Program line number boxes

 

Located just below the feed rate overrides are two boxes showing the program line numbers. The one on the right will always show the last line number where a pierce (actual cut only) occurred. This is a good reference when desiring to go back to the last pierce point. This will be a line with G23 code where the arc was “ON”. A good practice is to return to the G00 line just preceding this line to re-start a cut.

 

 

The box on the left shows the active line number to be executed. There are two sets of up/down buttons. The ones on the left of the box increment or decrement by 100 lines. The ones on the right of the box increment or decrement by 1 line. You may proceed to a line number and press Start Cycle to start on that line. If the line is a G01 code, the machine will start from where it presently is, cutting immediately if cutting button is on (lightning bolt). If a G02 or G03, unit will proceed to the start of that arc and beginning cutting (if cutting button is on).

 

 

Manual data input line (MDI line)

 

 

Located in the far lower right of the screen is a blank white box with a green arrow next to it. By clicking in this area, you may manually type in a line of G-code to be executed immediately. All G-code, M code and position commands may be entered one line at a time. This is known as the Manual Data Input (MDI). The MDI allows you to send the immediate G- Code that was typed in the text box.  For instance if you wanted to make a rapid move of the Y axis to the 3” location, then Type G0 Y3 in the MDI and either hit enter on the keyboard or click green arrow button, the line will be executed. All coordinates entered are program coordinates, not machine coordinates.

.

 


User defined / dedicated positions buttons

 

 

Located at the bottom of the screen are 5 rapid positioning buttons.

 

Home Pos button

 

This button always returns the machine to the lower left location where it found home during the homing procedure.  If the machine was not homed, this button will not work.

 

Load Pos and Service Pos buttons

 

These are user-defined positions. At installation, these are set to 0,0 or home position. To change these, select Setup->Machine Settings and the Offsets tab.  You will be presented with a screen allowing X and Y positions to be assigned to these buttons.

 

Raise Torch button

 

This button does a rapid raise to the up position of the torch (Z axis) on machines equipped with a THC or Z-axis lifter station.

 

0,0 Pos button

 

This button makes a rapid move to the 0,0 position currently programmed into the machine. This is the floating zero and can be anywhere on the machine.  It does NOT require that the machine be homed.   So be careful, it will move the axes until the numerical displays read 0,0

 

Zero X-Y button

 

This is a very important feature. The X and Y coordinate system may be re-zeroed independently using the “Zero” button at the top next to each axis or X and Y may be re- zeroed together using this button. This re-sets the program zero point for program execution. This does not affect the machine zero or travel limits.  This zero is known as the floating zero and can be located anywhere on the machine.

 

If you wish to cut a part somewhere out on the table, you may jog to a new zero point (lower left corner of where you wish to cut) and then press the Zero X-Y button. This will then move the program to this location for cutting. The machine will retain this as the program zero point until re-set again using the Zero button(s) even if power is lost or the machine is shut off. When the machine re-starts, after homing you may see negative numbers in the coordinate displays. This maintains the program zero relative to the machine travel limits so that you may re-run the program to recover from power outage or other catastrophes and still be exactly where it was before.

 

A quick re-zero would be by pressing the Home Pos button and then after the machine returns to the lower let corner, press the Zero X-Y button. Program zero and machine zero will now be the same again.

 

Pressing Zero XY button when a g-code file is opened will cause the ghost image to be redrawn in relationship to the table.

 

E-Stop Assist button

 

This button handles the E-Stop assistant. Please refer to the E-Stop Assist section of the help file

 

Zoom All and the Arrow (next to Zoom All) buttons

 

The Zoom All button shows the complete table with the parts to be cut in relation to where they will be cut.   If you drag a box around any object on the main screen and then click the zoom button that appears, then that object will be zoomed in, and fill the screen.   While Zoom all is enabled, the table is shown as a blue dotted line on the screen.

 

You can zoom up to 24 levels, zooming in more and more each time.  The Arrow button backs up one zoom level.  The Arrow button will be enabled if there is a zoom level you can back up to, otherwise it is disabled. 

 

Zooming while cutting is possible, but it can cause buffer underflows if zoomed or unzoomed during a cut.  If you must zoom during a cut, do it during rapid move between cuts or anytime the torch is NOT ignited. Zooming is not recommended while the torch is lit.

 


 

Plasma / Oxyfuel cutting selection

 

                                      

 

 

In the far right upper section just above the torch up and down jog buttons is the word Plasma or Oxyfuel. By clicking on this word, you can toggle between cutting methods and parameters.

 

 

Plasma Cutting THC functions

 

If Plasma is selected, you will have the ability to set a pierce height just under the large Torch letters. This has an up and down button next to it incrementing the pierce height by 1/16 + or - and sets the distance that the torch will back up after finding the plate. This may be changed at any time even while cutting and will be reflected on the next pierce operation.

 

 

 

 

The E-stop on lost arc is normally checked and is only unchecked for cutting very thin material (less than 22 gauge). The V window represents the actual cutting arc voltage at the present time. If not cutting it will show “---”. Next to this is the SP (set point) window. This sets the target cutting voltage and thus the cutting height. The unit will move the torch up or down in order to try to maintain this voltage when cutting. The plasma power supply manual will suggest correct voltages for a given set of consumables, amperages etc. It is best to start high (5 to 10 volts over the recommendation) rather than low to avoid crashing into the plate due to a low voltage set point. You may change this set point at any time even while cutting and the torch will respond by raising or lowering the cut height.

 

 

Oxyfuel Cutting functions

 

If Oxyfuel is selected, you will have the ability to set three (3) timers. The first timer sets the Preheat delay. After the machine reaches the pierce X Y location, the Preheat gas output turns on. The machine stays in position while the output remains on and the preheat delay timer counts down to zero. Then, the cutting oxygen output turns on. The machine still maintains position while the second pierce delay timer marked Pierce counts down to zero. Then the machine begins moving along the cut path. At the end of the cut path, both the high preheat and the cutting oxygen are turned off and the machine waits for the Post delay to time out. This post delay allows the pressure in the lines to drop back so that the machine will not still be cutting when the rapid movement to the next pierce point begins.

 

 

If the option for Raise Torch Between Cuts is set in the Machine Settings Torch tab, then the cycle will be similar with these added features.  First it is expected that the machine operator has jogged the oxy torch down to the height that is preferred for cutting and has clicked the SET CUT HEIGHT button.  This teaches the torch the cutting height and allows for the torch to rise to the home position for rapid moves to the next cutting location. Once the cut height has been set, the operator can select the pierce height using the up/down arrows just below the Torch check box, these will increment and decrement the pierce height by 1/16 for each click.  With these selection made, the cycle sequence will be as follows: First the torch will rapid to the starting location, it will then lower itself to the cut height PLUS the pierce height.  That is, it will stop x/16th's above the cut height and turn on the preheat gas output.  It will then wait for the preheat delay to timeout. Once the preheat delay has timed out, it will turn on the cutting oxygen output to pierce thru the material.  The pierce delay will start to count down.  When the pierce delay expires, the torch will lower itself to the cut height and begin it's XY moves along the path.  This ability to remain at the raised pierce height may prevent the blow back from clogging the torch tip when the cutting oxygen first begins to pierce.

 

Oxyfuel torch types and connections

 

You may use either a two or three hose torch. A three hose torch is more often used for machine cutting. Using this type of torch, you will have one gas (fuel) line and two Oxygen lines. One for preheat and one for cutting. Three regulators are used. One for the gas (fuel) usually which remains on all the time that the torch is being used and burns at a low flame. The second regulator operates high preheat oxygen sets the flame to a good blue level for heating and the last regulator sets the cutting oxygen pressure. You will need two high flow solenoids for gas service. Generally ASCO brand red-hat series brass solenoids operating on 115VAC. The outputs on the back of the console are pre-configured to deliver 115VAC when on at a maximum of 5 amps each. Mounting these near the torch greatly reduces the bleed- down or post-flow delay time and saves gases. All safety recommendations by the torch manufacturer including safety check valves should be used. Always check for leaks.

 

Torch CUT / No-CUT and THC (height control)

 

             

 

THC AND PLASMA                    THC AND PLASMA

SHOWN ON                      SHOWN OFF

 

Just below the Torch up and down jog buttons are two buttons for controlling cut and dry run as well as THC (torch height control for plasma only). If the lightning bolt button is depressed, then the machine will cut when running a G-code program using whichever process (plasma or oxy) was selected above. If the lightning bolt button is “X”-d out and gray, the no cutting or THC will operate. This includes the initial pierce height sensing operation for plasma.

 

 

If the cut (lighting bolt) button is on, then the THC button will be enabled. This is only operative in Plasma cutting mode. With THC depressed, running a program will cause the torch to find the pierce height, start the arc and cut using arc voltage control. Then “X”-d out the unit will find the pierce height but after cutting begins, no automatic height control will be used. Only the jog buttons will change torch height.

 


 

The Visual Cutting Area

 

The visual cutting area of the screen shows the work piece path that was represented by the G- Code file currently open.

 

 

 

 

The dark blue dotted line around the objects represents the limits of you table. If the parts go beyond the dotted line on the screen, then the torch will also attempt to go beyond the table.

 

 

 

When the table is filled with lots of small parts to be cut, then it is hard to actually see what is going on. In this case it is possible to ZOOM up on a particular area of the screen.  By left clicking and dragging a box around the object to view, you can zoom up on the object.  A button will appear (Zoom) after you have dragged the box around the object, if you click on it the zooming will take place, if you click away from the button, then the zoom is aborted

 

 

 

 

Once zoomed up, the Button with the Arrow next to the Zoom All button will be enabled. This is the Un-Zoom button and will take you back one zoom level until you reach the table limits. You can zoom up to 24 levels deep.

 

 

Zooming and un-zooming during actual cutting may result in “buffer underflow” errors. If you wish to zoom during a cut, it is suggested you do it when the torch is NOT lit.  As an example, when the torch is making a rapid move between objects, or when it is retracting or when it is descending to initialize the arc.   Just about anytime other than while the ARC is ignited.   This holds especially true when the object is large or the file has a lot of nested parts on the screen.  A simple one-piece gusset would not cause a problem.  Whereas a 48” square piece of artwork with lots of detail spells trouble.  Just use common sense.  Also, the speed of the PC and video card have a lot to do with this.

.

 

 

 

You can continue to zoom beyond 24 levels, but when you click the arrow button to back up, you will immediately back up to level 24 and continue from there backing up.

Chapter

4


 

The DXF to G-Code Converter

 

 

This section contains subjects related to the onboard DXF converter

 

 

·Main Converter Screen

·Setup Menu

 


Creating a G-Code File from a DXF drawing

 

These are the steps needed to transform a raw DXF file into a processed G-Code file ready for cutting using our software.

 

It is assumed you have completed the settings in the converter setup menu

 

 

Click on the Open button, navigate to a file in your operating program directory and locate a sample DXF file. Double left click on this file. This will load the dxf file shaped object into the lower left corner of the white area of the conversion screen. The object image is scaled in size to its relationship with the cutting table as a whole.

 

Click on the Object button. The object will be magnified to fill the entire white area making it easier to work with.

 

Click on the Zoom button. Using the left mouse button drag a window around a section of the drawing to magnify it.

 

Click on the Un-zoom button. This will return the screen to the previous view.

 

Click on the Start button. The cursor will change to crosshairs. Place the crosshairs over any section of the drawing where you would want the torch to start cutting, this is preferably a lead-in.  The segments will begin to be pieced together as they are sorted thru from the list of lines and arcs that make up the drawing. They will turn red indicating they have been joined together as one object to be cut.  When the path is complete, or at least this section of the file to be cut is complete, you can now...

 

Move the crosshairs to the next lead-in line.  Place the crosshairs over the free end of the lead-in line and left click. This is the next place the torch will lower itself to and begin cutting. As the segments are pieced together they will turn red.

 

Once all the lines making up the cut path have now been joined and sequenced. Left click on the Test Run button. The program will create a series of red dotted and solid blue lines. The dotted lines indicate rapid moves. The solid blue lines indicate cuts.

 

If the test run meets your approval click on the Save button. At this point the program will create a G-Code file and save it in the same directory as the DXF file was obtained from.

 

How it works

 

Your DXF drawing can be from any cad package that supports the  “.dxf” output including: ACAD, Turbo CAD, Fast CAD, AZ CAD, Corel Draw, Photoshop, Paint Shop Pro, and others. 

The drawing can be made with arcs, fillets, circles, points, lines, and polylines. (no blocks, ellipses or splines) 

Once the drawing is exported to a .dxf file, it can then be imported to this conversion utility. 

How does the converter work? 

Simple... click the start button... then when you click on the screen (the white area) the computer takes the location of where you clicked and starts looking all through the group of lines and arcs that make up the drawing until it finds the closest endpoint to where you clicked.  It then gets the other end of that line or arc etc and it then looks thru all the remaining segments for a line or arc that matches that endpoint... this continues until there is no line or arc closer than the join tolerance. 

At this point it will stop, draw an X on the screen of the next closest endpoint, and display the message " Next closest segment found is x.xx" distance away... Right click to accept it or left click to pick another (lifting Z)"  

What does that mean.

Well if the drawing is poorly drawn, and you intended on a continuous cut to the next point, by right clicking it will automatically insert a connecting line between the two endpoints and continue with the path building.

If instead it has reached the end of that particular cut, then you would move the cursor closest to the next begin point and click there to start the next path build.  And the torch will do the same thing when it is cutting, it also will stop the cut, raise the torch move to the new location, and begin cutting again. 

But what if it comes to a place where more than two lines join? How does it know which one to pick?  Well, it is based on the current direction of the cut, and it will choose the smoothest path from it's current path.  If one path goes off at a 10-degree angle the other goes off at 80 degrees, it will choose the 10-degree angle path.



Saving and Saving Special

Once your drawing is converted, you must save the drawing:

There are two options: Save and Save Special.

Save does exactly what is says, but save special is listed below.

 

 

Scale the object with this ratio xxx to 1

This option allows you to scale up or down the size of the converted drawing.  Value must be positive (greater than zero).

 

Save as an Array of Parts

 

If you want to cut multiple copies of the same drawing, you can do this by building an array. An array, for the purpose of this document, is a layout of one or more copies of the same object, which is organized in columns and rows of identical images, with X = to the number of columns, and Y = the number of rows.  Choose the number of rows and columns you want by typing in the number, or by using the left and right arrow keys under the number to adjust it. X multiplied by Y = the total number of images to be cut.

 

On the left side of this window look for “X (cols) and Y (rows)” area. Here, by changing the numbers, you can define the number of columns and rows in your array.

You can also have the system calculate for you the maximum number of parts it can fit into a certain width or height or both.

 

Our software can create arrays using three methods for spacing the objects in an array.

 

METHOD ONE:

When the first radio button is checked an array is created using the starting point of the first object plus an offset distance (both horizontal and vertical0 to define the starting point of the second object. The offset distance is specified in the areas labeled “X axis spacing” and “Y axis spacing”.

 

METHOD TWO:

When the first radio button is checked AND the checkbox directly below it is also checked the object starting point is ignored. The object’s extents are used in place of the starting point. An extent is a theoretical box around an object that is part of the DXF file. The sides of the box correspond to the objects width and height.  When using extents the “X axis spacing” and “Y axis spacing: areas will define the horizontal and vertical spacing between the objects (copies) extents boxes.

 

METHOD THREE:

When the lower radio button is checked, arrays are created using an objects starting and ending points. The beginning point of the second object in the array will be co-located with the ending point of the first object. Only one row can be created using this method.   It would be rare to use this method.

 

NOTE: The total material area needed to create your array will appear in the Object Width and Height windows. Once the conversion is completed, it is saved as a .tap file. It is possible to edit the generated code to your liking, if changes are made to the code from the edit command in the main program window (Production Screen).

 

*Note: this version of our CNC Plasma software only handles 2D drawings.

 


DXF Converter Setup Menu

 

The Settings Tab

 

 

Join Tolerance

AS the converter is building the cut path, it looks for line ends that touch each other, or are close to each other. This is the tolerance for being close to each other.  The default is set at 0.001. The larger the number, the further distance away the system will search for the next line. This is used for poorly drawn objects where the lines do not touch each other.

 

After conversion, save *.dxf as *.tap

This will automatically save the dxf file you opened as the same name except with a ".tap" extension.  This skips the dialog box requesting you to select a name for the file to save as.

 

Set G92 to initial position

This check box will issue a G92 command followed by the X and Y value of the first rapid move.  The G92 sets the current coordinate system position to the X and Y values.  This way when you jog the table to where you want to begin, the code will automatically set it's current position to the correct position. You do not need to push the Zero XY button on the machine.

It is for advanced users.

 

Use these Z commands when Points are encountered in the drawing

Sometimes points are used in a drawing where you want to pierce a hole, but not traverse the X and Y.  Just go down, pierce the hole and go back up.  In this case you would issue the G23 for the Z down and a G25 for the Z up. These codes will follow each other immediately, or there may be a G04 Pxx pause to clear the pierce completely. There will be no X Y movement during the pierce.

 

The Import Locations Tab

 

 

The import location specifies where the drawing will appear on your screen.

 

Co-Locate with Origin as drawn

The origin is the 0,0 value as defined in the DXF file, superimposed on the table’s 0,0 position.

 

Locate drawing “Zero” at X.xxx    Y.yyy

Specify where you would like the drawing’s zero to be by entering the values for X and Y. “Use Current Position” button changes values to match current gantry position.

 

Lower Left Extents at X.xxx    Y.yyy

This uses the lower left of the extents box (measured by the objects in the drawing file) to position the object at the X&Y location sited in the windows shown.

 

Use Current Position

This button changes values in the X and Y text boxes to match current gantry position.

 

 

The Conversions (Plasma, OxyFuel, Custom) Tabs

 

Here you fill in any values in the Plasma /OxyFuel and Custom Conversions Tabs

 

PreCode

When converting a drawing, and writing the resultant file to the tap file, some codes are required at the very beginning of the file.  These codes include things like the feed rate, the coordinate offsets, etc.  Anything placed in this text box will be put at the beginning of the file.

 

PostCode

When converting a drawing, and writing the resultant file to the tap file, some codes are required at the very end of the file.  These codes include things like the M30 command which indicate the EOF (end of file) or some sort of code to turn off the exhaust system after a 5 second delay, etc.  Anything placed in this text box will be put at the very end of the file.

 

Z up

This will allow you, for instance, to perform code between each and every path segment. Such as it would be convenient to be able to raise the Z-axis prior to moving from the end of the first segment to the beginning of the second segment (G25).  Whenever the path ends, this code is added to the file.

 

Z Down

This will allow you, for instance, to perform code between each and every path segment. Such as it would be convenient to be able to lower the Z-axis as soon as it gets to the beginning of the cut path (after a rapid move). (G23)  Whenever the path is about to begin, this code is inserted into the file.

 

The 4 code boxes can have as much of any G-Code you like entered in them; they are automatically saved when this window closes.  There are 3 different sets of Pre/Post and Z up/down commands. One for Plasma cutting, one for OxyFuel cutting and still another for your own custom application.

 

Typically when using the built in torch height controller, it is advisable to put “G23” in the Z down and “G25” in the Z up code windows. G23 sends the Torch down and strikes the arc, G25 raise the torch. When using the OxyFuel conversion, the G23 and G25 are not appropriate commands, but the M04 and M05 are the correct command for Oxyfuel.

(see G-codes and M-codes for more information on what to put in here)

 

Chapter

5


 

 

Modifying an Existing G-Code File

 

 

Our software allows you to change or modify an already existing G-Code.

 

 

 

·Scale an object

·Move it's origin

·Rotate the object

·Build and array of the objects,

·Convert it to a DXF

·Convert and existing EIA drawing to our G-Code

 


Modifying a G-Code

 

Our software allows you to change or modify an already existing G-Code. From the DXF Converter screen, choose the Other menu and select Modify GCode. In this window you can:

 

1.  Scale an object

2.  Move it's origin

3.  Rotate the object

4.  Build and array of the objects,

5.  Convert it to a DXF

6.  Convert and existing EIA drawing to our G-Code

 

Object scaled and it's starting point moved

 

Browse for a G-Code to Modify

 

The browse button will allow you to scroll thru the folders and find an existing ".tap" (G-Code file) to open.  Once the file has been opened, it should appear as an image in the Original drawing area (bottom left side).  If the drawing does not have the X and Y commanded positions on it's first G0, G1, G2or G3 line, it will NOT open the file in the Original window. Rather, it will open the file in the Modified window, which will allow you to modify or fix the problem, you can then save it or click the red arrow button between the text windows to move it from the modified to the original without saving.  Once you have a valid file in the original text area, it will show the path image in the Original drawing area. And the Starting XY positions will be filled in on the scale/move tab.  This starting XY is the very first position the torch is commanded to go to.

 

Scaling / Moving

 

After a file has been opened, you can now begin to modify it.  The first tab is the Scale/Move tab.  Here you can increase or decrease the size of the object.  You can also move the objects position relative to you table.

 

 

Scale Factor

This value can be any POSITIVE number greater than 0.  It could be 0.25 to scale it down to 1/4 it's current size or it could be 12 to scale it 12 times bigger than it's original size

 

Allow scaling of the original XY starting point

This checkbox will scale the starting XY values. If the starting XY is 0,0 then and scale factor is 2, well anything times zero is zero and the starting point will not move.  But if the starting point was 3,5 and the scale factor was 0.50, then the new starting point would be 1.5,2.5 which will move the image on the table down to the left.  After selecting the scale factor, clicking Modify will compute the new G-Code and draw the new image in the modified drawing area (bottom right).

 

Maintain original XY starting location when scaling

This checkbox will NOT scale the starting XY values. If the starting XY is 2,5 then after it is scaled it will remain 2,5.

 

Move starting XY location to X.xxx  Y.yyy

This checkbox will first move the starting XY location to this value and then perform any scaling operation while maintaining this value as the starting XY location.   If the original XY was found at 2,5 and you wanted it at 10,10... then scaling it with a scale factor of 1.00, will do nothing more than move the origin of the drawing so that the XY Starting point is at 10,10.  And if you had a scale factor of 3.0, then the part would be 3 times larger, but with a starting XY location of 10,10.

 

Measuring the amount of material needed to cut this newly scaled shape

By dragging a Windows rubber band (left click and hold while dragging the mouse) immediately around any of the drawn images, the size of the image will appear above the respective image box.

 

Saving As

By clicking the Save as button you can name the re-sized TAP file and save it to a location of your choice

 

Or you can continue working on the scaled object by...

Clicking the Red Arrow button between the text frames will move the modified code to the original code window.  This modified code NOW has become your original code. You could scale it again, or you could rotate it, build an array of these parts, and output it to a dxf...

 

 

 

 

Rotating an object

 

After a file has been opened, you can now begin to modify it.  The rotate allows you to turn the part in any direction.  Here you can rotate it forward or backwards.  You can rotate the object about many different locations.

 

 

Degrees to Rotate

This value can be any POSITIVE or NEGATIVE number between -360.0 to +360.0 degrees.  Positive values will rotate the object counter clockwise wand Negative numbers will rotate the object clockwise.

 

Rotate about...

These check boxes determine the pivot point of rotation.  The object's extents are used to calculate the all pivot points other than the starting XY position.

 

Once you are happy with the rotation, you can continue working on the object by...

Clicking the Red Arrow button between the text frames will move the modified code to the original code window.  This modified code NOW has become your original code. You could scale it again, move it, build an array of these parts, output it to a dxf...

 

 

Object rotated 90 degrees about it's center

 

 

Building an Array

 

The build array tab allows you to copy the object multiple times in a rectangular pattern. Putting them in columns and rows.  The rows can be shifted (staggered) and rotated. Also every other part in a column can be rotated.

 

 

Columns

This is the number of object you want placed next to each other, going from left to right on you table.

 

The E Button

This button will load the width of the extents of the object into the odd and even text boxes to give you a starting point for spacing your array

 

Odd column spacing

If the column number is odd, this is the centerline distance horizontally between the previous object and this one. The original object on the screen is column 1 row 1, the next column is column 2, and the next one is column 3, 3 is an odd number.  It will be begin this amount from the beginning of column 2 (the previous column), and subsequent columns, 5,7,9... will be spaced the same amount away for their previous columns 4,6,8...

 

Even column spacing

If the column number is even, this is the centerline distance horizontally between the previous object and this one. The original object on the screen is column 1 row 1, the next column is column 2, 2 is an even number.  This object will be begin this amount from the beginning of column 1 (the previous column), and subsequent columns, 4,6,8... will be spaced the same amount away for their previous columns 3,5,7...

 

Rows

This is the number of object you want placed above to each other, going from bottom to top right on you table.

 

The E Button

This button will load the height of the extents of the object into the odd and even text boxes to give you a starting point for spacing your array

 

Odd row spacing

If the row number is odd, this is the centerline distance vertically between the previous object and this one. The original object on the screen is column 1 row 1, the next row is row 2, and the next one is row 3, 3 is an odd number.  It will be begin this amount from the beginning of row 2 (the previous row), and subsequent rows, 5,7,9... will be spaced the same amount away for their previous rows 4,6,8...

 

Even row spacing

If the row number is even, this is the centerline vertically distance between the previous object and this one. The original object on the screen is column 1 row 1, the next row is row 2, 2 is an even number.  This object will be begin this amount from the beginning of row 1 (the previous row), and subsequent rows, 4,6,8... will be spaced the same amount away for their previous rows 3,5,7...

 

Rectangular Array 2 columns by 3 rows

 

 

Special Array Options

 

These special options allow you to modify the standard rectangular array but shifting and rotating.

 

 

Stagger even rows

This will offset the beginning of the even rows by the percentage if the object, this number can be Positive and Negative, shifting the object left or right from it's original starting location.  This only affects the even rows

 

Reduce even rows by 1

Sometimes when the objects are shifted, then last object may fall off the plate. This option allows you to remove the last object from that row.

 

Rotate object in even numbered rows

This allows you to rotate all the objects placed in the even numbered rows. This is the beginning of a simple nesting.  Some experimentation is needed here with the even and odd spacing to get the best nesting

 

4 columns - 2 rows - shifted 5% - rotated even columns 180 degrees

 

 

 

Rotate every other object in each rows

This allows you to rotate the even object in each and every row. This is the beginning of a simple nesting. Some experimentation is needed here with the even and odd spacing to get the best nesting

 

2 rows - 3 columns - rotated every other even object in all rows

 

 

Convert a G-Code file to DXF file

 

This option converts the lines and arcs of the G-Code file to a DXF file. This file should be compatible with most all CAD programs as it is very generic. To convert a file, browse to open it, click Modify and then click save as once the Modified text has stopped writing the file code.

 

 

Include rapid (G0) moves as lines in the output file

Typically rapid moves are NOT in any DXF file as they are solely used by the machine for moves to the next cutting location. But we give you the option to save then if you wish.

 

Convert an EIA file to G-Code file

 

One customer had a bunch of these files, he said they were from an old Burny machine. They were written using Absolute dimensions for the I and J arc center values. And the Start cut and stop cut were not the G23 and G25 that we use. We wrote this converter to allow these files to be used with our system.

 

 

Once it has been converted, you can continue working on the object by...

Clicking the Red Arrow button between the text frames will move the modified code to the original code window.  This modified code NOW has become your original code. You could scale it again, or you could rotate it, build an array of these parts, and output it to a dxf...

Chapter

6


 

The Code Wizard

 

So you want to build a simple gusset, a washer, or a flange with 4 boltholes in the corners?

 

 

·Simple shapes without CAD

 


Code Wizard

 

 

Brief Overview

The code wizard gives you the ability to create simple shapes without drawing them in CAD and saving as a DXF file. By right clicking on the Edit button or clicking on File-New G code - Code Wizard you will be presented with a box that creates G code from shape dimension parameters. Select the type of cutting as Plasma or Oxyfuel. Then select the part type to the right. Select preferences and dimensions. When ready, click on the Build G code button. Now either copy to clipboard or save the G code as a file. The program is now complete and ready to be cut. Arrays of these simple shapes may also be created.

 

 

In Depth

Plasma or OxyFuel

Checking Plasma will use the Pre, Post, Zup and ZDown codes that you have entered into Setup Screen of the DXF Converter under the Plasma conversion tab.  Likewise checking OxyFuel will use the same from the OxyFuel conversion tab.  If these conversion tabs are empty, then each time the torch is supposed to raise or lower to go to the next work piece, the code will be missing and thus make the G-Code output incomplete.

 

Circle, Rectangle, Gusset, or Donut

This is the basic selection of the type of simple part you would like to build. Though there are only 4 listed, by taking them one step at a time, you can build more complex shapes. For instance, if you wanted to build a rounded square flange with a 4-bolt hole pattern in the corners and a larger hole in the center, all this can be done.  First you would build a circle, then build a circular array of 4 smaller holes, that start at 45 degree angle, then you would build a rectangle of sufficient size as to encompass the big hole and 4 corner holes. Each time you clicked Build, it would have asked you if you want to overwrite the existing code, or add it to the current code. You would always ask to add it to the current code.

 

 

When you are finished and click Save it will add the Post code from the proper conversion type and write the program to a file name you select.  It is now ready to run, or you can go to Modify G-Code and build an array of these parts.

 

Clockwise or Counter Clockwise

Some cuts, whether they are holes or circles, (with a hole being the center is thrown away and the outside is used), are cut in a certain direction, either clockwise or counter- clockwise.  You can choose here which direction (path) you would like the torch to make as it moves around the part.  When cutting a donut, it is already assumed that you want to throw away the center piece, so the center cut is a hole, while the outside cut is a circle. And this direction of cut has been pre-chosen based on typical plasma cutting conventions, CCW for a hole, CW for a circle.

 

Include a Lead-in or Do Not include a Lead-in

You can choose to have a lead-in or not. It is probably preferred to have some sort of lead-in when cutting, as the initial pierce is usually not very clean.  The lead-in will be added to the scrap side (the piece thrown away) and lead into the cut path with a small arc, tangent to the cut path for a smooth transition.  The lead-in is usually a 1/4" radius unless the part to be cut is smaller than that, then it is 1/2 the size if the part.

 

Fillets in the Corners UR (upper right) LL (lower left)...

When cutting rectangular and gusset parts, you can choose to add a radius to any 90 degree corner. This radius can be in inside radius or outside radius.  We know that when making gussets, it is helpful to have a bite taken out of the 90-degree corner so the gusset will not interfere with other welds in that area. Likewise, square flanges look better with rounded corners.

 

Making an Circles or Donuts

 

 

Hole Center X

Enter the X-axis dimension where you would like the center of this hole to be located

 

Hole Center Y

Enter the Y-axis dimension where you would like the center of this hole to be located

 

Feed Rate

Enter Feed rate for how fast the torch should move while cut this circle.

 

Outer Diameter

Enter diameter for this circle.  This wizard does not take into account the kerf width. You will need to adjust this dimension, accounting for both kerf width whether it is a hole or a circle, by adding to or subtracting from the diameter.

 

Making an Gussets

 

 

X Start

Enter the X-axis dimension where you would like the intersection of the 90-degree corner to be located (lower left corner of the gusset)

 

Y Start

Enter the Y-axis dimension where you would like the intersection of the 90-degree corner to be located (lower left corner of the gusset)

 

X Leg Length

Enter the length of the bottom leg of the gusset, this is the length of the gusset in the X dimension.  Starting from the intersection of the 90-degree corner moving horizontally.

 

Y Leg Length

Enter the length of the vertical leg of the gusset, this is the length of the gusset in the Y dimension.  Starting from the intersection of the 90-degree corner moving vertically.

 

Feed Rate

Enter Feed rate for how fast the torch should move while cut this gusset.

 

Fillet radius

If you chose to put a fillet in the 90-degree corner, then enter radius for this corner.

 

Please remember:

     This wizard does not take into account the kerf width. You will need to adjust the dimensions, accounting for both kerf width whether it is a cutout or a gusset, by adding to or subtracting from the leg lengths.

 

Making an Rectangular Shapes

 

 

X Start

Enter the X-axis dimension of the lower left corner of the rectangle

 

Y Start

Enter the Y-axis dimension of the lower left corner of the rectangle

 

X Width

Enter the width in the X dimension of the rectangle, this is the length of the rectangle in the X dimension.  Starting from the lower left corner.

 

Y Height

Enter the height in the Y dimension of the rectangle, this is the height of the rectangle in the Y dimension.  Starting from the lower left corner.

 

Feed Rate

Enter Feed rate for how fast the torch should move while cut this gusset.

 

Fillet radii

If you chose to put a fillet in any corner, then enter radius for this corner.  This radius is the same for ALL corners. If you would like different radii in the corners, you will have to use your CAD package and draw it accordingly.

 

Please remember:

     This wizard does not take into account the kerf width. You will need to adjust the dimensions, accounting for both kerf width whether it is a cutout or a rectangle, by adding to or subtracting from the width and height.

 

Making an ARRAY of Parts

 

 

Rectangular

When rectangular is selected, the arrayed parts are arranged in rows and columns.  Any simple shape can be put into a rectangular array.

 

Columns

 

This is the number of parts to be placed in the X direction, each part placed to the right of the next part.

 

Rows

 

This is the number of parts to be placed in the Y direction, each part placed above the next part.

 

X Column Spacing

 

This is the distance in the X direction, each part is separated from the previous part.  It is NOT the distance from the end of one part to the beginning of the next, rather it is the centerline distance between parts.

 

Y Row Spacing

 

This is the distance in the Y direction, each part is separated from the previous part.  It is NOT the distance from the top of one part to the bottom of the next, rather it is the centerline distance between parts in the vertical direction.

 

 

 

Circular

When circular is selected, the arrayed parts are arranged in a bolt hole pattern.  Circular arrays only work with round parts, rectangles and gussets cannot be in a circular array.

 

Bolt Circle Diameter

 

This is the diameter of the bolt hole circle. The center of each arrayed part will be located on this circle.

 

Starting Angle Hole #1

 

This is the angle on the bolt hole circle where the first hole is to be located. Depending upon how the holes are rotated, CW or CCW, the next hole will be located some angular spacing away from this hole.

 

# of Holes

 

This is the quantity of holes placed on the bolt circle.  If you chose the first hole at 60 degrees, and the number of holes at 2, then if the angular spacing was 45 degrees, then the next hole would be located at 105 degrees on the bolt circle.

 

Angular Spacing

 

Angular spacing can be any value, but will be grayed out and pre-calculated if the equal spacing checkbox is checked. This is the distance between each hole from the Starting hole angle.

 

Equal Spacing

 

Equal spacing if checked will divide 360 degrees by the number of holes and place the value in the Angular Spacing text area.

 

Counter Clockwise

 

When checked this will locate the holes starting from the first hole, to the left (CCW) from the starting hole location.  Unchecked will locate the holes to the right, (CW).  The compass indicator will show the angular direction, because depending on CW or CCW, the starting angle could be located in a different quadrant.

Chapter

7


 

E-Stop Assistance

 

 

The system has stopped.... oh NO !

Right in the middle of a very large cut the torch went out...

 

What am I going to do !

 

 


 

E-Stop Assistant

 

 

The E-Stop Assistant is a control function that will allow you to back up in a program. This is allowed only after an E-Stop has occurred.  An E-Stop can occur for several reasons, with the main reason being loosing the arc.  If you loose the arc during a cut, the system will sense the lost arc and E-Stop all the motors.  The system will also E-Stop if the operator hits the E-Stop button or Space Bar during a cycle.  Other causes of E-Stops are servo motor failures, such a communications errors, excessive torque overload or excessive overheating. 

When and if an E-Stop occurs, you can get back to exactly where it E-Stop occurred very easily, and even backtrack thru the program to all the way to the previous pierce point.

 

When you have the E-Stop condition, all the drives will be turned off, and the outputs will also turn off.  Here are the steps needed to get back cutting again:

 

·         Click the All On button in the upper left corner of the main screen.

·         At this point is time it is safe for you to raise the torch if needed with the jog buttons

·         Go to the bottom of the screen and click on the E-Stop Assist button

·         The following Window will appear:

 

 

 

·         You may now click the Move to material load position or Move to torch service position for servicing the torch. During the move to these positions, they can be stopped using the Stop All Motion button. Once you have finished servicing the torch (if it was needed), you can now click on the Move to where E-Stop occurred button.  This will return the torch to the location it was when the system trigger a stop due to the E-Stop. From this location, you can now Back up thru the current cut path with the Rev button. The Fwd button at this time will not work because the cycle only saved in it's memory, those positions it has already commanded to the motors.  As you click the Rev button, you will see the motors X and Y, move backwards thru the code along the cut path.  If you brought it back too far, you can click the Fwd button all the way up to the point where the E-Stop occurred but not beyond.  When it has gone back to where you want to restart the program you can now click on the Initialize g-code to restart from this position button. This will find the correct line in the g-code and initialize the axes so they are ready to begin, even from in the middle of an arc.  Next click the Close button and you are now ready to click the Start Cycle button on the screen to begin the cycle.  This will start with a new attempt to pierce and then continue on.

 

Chapter

8


 

Joystick Cutting and Controls

 

 

Our cutting system is equipped with a uniquely flexible joystick that allows the user to have almost complete machine control in a portable, hand held device.  Normal G-Code cutting operations, jogging (X, Y, and the Torch axis), speed controls, canned and gantry relocations are all available to the user by the joystick use. In addition, the joystick gives the user a freehand (non G-Code) cutting control tool.

 

 

The system utilizes a Logitech Dual Action Game Pad (or compatible) as the control device. It is available through us or from most electronic stores, retail outlets. The joystick plugs directly into an available computer USB port. The joystick's working distance from the computer can be extended by employing a standard USB extension cable also locally obtainable. (or wireless Joysticks are now available, but you may experience noise issues from the plasma unit when it is cutting)

 

First install and test the joystick under Windows prior to attempting to use it with the CNC software. This can be done under the game controllers in the control panel of the Windows operating system.

 

·          Joy Stick Operations

Joystick Operation

 

 

To activate the joystick, go to the Setup pull down window. Go to Machine settings. Go to Joystick Tab. The window you arrive at should look as follows:

 

 

Enable the Joystick

 

This check box is to enable the Joy Stick, this will be grayed out if Windows does not find any joystick connected to it.   When in doubt, go to the Windows Control Panel and look in the Gaming Options for the joystick / game pad devices.  From the control panel you can also test and calibrate you joystick.

 

Reverse X Dir

 

This checkbox will reverse the direction of the motor.  If when you push the joystick to the right, and your torch goes to the left, it would be suggested that you change the state of this checkbox.

 

Reverse Y Dir

 

This checkbox will reverse the direction of the motor.  If when you push the joystick to the up, and your torch goes to down, it would be suggested that you change the state of this checkbox.

 

Use velocity mode for freehand joystick

 

The freehand joystick is the one on the LEFT

The joystick normally operates in torque mode. When the stick is centered it give no torque to the motors, when is pushed off center, the torque to the motor (corrected for direction) is increased moving the torch. If you are not paying attention and you run the torch to the end stop, and if it is in torque mode, it just applies a force against the end stop, but does not get a following error.  Releasing the stick at this point reduces the torque to zero and the motor just sits happily with no torque applied. 

 

However in Dual Drive Systems, if the axes have any mechanical misalignment, then the master is free to move at will because there is no torque on the motor, but this misalignment can cause the master to move, and this in turn will force the slave to move because it follows every single encoder pulse the master moves, and what happens is the slave, while compensating for misalignment, is pulling the master who is rotating and sending pulses to the slave to follow the master and it is a vicious circle.  And the system will walk it way all the way down to the other end of the table.  So for these systems, we have this checkbox that puts the motors into velocity mode where they have torque on them all the time on order to maintain position.  Bt what can happen here is any move that causes the system to hit something can cause a following error and shut the motors down. So be careful.

 

Maximum freehand cutting speed

 

The freehand cutting joystick's speed can be limited.  For those who do not want the joystick so sensitive to high-speed moves, they can limit the torque/speed with this slider control.

 

Joy Stick Buttons

 

Each button on the joystick is numbered. The function of each numbered button can be found by clicking on the joystick buttons and viewing the indicator that lights up.  NO movement will take place while the joystick setup screen is opened.

 

Joy Stick Button #12

 

Button on the joystick is used to turn on/off an output(s). Select the number with the help of the ? button.

 

 

Joystick Use

 

To activate the joystick click the radio button labeled joystick located under the jogging speed slider control on the main software screen.  If it is not visible, then you have not enabled the joystick on the above settings page.

 

The left joystick controls freehand jogging operation. The further away from center you move the joystick the faster the torch will move.  Pressing down on the left joystick while it is off center will result in a doubling of speed (torque).

 

Table limits are NOT in effect while using the joystick, caution must be observed so as not to run into the X and Y hard stops.

 

Straight Line Cutting

 

The right joystick only is used for straight-line cutting. It operates in a similar manner to the left joystick but only runs at a fixed speed curing a G23 while the torch is down and ignited.

 

Familiarize yourself with the location of buttons 8 and 6.

 

If a G-Code file IS presently loaded the joystick cutting operation speed will default to the G- Code initial cut rate modified by the feed rate percentage window. For example: If the G- Code initial rate is set to 120 inches per minute (F120) and the feed rate window percentage is set to 50% the resultant freehand cutting speed will be 60 inches per minute.

 

If NO G-Code is loaded presently, the cutting speed is defaulted to 100 inches per minute and modified by the feed rate percentage window setting. For example, if the feed rate window is set to 75% the resultant cut speed will be 75 inches per minute.

 

With joystick cutting you must emulate manually the operations done for you automatically by G-Code. For example:

 

Start a cut cycle

Send torch in a direction to cut.

Stop a cut cycle.

 

 

    To complete a freehand cutting operation do as follows:

 

1. Position torch over where you wish cut to begin with the left hand joystick.

2. Press button number 8 to start cut cycle, this issues a G23 to the controller.

3. As soon as the arc is established, move the right joystick in a direction you wish to cut. You can be pushing the joystick before the arc has struck, but it will not move until the arc strikes.

4. When reaching the point you wish the cut to stop release the joystick and quickly press button number 6, or just press button 6 and the joystick will stop when the arc goes out.

5. The arc will terminate and the torch will retract to it's home position.

 

Should you run the torch off the edge of the material or into a hole the arc will terminate and an emergency stop will occur. To clear this condition press button number 10.  This clears the emergency condition. Then press button number 6 to complete a normal stop cycle.

Chapter

9


 

Implemented G-Codes

 

·G0 Rapid

·G1 Straight Line

·G2 CW Arc

·G3 CCW Arc

·G4 Pause

·G10 Coordinate reset

·G17 XY Plane

·G18 Plane

·G19 Plane

·G20 Inch

·G21 Metric

·G23 Start Plasma

·G24 Move Torch

·G25 Stop Plasma

·G26 Enable THC

·G27 Home Torch

·G28 Disable THC

·G53 Use Machine Coordinates

·G54 - G57 Use Program Coordinates

·G76 Repeat

·G90 Absolute

·G91 Relative

·G92 Set Program Coordinates

 

 


 

G-Codes used in the CNC Plasma Cutter

 

G-Code interpreters will operate in different ways. This G-Code interpreter tries to follow most of the standards, but there are a few exceptions and other suggestions to follow. This G-Code interpreter will interpret a number with a decimal point. For example, 1.2345.

 

G-Codes are normally broken into different groups.

group 0 = {g04,g10,g23,g24,g25,g26,g27,g28,g76,g92}

group 1 = {g0,g1,g2,g3}

group 2 = {g17,g18,g19}

group 3 = {g90,g91}

group 6 = {g20,g21,g70,g71}

group 12 = {g53,g54,g55,g56,g57}

 

Multiple G-Codes may appear on the same line of G-Code, but only one command from any one group is allowed. The CNC interpreter allows this to some degree, but there may be some ambiguity as to which command is executed first. Therefore, it is far safer and more predictable to use only one G- Code per line. Using one G-Code per line is highly recommended.

 

Some G-Codes are said to be modal, meaning that once the G-Code is active, additional data can appear without needing to re-state the G-Code on each line. For example, a G0 rapid move is usually followed on the same line by X or Y data. If no other command from the same group appears, additional X and Y data may be entered without an additional G0 code.

Again, this programming practice can introduce ambiguity and is highly discouraged.  WARNING in this program G53 is MODAL.

 

M-Codes are usually allowed on the same line as G-Codes. The CNC interpreter allows only one M-Code on a line, which always gets executed after the G- Code. Again, placing multiple codes on one line can introduce ambiguity and is highly discouraged.

 

Comments are delimited with parentheses () and must appear on a single line. Comments within comments are not allowed (( )). Comments are encouraged, given how unreadable G-Codes tend to be.

 

The maximum G-Code file size is restricted only by the Windows operating system; if it can give you memory, then it will allow very large file sizes. Some CAM systems, which automatically generate G-Code files, may produce larger files. In these cases, the files can be broken up into multiple files, which are loaded and executed separately. Use of subroutine files is one way for breaking up code.   We have run 47 megabyte files successfully.

 

All G-Code letter characters (G, X, Y, Z, M, F, etc.) must be capitalized and have a space in front of them or appear at the beginning of a line.

All programs must end with an M02 or and M30.

 

G-Codes that are not listed below are ignored by the interpreter.

 

G00 Rapid Motion

Initiates a rapid, uncoordinated move to the specified X and Y coordinates.

Examples:

G0 X1.0 Y2.0 (moves to X=1.0, Y=2.0)

G0 X-0.5 (moves X to -0.5, and Y is unchanged)

 

G01 Linear Motion

Moves in a coordinated straight line to the specified X and Y coordinates at the specified feed rate. Feed rates are specified in inches, or millimeters, per minute.

Example:

G01 X1.0 Y2.0 F30.0 (moves in a straight line to X=1.0, Y=2.0 with a feed rate of 30 inches (or mm’s) per minute)

 

G02 Clockwise Circular Arc

Moves along a clockwise circular arc to the specified X and Y coordinates at the specified feed rate. The center point of the arc is specified using I and J values, which are relative to the starting point of the arc. (The I value is the distance along the X axis and the J value is the distance along the Y axis.  R values are not yet supported.) The distance from the starting point to the center point must be the same as the distance from the ending point to the center, or else an error will be generated. The plane in which the arc lies is selected using G-Code G17. To specify a complete circle, the X and Y coordinates can be omitted, or can be set equal to the starting point. The motion will be clockwise with respect to looking down upon the selected plane.

Example:

(Starting point: X = 1.0, Y = 0.0)

G17 F30.0 (select the X-Y plane, set the feed rate to 30 in/min)

G2 X0.0 Y-1.0 I-1.0 (creates an 90 degree arc to the point X=0.0, Y=-1.0 with a radius of 1.0, centered about the point X=0, Y=0)

 

G03 Counterclockwise Circular Arc

Moves along a counterclockwise circular arc to the specified X and Y coordinates at the specified feed rate. The center point of the arc is specified using I and J values, which are relative to the starting point of the arc. (The I value is the distance along the X axis and the J value is the distance along the Y axis.  R values are not yet supported.) The distance from the starting point to the center point must be the same as the distance from the ending point to the center, or else an error will be generated. The plane in which the arc lies is selected using G-Code G17. To specify a complete circle, the X and Y coordinates can be omitted, or set equal to the starting point. The motion will be counterclockwise with respect to looking down upon the selected plane.

Examples:

(Starting point: X = 1.0, Y = 0.0)

G17 F30.0 (select the X-Y plane, set the feed rate to 30 in/min)

G03 X0.0 Y1.0 I-1.0 (creates an 90 degree arc to the point X=0.0, Y=1.0 with a radius of 1.0, centered about the point X=0, Y=0)

 

G04 Dwell

Pauses the program for some number of seconds specified with the P parameter. The actual dwell will only be approximately equal to the specified time.

Example:

G04 P1.5 (pause the program execution for about 1.5 seconds)

 

G10 Coordinate System Reset

This code "resets" the present coordinate system (G54-G57) to 0,0.

You must be in G54 thru G57 for this to function. All axes are set to Zero. If your display was reading X=1.2500 Y=1.0000, the display will read X=0 Y=0 after this G10 is issued. This offset for the G54 thru G57 from machine home is also memorized.

If you want to reset only one axis, look at the G92 command.

Example:

If X is 2.354 and Y is 4.555, then after this command:

G10 (no other parameters needed)

X will be 0.000 and Y will be 0.000

 

G17 X-Y Plane Selection (This is the normal plane of operation)

Selects the X-Y plane for circular motions. The starting and ending points for circular motions do not have to have the same Z value. In that case, a helical arc will be drawn. Clockwise or counterclockwise will be interpreted as the direction of motion when looking down along the Z-axis.

Example:

G17 (no other parameters needed)

 

G18 Z-X Plane Selection  (This plane is NOT applicable to the plasma cutter)

Selects the Z-X plane for circular motions. The starting and ending points for circular motions must have the same Y value. Clockwise or counterclockwise will be interpreted as the direction of motion when looking down along the Y-axis.

Example:

G18 (no other parameters needed)

 

G19 Y-Z Plane Selection  (This plane is NOT applicable to the plasma cutter)

Selects the Y-Z plane for circular motions. The starting and ending points for circular motions must have the same X value. Clockwise or counterclockwise will be interpreted as the direction of motion when looking down along the X-axis.

Example:

G19 (no other parameters needed)

 

G20 and G70 Inch Mode

Inch is the Default operating mode.

Example:

G20 (no other parameters needed)

 

G21 and G71 Metric Mode

Pseudo Metric mode takes metric code in, (such as G1 X20) and immediately recalculates the X into inch mode as X.787. The display on the screen will show inches. G20 and G70 are ignored if the user units are set to INCH; likewise G21 and G71 are ignored if the user units are set to METRIC.

Example:

G21 (no other parameters needed)

 

G23 Start Plasma Torch Cycle

This command will start the plasma torch moving down to search for the plate. When the plate is found, it stops and retracts to the pierce height. Once it stops at the pierce height, it sends a signal to the Plasma Unit to start the arc.  Once the Arc confirmation signal is received by the control, then the XY axes will begin their move.

Example:

G23 (no other parameters needed)

 

G24 Rapid Move of Torch to Commanded Position

This command will send the torch to a commanded position at Rapid speed.  If there is a need to position the torch at a known location, without starting the plasma control, then use this command.  The Z word is in absolute coordinates. Home is usually 0, and fully down is usually -4.0... valid values are between those limits.

Example:

G24 Z-2.25 (will send the torch to the –2.25” position)

 

G25 End Plasma Torch Cycle

This command ends the plasma cycle.  When this command is read, the output to the Plasma Unit turns off, extinguishing the Arc. The torch then raises to the top of it’s travel (unless the Z argument is used). Once the torch arrives at the top, it signal the XY motors that it is now OK for them to move.   You have the option of changing where the Z-axis goes when it raises. Under standard operation, when only “G25” is issued, the torch raises to the Torch Maximum work area position (typically “0”).  If you use the “Z” axis argument, such as G25 Z-1.25, the Z-axis will only raise to the –1.25” position.  Issuing an X or Y argument will cause a syntax error.  Like the G24, the Z word is in absolute coordinates

Examples:

G25 (no other parameters needed)

or

G25 Z-1.25 (will send the torch to the –1.25” position)

 

G26 Turn ON the Automatic THC

This command will depress the THC button on the screen. When the button is depressed, it enables the THC height controller based on the arc voltage.  When it is not depressed, the THC will remain motionless, and will NOT compensate for the arc voltage changes.

Example:

G26 (no other parameters needed)

 

G27 Home Torch (seldom used or needed)

This command will send the torch searching for home position.  There is no need to ever use this command, it is left over from older versions.

Example:

G27 (no other parameters needed)

 

G28 Turn OFF the Automatic THC

This command will UN-press the THC button on the screen. When the button is NOT depressed, the THC height controller will remain motionless, and will NOT compensate for the arc voltage changes.  It's like a HOLD for the Arc Voltage height compensation.

Example:

G28 (no other parameters needed)

 

G53 G54 G55 G56 G57 Coordinate offsets

Selects the coordinate offset that you would like to work in. G53 is equal to the machine home position. If you go to X0 Y0 in G53 mode, you will travel to the machine home position. The G54, G55, G56 and G57 modes will offset the machine zero so that when you travel to X0, Y0 in G55 mode, the machine value will be the value set in the G offsets window under the G55X, Y, and Z values, although the interpreter will think it is at machine 0,0.

WARNING G53 is MODAL in this program.

Example:

G54 (no other parameters needed)

 

G76 Repeat a section of the program

This call sets the number of repeat cycles the code will do.

This is still under evaluation and most likely will change, but the example would be as follows: Here the system will move rapid from 0,0 to 2,2, then in feed rate from 2,2 to 4,4 and then the program will jump to L1 and it will feed rate to 2,2 then to 4,4 for the Px cycles. Here it is for a total of 5 times (P5). Then it will loop for three times between the L2 and the following G76 P3 command. This is useful if you go to a subroutine after an incremental (G91) move. If no "L" tag is found, it will restart from the beginning of the program.

Example:

G0 X0 Y0 Z0 (go to home)

L1 (tag label for where to restart from)

G01 X2 Y2

G01 X4 Y4

G76 P5 L1 (go back to the location of the L1 label in the program)

(move on only after the 5 passes above)

L2

G91 (switch to incremental move)

G1 X1 (increment X over 1 inch)

G90 (switch back to absolute move)

M98 P111 (Run the O111 subroutine)

G76 P3 L2 (go back to the location of the L2 label in the program)

(move on only after the 3 passes above)

M30 (end of program)

 

G90 Absolute Mode

Selects using Absolute coordinates in the G commands. This is the standard normal usage.

Example:

G90 (no other parameters needed)

 

G91 Relative Mode

Selects using Relative coordinates in the G commands. Any G motion command such as G01 X2 will travel two inches in the positive direction from its present location. Avoid relative moves as it makes reading the G-Code difficult, and it is very possible to forget where you were in the absolute coordinate world.

Example:

G91 (no other parameters needed)

 

G92 Set Coordinate System Offset

This Code sets the present coordinate system (G54-G57) to the values set by the X or Y values that follow the command.

Example:

G54

...

G92 X2 Y1.5

This will make the present location of the coordinate system (G54) equal to X=2.000 and Y=1.500   You must be in G54 thru G57 for this function to work. If you are in G53 mode, it will be ignored. Any or all of the axes can be defined. In other words, "G92 Y2.3" will only set the present position to Y=2.300; all other axes will remain the same.

Chapter

10


 

Implemented M-Codes

 

·M0 Program Halt

·M01 Program Pause

·M02 End Program

·M03 and M04 and M05 and M08 and M09

·M14 Turn ON any single or multiple outputs

·M15 Turn OFF any single or multiple outputs

·M21 Continuous Path On

·M210 Set Maximum Angle Amount

·M22 Continuous Path Off

·M23 Slow at Vertex On

·M24 Slow at Vertex Off

·M25 Sets the pierce delay time

·M26 Enables the THC for automatic arc voltage height sensing

·M28 Disables the THC for automatic arc voltage height sensing

·M30 Program End and Reset

·M41 Turns on an output as soon as motion starts

·M42 Turns on an output as soon as motion starts

·M43 Turns on an output as soon as motion starts

·M45 Turns off output(s) immediately

·M46 Turns off output(s) immediately

·M47 Turns off output(s) immediately

·M50 - M57 Waiting for Inputs from the real world

·M60 - M73 Outputs to the real world

·M80 - M85  Special motor command codes for advanced programmers

·M86 - M91 Special codes for sound functions

·M95 Dwell (exactly the same as an G04)

·M98 Go To a Subroutine

·M99 Return from a Subroutine

·M100 Special Polishing routine

·M101 Special Pause with optional instructions


M-Codes used in the CNC Plasma Cutter

 

The M-Codes implemented appear below. If an M-Code not listed below is encountered, program execution will stop, and an error message will appear. "Unknown M-Code"

 

M0 Program Halt

Causes the program halt execution. It acts just like an M02 except it does NOT reset the g-code to the beginning.  Execution can be started by clicking the "Start" button.

 

M01 Program Pause

Causes the program execution to pause. Execution can be resumed by hitting the "OK" button.

 

M02 End Program (See M30 below)

 

M03 and M04 and M05 and M08 and M09:

 

If you are NOT in OxyFuel Mode then:

M03 Turns on the selected Motor output.  And

M05 Turns M03 selected output OFF

 

If you ARE in OxyFuel Mode then:

M04 Sends the torch down to the cutting height (if the “Raise torch between cuts in OxyFuel mode” is checked). It then turns on the output to operate the valve for the preheat and starts the timer for preheat.  Once the preheat has expired, it turns on the output for the cutting oxygen and starts the pierce delay. When the pierce delay expires, the X and Y motors are commanded to move following the path.

 

M05 Turns M04 OFF, turning off the two valves for cutting oxygen and preheat. If the “Raise torch between cuts in OxyFuel mode” is checked, then the torch will memorize the height where it was when it finished cutting, and retract to the top of it’s travel.   This memorized value is used the next time the torch goes down to start a cut.

 

If you are NOT in OxyFuel Mode then:

M08 Turns on the selected Motor output.

M09 Turns M08 selected output OFF

 

M14 Turn ON any single or multiple outputs

This allows the programmer to turn on one or more outputs. This command must be followed with a “P” word.  The “P” word is the binary representation of the outputs.  The easiest way to figure this is to go to the advanced tab under machine settings and click on any of the “?” marks.  This will allow you to select one or more outputs.  The number that it calculates is the same number you should use as the P-word. 

Usage is M14 P7.  Turn on XA, XE and XF outputs

(Hint XA=1, XE=2. XF=4, YA=8, YE=16…)  1+2+4=7

 

M15 Turn OFF any single or multiple outputs

See the description for M14… select the Pword for the outputs you would like to turn OFF.

Usage is M15 P4.  Turn off the XF outputs

 

M21 Continuous Path On 

(VERY seldom used and only by advanced programmers)

Turns on the continuous path feature. Path contouring can also be turned on and off via the control panel.

 

M210 Set Maximum Angle Amount 

 (VERY seldom used and only by advanced programmers)

This sets the maximum angle where it will break the continuous path feature.

Usage is M210 P70.

Where P is the angle. Max angle can also be set in the machine settings page.

 

M22 Continuous Path Off 

(VERY seldom used and only by advanced programmers)

Turns off the continuous path feature. Path contouring can also be turned on and off via the control panel.

 

M23 Slow at Vertex On 

(VERY seldom used and only by advanced programmers)

Turns on the slow at vertex feature. Slow at vertex can also be turned on and off via the control panel.

 

M24 Slow at Vertex Off 

(VERY seldom used and only by advanced programmers)

Turns off the slow at vertex feature. Slow at vertex can also be turned on and off via the control panel.

 

M25 Px.xxx  Sets the pierce delay time with the P Word.

When you are cutting thick material with the plasma, it is best to have a slight delay to allow the torch to full pierce thru the material prior to starting the XY in motion.  This M25 Px.xxx where x.xx is the delay time (i.e. 1.25)  When the torch gets the arc confirmation, it will delay this time (1.25 second) and then begin it's path movement.

 

M26 Enables the THC for automatic arc voltage height sensing

Turns on the THC button on the screen. 

 

M28 Disables the THC for automatic arc voltage height sensing

Turns off the THC button on the screen. This is useful when you know you are about to move to a small hole that will cause the torch to dive if it was under arc voltage height control.

 

M30 & M02 Program End and Reset

Causes the program execution to halt, and the program will be reset to the beginning. M30 or M02 should appear as the last line of every program. This is an M02, not an M2, you must use the number "0" before the 2, or just use M30. This is only required by the M02, all other M codes, M3, M5, M8, M9 do not require the number “0” to be used.  M02 ends the program and resets the g-code to the beginning.    M30 does the same but it also turns off all outputs that are selected on the advanced tab of the machine settings.

Example:

M02 (no other parameters needed)

M30 (no other parameters needed)

 

M41  Turns on an output as soon as motion starts... 

Sends m=(p-word) GOSUB24 command to the X motor

M42  Turns on an output as soon as motion starts...

Sends m=(p-word) GOSUB24 command to the Y motor

M43  Turns on an output as soon as motion starts...

Sends m=(p-word) GOSUB24 command to the THC motor

 

These commands will send the command "m=xxx GOSUB24 " to the selected motor. This subroutine will tell the motor to loop until the in-motion flag is true, at that moment in time, it will turn on one or more outputs.  The P word specifies the outputs. The motor has three outputs Ports A, E and F.  Port A has a value of 1, port E is 2 and Port F is 4.  If you want ports A and F to turn on, the send M41 P5  (P5 is Port A (1) plus Port F (4), 1+4=5).  If you just want port E to turn on, then command M41 P2.

Example:

M42 P7 ( this will turn on all the outputs on the Y motor as soon a motion begins)

 

M45  Turns off output(s) immediately...

Sends m=(p-word) GOSUB26 command to the X motor

M46  Turns off output(s) immediately...

Sends m=(p-word) GOSUB26 command to the Y motor

M47  Turns off output(s) immediately...

Sends m=(p-word) GOSUB26 command to the THC motor

 

These commands will send the command "m=xxx GOSUB26 " to the selected motor. This subroutine will tell the motor to turn off one or more outputs.  The P word specifies the outputs. The motor has three outputs Ports A, E and F.  Port A has a value of 1, port E is 2 and Port F is 4.  If you want ports A and F to turn off, the send M45 P5  (P5 is Port A (1) plus Port F (4), 1+4=5).  If you just want port E to turn off, then command M45 P2.

Example:

M46 P7 (this will turn OFF all the outputs on the Y motor immediately)

 

M50... M57 Waiting for Inputs from the real world

These commands will cause the program to pause indefinitely waiting for an external input to be true. The inputs are selectable from the Machine Settings Inputs tab. You can set ports "A" or "G" from Axis "X, Y or Z" to "resume on M5x". When these inputs are true, then the system will continue. This could be useful for a Z-axis, which is pneumatically driven. Wait for the signal that the axis is down before resuming motion.

 

M60... M73 Outputs to the real world

Turns on/off the user selected Motor outputs. (see the outputs page of the Machine Settings)

M60 Pxxx ... M73 Pxxx (with the P word)  This will change the "Set Point" value when it turns on the output.  Don't know for sure why you would want to do that, but a customer asked for it so we put it in there.

 

M80... M85  Special codes for advanced programmers, it does special motor command functions

Will either issue a command directly to the Motor such as a gosub or some other SM command.  This is an advanced setting and should only be used buy those who are familiar with the motors and their commands.  This is a VERY powerful feature, allowing the operator to expand the CNC systems capability to the end of their imagination.

 

M86... M91 Special codes for sound functions

Will play a sound from the PC sound card.  This is useful to sound an alarm prior to Gantry movement or alarm when the cycle is completed.

 

M95 Dwell (exactly the same as an G04)

Pauses the program for some number of seconds specified with the P parameter. The actual dwell will be approximately equal to the specified time.

Example:

M95 P1.5 (pause the program execution for about 1.5 seconds)

 

M98 Go To a Subroutine

M98 P1234 (send the program to the subroutine label 'O1234')

The 'P' parameter tells the interpreter which subroutine label to go to. The subroutine label starts with the letter 'O'.  

To return from a subroutine, end the sub with an M99. (Nested subroutines are not included in this version). The subroutine can be included in the main file, after the M30 or M02, or it can be in a file located in the same folder as the main file, it must have a filename such as "O1234" without any extension. Main files that contain subroutines (after the M30/m02) will have their subroutines extracted and rewritten to the folder as "Oxxxx" during the file open process in the program. Thus, every subroutine now has its own filename and is opened as a file when the call to go to it occurs.

 

M99 Return from a Subroutine

M99 (returns the interpreter to the next line below the M98 that called it in the main program. The subroutine file must end with M99, not M30.

Example:

M99 (no other parameters needed)

 

 

Sub-Routines in the G Codes

Subroutines can be added to the G-Code provided they are not nested. Subroutines must be added after the M30 or M02 of the main program. The subroutine's first line must be the letter 'O' followed by an up to four-digit number. This “Oxxxx” must be by itself on this line, the code should follow immediately on the next line. The subroutine must end with an M99 as the last command on a line all by itself. Calling a subroutine from the main program should be done with an M98 code followed by the letter 'P' and the up to four-digit number of the subroutine. If there is a file in the local folder with a filename of "Oxxxx" without extension, it will consider that as the subroutine.

Example:

G00 X1 Y1

M98 P200 (go to sub #200)

G00 X2 Y2

M98 P300 (go to sub #300)

G00 X3 Y3

M98 P193 (go to sub #193) *** This will look for a file named "O193"

G00 X0 Y0

M30 (end of program)

 

O200 (subroutine label #200)

G91

G01 X.5 Y.5

G90

M99 (return to main program)

 

O300 (subroutine label #300)

G17

G01 X.5 Y.5

G02 J.25

M99 (return to main program)

*** The program will look in the present folder for a file named "O193" because it does not exist in the main program.

 

Note: At this time an M98 cannot be placed in a subroutine code block (no nested subroutines.)

 

 

M100  Special Polishing routine

M100  This is a special M code that controls the torch vertical slide to allow it to do brush polishing.  This command will send the torch down at a fixed down force, once it detects that it hit the plate, it will start a timer for the swirl time, it will the retract a fixed amount and be ready to move to the next location.  Q word = down force, P word = swirl time, R word = retract amount

Example:

M100 Q60 P2.50 R1.0 (Down force = 60, swirl time = 2.5 seconds, retract amount = 1")

 

M101 Special Pause with optional instructions

M101 This command will pause the g-code command processor with a message for the operator.  He will be given a choice of OK to continue and Cancel to quit. OK continues with the gcode, cancel ends the program, (similar to an M30)  The message prompt is the text between the brackets "[text goes here]"

Example:

M101 [Please rotate the part 180 degrees]

 

 

 

Chapter

11


 

 

Wiring Harnesses

 

This section covers the connections of the wiring harness supplied with our drive systems:

 

 

·Wiring for the Single X axis drive system

·Wiring for the Dual X axis drive system

 


Single X drive Wiring Layout

 


Dual X drive Wiring Layout

Chapter

12


 

Grounding

 

 

Improper grounding is the leading cause of catastrophic failures in the plasma industry.

 

Do yourself and your wallet a favor.... read and test your system for proper grounds

 

Is it grounded ?

 


 

IMPORTANT GROUNDING TEST

 

VERIFY THIS BEFORE OPERATING THE PLASMA CUTTER

 

In order to avoid possible damage to electronic components, motors or your PC it is imperative that good grounding be verified prior to operating the plasma generator. Failure to do so will void the warranty and could cause expensive damage to the drive system. Remember that the plasma arc is basically controlled lightening.  If your area where you live was prone to frequent lightening strikes, you would want a good lightening rod and surge suppressors connected to every PC or electronic appliance. So with that in mind, please remember there is a computer in each motor, improper grounding could easily allow the plasma arc to act like uncontrolled lightening and destroy any and all electronics and computers in the area.  Before you decide against proper grounding, please visit our web site and look at the price of replacement motors.

 

We suggest you drive a ground rod into the earth within 12 feet of the machine. Ground rods are available from your local home improvement/hardware store (Ace, Lowe’s, Home Depot, etc)  Run a large (#6) ground wire from the plasma power leads and the table frame to this ground rod. Also use a ground lead (at least #12) for the 110 circuit that drives the PC and control system to this same ground.  See illustration.

 

Preferred grounding procedure is shown above

All grounding wires should be short in length and larger than 8-awg wires.             .

 

 

GROUND TEST PROCEDURE

 

Connect a 100 W bulb to the ground rod and AC hot. Measure AC voltage with a meter between the ground rod and the AC neutral. Voltage must be below 0.75 VAC. See diagram below

 

.

 

A certified, licensed electrician should accomplish the test described. Do not attempt the test yourself as potentially fatal level voltages are involved.