C2C - Contour to contour

HMI - Human Machine Interface

The graphical user interface provided by the PA software.

HSU - Height sensing unit

Kerf - Radius correction of the tool

MTBP - Machine Tool Builder's Panel

Panel including the basic requirements for a machine tooloperator: emergency stop push button, cycle start and stoppush buttons, jog plus and minus push buttons, feed rateand spindle speed override pots and a number of auxiliarypush buttons.

MDI - Manual Data Input

NC-Start - Numerical Control Start Button

NC-Stop - Numerical Control Stop Button

PA - Power Automation

PAMIO - Power Automation Modular Input Output

Extendable Superbus based interface allowing connectionof additional I/O modules.

PC - Personal Computer

PCI - Peripheral Component Interconnect

Personal computer extension for periphery devices con-nected to the motherboard.

RMS - Rotating Measuring Systems (Encoder)


General information

18.04.2017 | 8

2 Main screenThe main screen can be seen as different components

n Fixed main controlling bar with the most important functions of themachine (on the left side) (see Ä Chapter 2.1 “Main control bar”on page 10)

n Status bar on the top of the screen (see Ä Chapter 2.2 “Statusbar” on page 11)

n Menu bar on the lower part of the window (see Ä Chapter 2.3“Menu bar” on page 12)

n Error window (see Ä Chapter 2.4 “Error window” on page 14)

Fig. 1: Main screen

Components


Main screen

18.04.2017 | 9

2.1 Main control barThe main control bar is fixed and shown in almost all menus. The mostimportant functions are defined there:

Button Function

Restart at cont. Activate to select a contour from where the programshould be started (see Ä Chapter 3 “Path graphics”on page 17)

Select job Button to open the "Select job" window. In the Select jobwindow it is possible to select a job from hard disk orflash drive (see Ä “Select Job” on page 39).

Select sheet This button is to select the sheet from the database (seeÄ “Select Sheet” on page 30).

Test-run Button to de-/activate the testrun mode. In test-run modethe machine moves without cutting to test the program(see Ä “Test-run” on page 29).

Feed Override The feed override is given in % from 0-100. With plusand minus of the feed override, the value can bechanged in steps of 0.1, 1 or 10. The step size can bechanged by pushing the bar between the plus and minusbutton


Main screen

18.04.2017 | 10

2.2 Status barThe status bar (Fig. 2) is always visible and shows the CNC status, thetime of the currently running program and the actual system time. Withthe button on the right side the CNC software can be shut down.

Fig. 2: Status bar

Status Bar


Main screen

18.04.2017 | 11

2.3 Menu barThe Menu bar consists of the buttons to navigate between the menus.If no menu is selected the whole screen is used for the path graphicsto show the drawings (see Ä Chapter 3 “Path graphics” on page 17).The buttons to navigate:

Button Function

Show error To show/hide the error window (see Ä Chapter 2.4“Error window” on page 14)

Reset Reset all functions, programs and errors

Machine Control Show/hide the machine control windows with the func-tions to control the machine (e.g. jogging) (seeÄ Chapter 4 “Machine control” on page 21)

Job control Show/hide the job control windows with different func-tions to set up the job (see Ä Chapter 5 “Job control”on page 25)

Heads Cuts Show/hide the head window which is used to change thecut or drill parameters (IHT and Hypertherm parameter)(see Ä Chapter 7 “Heads” on page 51)

File Transfer Window Show/hide the file transfer file window for file operations(delete/copy) (see Ä Chapter 6 “File transfer”on page 49)

Menu Bar


Main screen

18.04.2017 | 12

Button Function

Sheet Database Show/Hide the sheet database of the plasma cuttingparameter

Diagnostics Show/Hide the diagnostic panel of the automatic gasconsole

Machine Setup Show/Hide the password saved machine setup to acti-vate different options (see Ä Chapter 8 “Machine setup”on page 63)

Start/Stop button Dependent on the job status (started or stopped) thisbutton shows the start/stop symbol to start/stop the pro-gram)


Main screen

18.04.2017 | 13

2.4 Error windowWith the button "Show error" you can show/hide the error windowmanually (Fig. 3).

Fig. 3: Error Window

Error Window


Main screen

18.04.2017 | 14

But if an error appears, the window will be opened automatically toshow the error message. Because of the small window the text of theerror message is not always shown completely. In this case you canselect the error message and show the complete description bypressing the button with the question mark (Fig. 4). To delete andreset error message of errors which are not active anymore the buttonwith the red cross is used.

Fig. 4: Detailed description of the error


Main screen

18.04.2017 | 15


Main screen

18.04.2017 | 16

3 Path graphicsThe middle of the screen is covered with the path graphics window(Fig. 5). Depending on the opened menus the path graphics covers abig or small area or is hidden completely.

The path graphic window shows the preview of the selected program.During the cutting process the actual cut line is shown additionally.

Fig. 5: Path graphics window

Path graphics window


Path graphics

18.04.2017 | 17

To navigate there are different buttons on the screen (Fig. 5):

Table 1: Assignment Of Keys Inside The Path Graphics WindowKey Function

Zoom + Zoom into the drawing

Zoom - Zoom out of the drawing

Fit in SW limitsThe zoom and position are automaticallyadjusted to see the whole area of the softwarelimits

Fit in The zoom and position are automaticallyadjusted to see the whole drawing in the screen

Follow pathThe position of the window will automaticallyfollow the cursor so that the actual position isalways shown

Clear ScreenThe display of the current cut path (red line) willbe deleted

Clear cut path (red line)

Show Axis Pos Show the positions of all NC axes

NC Info Show the program path and name of theselected program

Show NC Code Show the actual and the next two blocks of thecurrenty running program


Path graphics

18.04.2017 | 18

There are different possibilities to select the part or contour on whichthe program should be restarted. You can find the description of thesepossibilities in Ä Table on page 19.

The selected part is shown in green colors (Fig. 6). If you want to startthe program at this outline you just have to press the "Start" button. Ifyou don’t want to use the restart function you have to deactivate it withthe “Restart at cont.” button.

Fig. 6: Optional assignment of keys (Restart at a certain contour

If the option for restarting at a certain contour is selected (button“Restart at cont.” the following buttons will be available too ( Ä Tableon page 19):

Key Function

Contour/PartButton to switch between contour/part. Thisbutton should show which outline you want toselect

Select next Selects the next contour or part (depending onContour/Part button)

Select previous Selects the previous contour or part (dependingon Contour/Part button)

Select by touchWith this option you can select any contour orpart (depending on Contour/Part button) on thescreen by clicking once

Restart At Contour


Path graphics

18.04.2017 | 19


Path graphics

18.04.2017 | 20

4 Machine controlThe machine control window is used for controlling the machine. Thereare defined different move options, jog button, feed override settings.The machine control is divided into two windows which are positionedon the left and right side of the screen.

4.1 Machine control - left sideHere all jog options are defined (Fig. 7). One joystick for moving the Xand Y axis into + or – direction. Also an extra panel to move the Z-axisup and down. In case of more than one Z-axis or other additional axesyou can switch between all extra axes by pressing the letter of theaxis.

With this you can switch through all additional axes and jog them in +/-with the up/down arrows.

The increment panel with the button “Incr. step” is to activate the incre-mental move mode of the CNC. Then you can define a step size,which is used when you press any jog +/- button. With activated incre-mental jog the axes will always move the defined step size.

Fig. 7: Machine Control - left side

Machine Control Window

Manual Jog Options


Machine control

18.04.2017 | 21

This option allows the user to cut with the jog panel manually bypressing this button. When the manual cutting button is green the cut-ting head will start plate finding, piercing and cutting whenever the jogpanel buttons are pressed. When the buttons are no more pressed, thecutting head will stop cutting and goes back to its original position.

Manual Cutting


Machine control

18.04.2017 | 22

4.2 Machine control - right sideButton Function

Start PosA dialog box will open to confirm themachine movement. After confirmation themachine will move to the start positionwhich is defined in the cycle parameters.

Service PosA dialog box will open to confirm themachine movement. After confirmation themachine will move to the service positionwhich is defined in the cycle parameters.

Shutdown PosA dialog box will open to confirm themachine movement. After confirmation themachine will move to the shutdown positionwhich is defined in the cycle parameters.

Load PosA dialog box will open to confirm themachine movement. After confirmation themachine will move to the load position whichis defined in the cycle parameters.

Defined PosA dialog box will open to define a positionfor each axis. After pressing start themachine will move to the given position.

Edge cut

A program with different options to cut off apart of the sheet. Begins at actual or definedposition and ends at the end of the plate orwith a defined position. The height control isnot active during the cut.

Feed override

For the feed override you have plus andminus buttons to change immediately insteps of 1, 5 or 10%. Additionally there arethree buttons to change the feed overridewith one click to 25, 75 or 100%. You alsohave one button to change with one click to0% and if you press again to go back to theprevious value (you can see instead of 0 theprevious value on this button). In the middleof the feed override you can find the set andactual speed of the movement.

Machine Movements


Machine control

18.04.2017 | 23

Fig. 8: Machine control - right side

Fig. 9: Feed override


Machine control

18.04.2017 | 24

5 Job controlThe job control window has two different views. The view and function-ality is dependent on the actual CNC status. If the program is activeyou can see functions which are made to affect the machine during thecutting process. If no program is active all functions are displayedwhich are used for setting up parameters before the start of a program.

5.1 Job control cycle off – left side

Fig. 10: D-correction

Function Description

D-correction (Fig. 10)

Normally the cutting offset isdefined in the NC program. Withthis option you can adjust thebeam width later. With this valuethe cutting line is shifted to com-pensate the diameter of thebeam.

Job Control

D-Correction


Job control

18.04.2017 | 25

Fig. 11: Cut Speed


Cut speed (Fig. 11)

Normally the cut speed is fixedand defined in the program, butwith this module you can changethe cut speed of an existing pro-gram.

With “Set cut speed” the speedis defined and with “Activate cutspeed” the set speed is used, aslong as the button is not deacti-vated again

Cut Speed


Job control

18.04.2017 | 26

Fig. 12: Activate THD


Activate THD (Fig. 11) With “Activate THD (TorchHeight Deactivate)” the heightcontroller will stop distance con-trolling on corners and end con-tours.

When pressing “SET THD” adialog will be opened. The usercan decide the distance to deacti-vate the tourch height controllingbefore and after reaching cornersand also the delay time of thedeactivation.

Activate THD


Job control

18.04.2017 | 27

Fig. 13: Set THD


Ignore ARC feedback In some cases the user needsnot to wait for the feedback fromthe plasma sources. In this casethe function “Ignore ARC feed-back” will ignore the arc feed-back.

Ignore ARC Feedback


Job control

18.04.2017 | 28

Fig. 14: Test-run


Test-run (Fig. 14)

With “Test-run” the test-runmode can be activated. In testrunthe program will be run normallybut without any cutting.

If you activate this mode the dis-tance control will be deactivatedautomatically.

By deactivating the test-run modethe distance control type is set tothe old value before the test-runmode.

In some cases it is necessary touse the distance control in test-run mode, and then you can justactivate the distance controlagain in the distance control set-tings.

To use a different speed in test-run mode you can define a test-run speed with “Set test-runspeed”.

Test-run


Job control

18.04.2017 | 29

Fig. 15: Select Sheet


Select Sheet (Fig. 15)A dialog will be opened and theuser can choose the propertysheet material from the database.

This panel is used to define the angle of the cut sheet.

Fig. 16: Sheet angle option

Use angle Use the actual angle. This angleis shown in the right corner.

Set angle manually

Set angle by defining the posi-tions or direct input.

There are three possible options:

n Move to positions (seeÄ “Move To Positions”on page 31)

n Manual input (see Ä “ManualInput” on page 32)

n Set positions (see Ä “SetPositions” on page 33)

Select Sheet

Sheet Angle Menu

Options


Job control

18.04.2017 | 30

Fig. 17: Move to positions

Set sheet angle selectionWith the option "Move to posi-tions" you have to move to twopoints on one sheet side.

Axis selectionWith “Axis selection” you candefine if you weather want usethe X-axis side or Y-axis side.

Set P1 / Set P2If you move to the position, youcan adopt the position values forthis point by pressing “Set P1” or“Set P2”.

Laser guide With the button "Laser guide"the laser pointer will be activated.

Move To Positions


Job control

18.04.2017 | 31

Fig. 18: Manual input

Set sheet angle selectionIf you select “Manual input” youcan put in directly an angle indegrees.

Manual Input


Job control

18.04.2017 | 32

Fig. 19: Set positions

Set sheet angle selection

The “Set positions” option hasthe same functionality as the“Move to positions” option, butthe X- and Y-coordinates of thepoints have to be defined man-ually by the input fields.

Axis selectionWith “Axis selection” you candefine if you weather want usethe X-axis side or Y-axis side.

CalculateTo calculate the angle you haveto press the "Calculate" button.The calculation is only done ifthere are reasonable values.

Set Positions


Job control

18.04.2017 | 33

Fig. 20: Plate detection options

Sheet size detection

Size of the plate will be deter-mined.

Sets the size of the sheet to get afaster and more precized angledetection.

Plate Detection Options


Job control

18.04.2017 | 34

5.2 Job control cycle off – right side

Fig. 21: Single Step


Single Step

Program will be run in single stepmode, means NC program will beprocessed block by block throughpressing the start button. Thisfunction can be hidden in theMachine setup and is only fortesting and analyzing.

Single Step


Job control

18.04.2017 | 35

Fig. 22: Job End Action

Fig. 23: Job End Action


Job End Action (Fig. 22) With the combo box "Job EndAction" you can define whatshould happen after a program isfinished. There are differentoptions to move the machineafter the program end:

n No move– Machine stops after the

last lead outn Start pos.

– Machine moves to thestart point of the program

n Shutdown pos.– Machine moves to the

shutdown positionn Load pos.

– Machine moves to theload position

n Service pos.– Machine moves to the

service position

Job End Action


Job control

18.04.2017 | 36

Fig. 24: Start position type


Start position type

The start position can be definedin different ways:

n Actual Machpos. = actualmachine position is used asstart position

n Last Startpos. = Startpositionof the last active program isused for start

n Manual input = Startpositionis defined with absolute posi-tions for X-and Y-axis

n External guide = ExternalGuide Offset is used to setthe start position (optional)

External Guide (optional) Switch on/off the external guide

Act Pos (optional) Set directly ActPos as StartPosoption

Last Pos (optional) Set directly Lastpos as StartPosoption

Start Position Type


Job control

18.04.2017 | 37

Fig. 25: Job selection


Select Job see Ä “Select Job” on page 39.

PACUT

This function is only available ifyou are using the PaCut on thecontrol to generate the NC pro-grams. With this button you canswitch to the PaCut program orstart it.

Feed Override see Ä Table on page 23.

Job selection


Job control

18.04.2017 | 38

Fig. 26: Select Job


Select Job (Fig. 26)

Popup to select a job from harddisk or flash drive. The disk/foldercan be selected by scrolling upand down. If you put in letters inthe edit field, the list will be fil-tered to this input. To open afolder you have to scroll it into thegreen area and keep it presseddown. Now the folder will beopened and you can see the sub-folder/file in it. Then you canselect a program by scrolling.

Select Job


Job control

18.04.2017 | 39

5.3 Job control cycle on - left sideDuring the running of the program (Cycle on), the Job Control windowsshow different options, which are allowed to change during the job. Allother options are hidden. The functionality is explained in Ä Chapter 5“Job control” on page 25.

Fig. 27: Left side of the screen (Cycle on)


Ignore ARC feedback see Ä “Ignore ARC Feedback”on page 28


Job control

18.04.2017 | 40

5.4 Job control cycle on - right side

Fig. 28: Right side of the screen (Cycle on)


Job control

18.04.2017 | 41


Single Step see Ä “Job selection” on page 38

Set Start-Pos.Type

see Ä “Start Position Type” on page 37

PACUTThis function is only available if you are using thePaCut on the control to generate the NC pro-grams. With this button you can switch to thePaCut program or start it.

Feed Override see Ä Table on page 23


Job control

18.04.2017 | 42

5.5 JobControl Cycle Stop - left sideDuring the running of the program, the user can press the stop buttonto stop the program. That means the program is still active and can becontinued. In that case, the Job Control window shows differentoptions which are allowed during the stop handling. These functionsare explained in Ä Chapter 5 “Job control” on page 25.

Additionally there are some special stop handling functions which allowthe user to move with the machine.


Job control

18.04.2017 | 43

Fig. 29: CycleStop - left side


Test-Run see Ä “Test-run” on page 29

Use angle see Ä “Options” on page 30


Job control

18.04.2017 | 44


Move backw.

If this button is activated and the user presses thestart button, the program will start and movesbackwards (without beam) until the user pressesstop again. If there is no stop signal from user, themachine will stop at the maximum possible back-ward blocks. After that the user has to press stop.

Move axis

With this option the user is allowed to move allaxes of the machine (e.g. for service issues) withthe jog buttons. After pressing the start button,the machine axes will retreat to the last position inthe program and continue with the program.

Manual Joboptions

see Ä “Manual Jog Options” on page 21

Manual cutting see Ä “Manual Cutting” on page 22


Job control

18.04.2017 | 45

5.6 JobControl Cycle Stop - right sideDuring the running of the program, the user can press the stop buttonto stop the program. That means the program is still active and can becontinued. In that case, the Job Control window shows differentoptions which are allowed during the stop handling. These functionsare explained in Ä Chapter 5 “Job control” on page 25.

Additionally there are some special stop handling functions which allowthe user to move with the machine.


Job control

18.04.2017 | 46

Fig. 30: Cycle Stop - right side


Single Step see Ä “Job selection” on page 38

Set Start-Pos.Type

see Ä “Start Position Type” on page 37


Job control

18.04.2017 | 47


PACUTThis function is only available if you are using thePaCut on the control to generate the NC pro-grams. With this button you can switch to thePaCut program or start it.

Feed Override see Ä Table on page 23


Job control

18.04.2017 | 48

6 File transferThis window (Fig. 31) is used to copy or delete files on the hard disk,flash drive or other devices. In the upper window you can scrollthrough the devices and select one. There are also some shortcutswhich are predefined.

In the lower window you can select the folder and files which should bedeleted or copied. To select a folder/file you have to scroll through thelist and click on the marked folder/file (shown in the green line). If youpress long then the folder is opened. To copy files you can use thearrows in the middle of the screen.

Fig. 31: File Transfer

Button Function

DEL Delete the selected files inside a directory

Select all Select all files of a directory

File Transfer


File transfer

18.04.2017 | 49

Button Function

Deselect all Deselect all files of a directory

Copy Copy the selected files


File transfer

18.04.2017 | 50

7 HeadsThe Heads window shows all heads of the machine (see Fig. 32).

There are panels for each head to set the specific settings.

n IHT & Hypertherm Head (see Ä Chapter 7.1 “IHT & HyperthermHead” on page 51

n Spindle Head

Fig. 32: Heads

This can be done all the time (with activated or deactivated program).With program start the water and sand will be activated automaticallydepending on the program but you can interact at any time.

If you want to change the water pressure or the sand amount you haveactivate the button “Change cut par”. Then you are allowed to changethe water pressure with the plus and minus button in steps of "100" or"500".

To change the step size you have to click on the bar on the right side.

Also the sand amount can be changed in the same way. Here thesteps are "10" and "100".

If you want to go on with the values from the program you have todeactivate the “Change cut par” button. Then the pressure will bereset with the next part/contour.

7.1 IHT & Hypertherm HeadThe IHT & Hypertherm head shows two different panels:

n Hypertherm panel (see Ä Chapter 7.1.1 “Hypertherm panel”on page 52)

n IHT panel (see Ä Chapter 7.1.2 “IHT panel” on page 53)

Heads Window

Panels


Heads

18.04.2017 | 51

7.1.1 Hypertherm panelIn this panel it shows the cutting parameter that read from the auto-matic gas console (Fig. 33). When the user choose a sheet from thedatabase, the automatic gas console reads the sheet number andgives back the property cutting parameter to the controller.

In addition, there is a separate error message that comes from theautomatic gas console of the plasma source.

Fig. 33: Hypertherm panel

Cutting Parameter


Heads

18.04.2017 | 52

7.1.2 IHT panelThe IHT panel shows the virtual operator of the IHT distance controller(see Fig. 34). The user is able to change the cutting parameter throughthe operator panel.

Fig. 34: IHT panel

The following parameter will be set:

n Ignition height (Fig. 35)n Piercing height (Fig. 36)n Piercing time (Fig. 37)n Regulation delay (Fig. 38)n Cutting height (Fig. 39)

Virtual Operator

Cutting Parameter


Heads

18.04.2017 | 53

n Upper Threshold (Fig. 40)n Retract Position (Fig. 41)

Fig. 35: Ignition height

Fig. 36: Piercing height

Fig. 37: Piercing time


Heads

18.04.2017 | 54

Fig. 38: Regulation delay

Fig. 39: Cutting height

Fig. 40: Upper Threshold


Heads

18.04.2017 | 55

Fig. 41: Retract Position


Heads

18.04.2017 | 56

7.2 Spindle HeadThe spindle head shows and controls the spindle functions (see Fig. 42).

Fig. 42: Spindle head window

Spindle Functions


Heads

18.04.2017 | 57

The following buttons are defined:

n Manage Tool Placen Reference Tool changern Goto Tooln Manual Drilln Tapping

– Set Tap Revolutionn Tool information

– Sheet Thickness– C2C Height– Tool Length– Tool diameter

n Pulse Cooling– Set Cooling

n Current Alarm– Set Alarm


Manage Tool Place In this dialog the tools will beassigned to the tool changerplaces (see Fig. 43.

Fig. 43: Tool Place


Reference Tool changer The button references the toolchanger to its start point

Spindle Functions

Manage Tool Place

Reference Tool Changer


Heads

18.04.2017 | 58


Goto Tool The button starts the toolchanger and goes to the placewhich is defined in the tool


Manual Drill The button starts the manual drillwith the tool which has beenchosen from the tool data.


Tapping The button activates the tappingfunction.


Set Tap Revolution The button sets the tap revolutionper minute.

Goto Tool

Manual Drill

Tapping

Set Tap Revolution


Heads

18.04.2017 | 59

The following four buttons give information about the tool:


Sheet Thickness The buttion gives informationabout the sheet thickness.


C2C Height The buttion gives informationabout the C2C height.


Set Tool Length The buttion gives informationabout the tool length.


Set tool Diameter The buttion gives informationabout the tool diameter.


Pulse cooling The button activates the pulsecooling of the tool in the spindle.


Set Cooling With this button you can set theon and off time of the inside andoutside cooling valves.


Current Alarm The button activates the supervi-sion of the spindle current fromthe drives.

Tool Information

Pulse Cooling

Set Cooling

Current Alarm


Heads

18.04.2017 | 60


Set Alarm With this button you can set threedifferent alarm levels. The thirdalarm level generates stop cycle.

Set Alarm


Heads

18.04.2017 | 61


Heads

18.04.2017 | 62

8 Machine setupThe machine setup is password protected. There are three protectionlevels with different access rights. The passwords are free definable.

If you open the Machine setup page and there is no user logged in, apopup window will automatically be opened where you have to put in apassword. According to the password level, the options for this kind oflevel will be shown.

If the password is wrong, the access will be denied. For retry you haveto change the view in the menu line (e.g. to machine control) and goback to machine setup.

If a user is logged in, it will stay logged in until the button “log out” ispressed. You find this button on the right downside corner of themachine setup.

Fig. 44: Password

The Setup screen is divided into 3 parts. After log in you will see thegeneral options (see Ä Chapter 8.1 “General Options” on page 65)which are frequently used by the machine user.These options are spe-cial and should be protected.

There are two buttons which are used to come to the 2 other sectionsof the machine setup.

With the basic settings button a popup will be opened, where you canfind options which can be changed from time to time during the use ofthe machine (see Ä Chapter 8.2 “Basic Settings” on page 69).

Password

Setup


Machine setup

18.04.2017 | 63

The "Basic Setup" button will open a window with settings which arenormally set up once at the installing of the machine and are almostnever changed.

There are several timers to count the system and user times whichcan be defined individual (see Fig. 45).

Fig. 45: Setup


Machine setup

18.04.2017 | 64

8.1 General OptionsFunction Description

Display singlestep

Show/hide the Single step button on the Job con-trol window. The single step button is only for testpurposes, if you have to go through a NC pro-gram step by step.

Handrelease Handrelease button is only visible for machineswith reference axes. Therefore it could be neces-sary to release the axes before the referencecycle to move them manually.

IOService not used yet.

HMI With this button you can open the standard CNCHMI to get access to the machine parameters orcheck other things.

FileNameFilter This button opens a popup where you can set afilter, to filter NC Programs in the Select Jobpopup.

Fig. 46: General Service

General Service


Machine setup

18.04.2017 | 65


Auto stop aftercontour

If active, the NC program will be stopped after thenext contour.

Auto stop afterpart

If active, the NC program will be stopped after thenext part.

FBurn=Cut4 4th cut table is used as film burning table.

Fig. 47: Diverse options

Divers Options


Machine setup

18.04.2017 | 66

There are several timers to count the system and user times which canbe defined individual (Fig. 48).

Fig. 48: Timers

After you activate the "Timers Setup" button another window will opento set the timers (Fig. 49):

n Timer can be shown or hiddenn Possible timer formats: ms, hh:mm:ss, dd:hh:mm,

dddd:hh:mm:ss, hh:mm, dddd:hh:mm:ss:ms, dddd:hh:mm,ss:msd = days, h = hours, m = minutes, s = seconds, ms = milliseconds

n Timer resettable = Timer can be resetted by button on HMI (ResetTimer)

n Timer as fixed counter = Timer counts down from a fixed startingtime

n Timer as flexible counter = Timer counts down from a starting timewhich can be defined on HMI

Timers


Machine setup

18.04.2017 | 67

Fig. 49: Set timers


Machine setup

18.04.2017 | 68

8.2 Basic SettingsFunction Description

Safe start option Safe start position option and remember afterCNC shut down.

Safe HSU Option Safe HSU option and remember after CNC shutdown.

Disable StartPanel

Hide the panel with Start/Stop buttons on thescreen.

Disable joystick Hide the SW Joystick on the screen.

Show file transfer Show/Hide the File transfer button in the mainmenu.

Fig. 50: Visual settings

Visual Settings


Machine setup

18.04.2017 | 69


Pipe mode If you have a machine with setup pipe option, youcan activate the pipe cut mode here.

Start alw lastcont

Start always at last contour if the program wascanceled.

Nc prog timereset

If deactivated, the program timer will continuecounting if you start a new NC program.

If activated, the time will be reset and you onlysee the time of the last program.

Backward pushbutton

The backward button in stop handling is used aspush button. That means, the machine will auto-matically run backwards as long as you press thebackward button.

If deactivated, you have to activate the backwardfunction and start again manually to move back-wards.

Z feed in Auto Allows changing the feed of the Z-axes move-ment, if you use the Z-axes movement during NCprogram function.

Servicepos asOffset

If activated, the servicepos given in the cycleparameters is moved relative to the actual posi-tion (used normally at job end to move the headaway from the last cut position).

Fixed Calpos Fixed position to do the calibration, otherwise theactual position is used.

Diverse Settings


Machine setup

18.04.2017 | 70

Fig. 51: Diverse settings


Machine setup

18.04.2017 | 71


Use safetyretract

Use safety retract options if no C2C movementtype is set in database.

Large up Large movement of Z retract.

Small up Small movement of Z retract.

Dist for switch tolarge up

Below this distance the small retract is used, oth-erwise the large distance is used.

Fig. 52: Retract settings

Retract Settings


Machine setup

18.04.2017 | 72


Laser guideoffset X

Set the offset in X direction for the external laserpointer.

Laser guideoffset Y

Set the offset in Y direction for the external laserpointer.

Fig. 53: External guide settings

External Guide Settings


Machine setup

18.04.2017 | 73


Retry cycles Number of cycles to retry an automatic start aftertip touch error.

Retry distance Distance after the retry counts are reseted.

Fig. 54: Retry cycle

Retry Cycle


Machine setup

18.04.2017 | 74


Activate Cutcnt Activates the cut count function.

Cutcnt nozzle/Cutcnt nozzle+calib

Uses only the nozzle clean program or use nozzleclean and calibration.

No reset cutcnt Don’t reset cut counter after program end.

Cutcntlimit Number of cut counts after that a nozzle cleaningis done.

Fig. 55: Cut count

Cut Count


Machine setup

18.04.2017 | 75


Machine setup

18.04.2017 | 76

9 Service and return process9.1 ServiceBy PhonePA's well-educated service staff is available to answer your technicalquestions. Due to the close co-operation with our customers, our engi-neers can solve problems often immediately by phone.

If on-site support is necessary, our service staff will diagnose theproblem and will prepare our field service engineer beforehand. This isto make on-site service as much effective as possible.

By Remote Control SoftwareEvery PA CNC is equipped with an Ethernet interface. If you have anetwork on-site, you only have to integrate the CNC system to yournetwork for world-wide-web access.

Power Automation provides a remote control software which allows ourservice staff to log into your CNC. This provides all the informationavailable on the machine. They can check all the data like the PLCprogram, machine parameters, or the NC programs directly on the realsystem under real conditions. This is the fastest and most cost-effec-tive way to solve problems.

On-SiteIf necessary our service engineers will visit you to help you solve yourproblems on-site. Our engineers are trained continuously to be alwaysup to date. Thereby you always can expect the best support.

Due to our service centers worldwide, our service staff can be on sitenormally within 24 hours at the latest.

Service At Power Automation


Service and return process

18.04.2017 | 77

9.1.1 Service addresses

Power Automation GmbH (Headquarters)Gottlieb-Daimler-Strasse 17/2

D-74385 Pleidelsheim

Tel: +49-7144-899-0

Fax: +49-7144-899-299

[email protected]

Power Automation America, Inc.8601 Jameel Road, Suite 140

Houston, Texas 77040 USA

Tel: +1-713-263-9400

Fax: +1-281-715-2500

[email protected]

Power Automation Office TurkeyKustepe Mah. Mecidiyekoy Yolu Cad.

Trump Towers No. 12 Kule: 2 K:18

Daire no: 3211022839 Sisli / Istanbul

Turkey

Tel: +90-212-306-3280

Fax: +90-212-306-3101

[email protected]

Shenzhen Double CNC Tech Co., Ltd8th Floor,WeiXinDa Building

Bao Min Road 2

Xi Xiang Town

Bao'an District, Shenzhen, Guangdong

PR China

Service Addresses



18.04.2017 | 78

Power Automation France SARLCité de la Photonique

Bâtiment Pléione

11 avenue Canteranne

33600 Pessac

France

Tel: +33-559-4010-50

Fax: +33-559-4010-59

[email protected]

ACE AutomationA-721, Twinrex B/D

Deokpungdong-ro 111-10, Hanam-si

Gyeonggi-do, 465-831

South Korea

9.2 Spare partsDue to the high quality of our products we can assure you that you willnot need this service often. Spare parts are often urgent so PowerAutomation provides the relevant spare parts at the local service cen-ters for immediate dispatch.

Our 3 service centers in Europe, North America and Asia allow us todeliver all needed parts typically within 24 hours.

Only trust PA's original parts - because every part passes our tightquality checks.

We also offer consulting services to identify the most critical parts forthe machines in your production facilities. We suggest what criticalstock may be required to ensure a minimum downtime of yourmachines. Our specialists look for common parts to keep your inven-tory levels at a minimum.

Spare Parts



18.04.2017 | 79

9.3 Return policy and procedure

Power Automation will only accept control units and components forreplacement or repair, if they have been returned in adherence to theprovisions given below.

n If material warranty is void or if no error is detected, a testing flatrate will be charged. If an error is determined, the testing flat ratewill be charged to the repair costs.

n If material warranty is void you will receive a repair offer.n Before the repair starts we need a repair order from you, if the

material warranty is extinguished.

1. Contact Power Automation to receive an RMA form in Excelformat. Ä “RMA Form” on page 81

2. Open the 'RMA Process' form provided by Power Automation.

Use one form for each single part you want to ship back toPower Automation.

3. Fill in the form.

The fields marked with a red star (*) are mandatory fields.

Only fill in the fields next to the yellow bar on the left side of theform.

Do not fill in the fields next to the blue bar on the left side of theform. These fields are for internal notes only and blocked.

4. Send the completed form as an Excel file by email [email protected] to your local support (see web-page).

ð We will check the data and send the form back to you as aPDF file including an RMA number or tell you what informa-tion is missing if necessary.

5. Print the RMA form and add it to the accompanying componentsand documents.

6. After the check and repair the components will be shipped to youimmediately.

Policy

Acquiring RMA Number



18.04.2017 | 80

Fig. 56: RMA Form

RMA Form



18.04.2017 | 81

1. Pack the goods properly.

Controls must be packed in original or equivalent packaging. Ifthe packaging is not proper, Power Automation will charge apackaging flat rate.

NOTICE! Damages due to inadequate packaging Inadequatepackaging may result in damages to the control unit. Thiswill void the material warranty. PA does not bear any liabili-ties for damages in transit.

2. Write the RMA number on the cardboard box clearly readablefrom outside.

The incoming goods department rejects all deliverieswithout a visible, valid RMA number.

3. Ship the goods FREE DOMICILE / DDU. Other deliveries will berejected.

The goods have to arrive within 4 weeks after the date of theapproved RMA form.

9.4 TrainingHaving the best CNCs is one thing, to bring out the best of it is theother.

The PA training program comprises of a number of individually combin-able training modules which offer you a well-founded knowledge forusing PA CNCs. At our training centers we bring your employees -beginners and experts- up to scratch in CNC technology. We also offerindividual training courses at your site. The contents of the courses willbe customized to your requirements.

For more information see Ä Chapter 9.1.1 “Service addresses”on page 78.

Return

Conditions Of Supply

Training Courses



18.04.2017 | 82

10 Proof of changeVersion Change Date

1 Original Version 02/18/2016

2 New name: Plasma Turn-key Sol-ution Operating Manual

04/18/2017

Proof Of Change


Proof of change

18.04.2017 | 83


Proof of change

18.04.2017 | 84

11 Index

CCurrent Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Cutting Parameter . . . . . . . . . . . . . . . . . . . . . . . . 53

EError window . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

FFeed Override . . . . . . . . . . . . . . . . . . . . . . . . . . . 10File Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

GGoto Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

HHeads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Hypertherm panel . . . . . . . . . . . . . . . . . . . . . . . . . 52

JJob Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Job Control - Cycle off . . . . . . . . . . . . . . . . . . 25, 36Job Control - Cycle on

left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

JobControlCycle Stop . . . . . . . . . . . . . . . . . . . . . . . . . 43, 46

LLimitation of liability . . . . . . . . . . . . . . . . . . . . . . . . 6

MMachine Control Window . . . . . . . . . . . . . . . . . . . 21Machine Movements . . . . . . . . . . . . . . . . . . . . . . 23Machine setup

General options . . . . . . . . . . . . . . . . . . . . . . . . 65Main control bar . . . . . . . . . . . . . . . . . . . . . . . . . . 10Manage Tool Place . . . . . . . . . . . . . . . . . . . . . . . . 58

Manual Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Manual jog options . . . . . . . . . . . . . . . . . . . . . . . . 21Menu bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

PPassword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Path graphics window . . . . . . . . . . . . . . . . . . . . . 17Pictures

in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . 5Proof of change . . . . . . . . . . . . . . . . . . . . . . . . . . 83Pulse Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

RReference Tool changer . . . . . . . . . . . . . . . . . . . . 58Restart at contour . . . . . . . . . . . . . . . . . . . . . . . . . 10RMA form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81RMA-number . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

SSelect job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Select Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Select sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Select Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Service Addresses . . . . . . . . . . . . . . . . . . . . . . . . 78Set Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Set Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Set Tap Revolution . . . . . . . . . . . . . . . . . . . . . . . . 59Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Sheet Thickness . . . . . . . . . . . . . . . . . . . . . . . . . 60Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Spindle Functions . . . . . . . . . . . . . . . . . . . . . . . . . 58Spindle Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Status bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11


Index

18.04.2017 | 85

TTapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Test-run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Tool Information . . . . . . . . . . . . . . . . . . . . . . . . . . 60Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82


Index

18.04.2017 | 86

operating manual plasma turn-key solution - power automation · 1.7 glossary cnc - computerized...

Documents