Operación Del Edge Pro. Proarc

OWNER’S MANUAL

IMPORTANT: Read these instructions before installing, operating or servicing this product.

MODEL : MASTER 35 ~ 60

CNC CUTTING MACHINE

(OPERATION EDGE Pro)

Serial number：1001012 ~ and later

Revised date : Feb. 06, 2010

UNITED PROARC CORPORATION

No. 3 Gungye 10th Road, Pingjen Industrial Park, Tel No：886 3 4696600 Pingjen City, Taoyuan 324, Taiwan Fax No：886 3 4694499 http： //www.proarc.com.tw E-Mail：[email protected]

RD-991E

TABLE OF CONTENTS

Operation

Service

Parts List

Circuit Diagram

1.1 Control panel ..................................................................................... 1

1.2 OPC Power up/off procedure ............................................................ 4

1.3 Gas control box ................................................................................. 8

1.4 Two stage piercing .......................................................................... 11

1.5 Flame marking torch ........................................................................ 14

1.6 Positive anti-dust pressure settings and operation .......................... 16

1.7 Gas circulating drawing ................................................................... 17

1.8 Sequence diagram (High / Low Preheat) ........................................ 19

2.1 Trouble shooting guide ..................................................................... 20

3.1.1 Operation console ........................................................................ 32

3.1.2 Operation console(inside) ............................................................. 34

3.2 Servo amplifier box .......................................................................... 36

3.3 Relay box (standard)……………………. ......................................... 39

3.4 Gas box……………………. ............................................................. 40

4.1.1 Control system .............................................................................. 44

4.1.2 Main circuit ................................................................................... 42

4.2.1 EDGE single ended I/O pinout ..................................................... 44

4.2.2 EDGE drive / encoder pinout ........................................................ 46

4.2.3 EDGE EIA / Code ......................................................................... 48

4.3.1 OPC：I/O Relay board & OPC I/O interface ................................ 48

4.4.1 Relay box : TB4 interface ............................................................. 50

4.4.2 Relay box : Gas control board interface ....................................... 51

4.4.3 Relay box : Torch motorized control interface .............................. 52

4.4.4 Relay box : Torch station interface ............................................... 53

4.4.5 Relay box : I/O connector interface .............................................. 54

4.5 Servo control box : Amplifier CN1 servo relay board interface ......... 55

4.6 Amplifier parameters ........................................................................ 56

TABLE OF CONTENTS

Appendix

Option

Appendix A：Serial communication ...................................................... 58

Appendix B：Signal tower ..................................................................... 59

Appendix C：Torch collision interface ................................................... 60

Appendix D：Pneumatic flame marking interface ................................. 62

Appendix E：Plasma system command THC machine interface .......... 63

Appendix F：Plasma system hpr-260 sensor THC interface ................ 64

Appendix G：Two command THC interface ......................................... 65

Appendix H：Inova Torch Height control System Interface .................. 67

Appendix I：Safety device interface ....................................................... 68

Appendix J : Blower fan interface .......................................................... 69

Appendix K：Fume collection interface ................................................. 70

Appendix L：Scriber interface .............................................................. 71

Appendix M：HSD-130 & SPHC Interface ............................................ 72

Appendix N：Plasma system power max 1650 sensor THC interface .. 73

Appendix O：Flame vent off ................................................................. 74

Option A：Relay box (6 cut) ................................................................ 75

Option B：Torch motorized board for 4st / EX 2st interface .................. 76

Option C：Gas station board for 4st interface ....................................... 77

Revisions ............................................................................................... 78

1

FUNCTION OF CONTROL PANEL

(Note：Depending on the optional functions you have purchased, your system may not include

all of the following functions, irrespective of they are physically appeared on the panel).

1. Plasma / Laser point

2. Option

3. Flame Gas control / Flame – Select switch

4. Torch & Motorized station / Up – Down

5. Servo power system / Emergency stop

1.1 CONTROL PANEL

2

1.1 CONTROL PANEL

1. Plasma / Motorized lift Up – Down / Laser point

Plasma ON Laser Point ON

Plasma OFF

Plasma Auto

2. Option system

A. Height sensing

B. Ignite

C. Water spray

D. Powder marking

E. Option

3. Flame Gas control

3.1(Preheat)

Low Preheat ON High Preheat ON

Low Preheat OFF

Low Preheat Auto High Preheat OFF

Laser Point OFF

3

1.1 CONTROL PANEL

3.2 (Cutting Oxygen)

High Cut Oxy ON Low Cut Oxy ON

High Cut Oxy OFF

High Cut Oxy Auto Low Cut Oxy OFF

4. Torch & Motorized station / Up – Down

Torch ON/OFF Station

Torch UP/Down

5. Servo power system

A. Servo power

B. Emergency stop

4

1.2 OPC POWER ON/OFF PROCEDURE

1. OPC Power on procedure:

Step 1. Switch on the main power circuit breaker of the servo control console.

Step 2. Switch on the main power of the servo control box.

5


Step 3.Turn on the power of the EDGE Pro controller (the green light should be on).

Wait for the operating system to boot up completely before proceeding to the

next.

Step 4.Switch the servo power on, select switch on - the green light should be on.

OPC power up procedure is now completed.

6


2. OPC power off procedure：

Step 2.Turn off the servo power, turn the select switch off.

Step 3.Turn off the EDGE Pro controller power. Wait until the operating. system

has been completely shut down before proceeding to the next step.

7


Precede the following procedure only after the CNC Controller has been shut off.

Step 3. Turn off the power of the servo control.

8

1.3 GAS CONTROL — GAS PRESSURE ADJUSTMENT

Capacity * High cutting OXY：Max setting 10kg/ cm2.

Max pressure shown on gauge 15kg/cm2. * Low cutting OXY：Max setting 10kg/ cm2

Max pressure shown on gauge 15kg/ cm2. * High preheat OXY：Max setting 7 kg/ cm2.

Max pressure shown on gauge 10 kg/ cm2. * Low preheat OXY：Max setting 7 kg/ cm2.

Max pressure shown on gauge 10 kg/ cm2. * High preheat fuel gas：Max setting 1 kg/ cm2.

Max pressure shown on gauge 2 kg/ cm2. * Low preheat fuel gas：Max setting 1 kg/ cm2.

Max pressure shown on gauge 2 kg/ cm2.

.

9


Gas Pressure adjustment procedure

Preheating Gases

1. Adjusting LOW PREHEAT

Please set cutting torch #1 switch to "1" ( ON position ) and set the Low Preheat

switch to "1" ( force ON position ). Open the preheat oxy and fuel gas knobs on

the torch until a trickle gas flow is present, then adjust both low preheat oxygen

and low preheat fuel gas pressure on the pressure adjustment panel. After the

adjustment, please set the Low Preheat switch to "0" ( closed position ).

2. Adjusting HIGH PREHEAT

Open the preheat oxy and fuel gas knobs on the torch and set the Low Preheat

switch to "1" (force ON position), then set the HIGH PREHEAT switch to "1" (On

position). Press START button to initiate flame-cutting procedure. During the

countdown of preheating time, you can adjust the desired HIGH PREHEAT gas

pressures (oxygen and fuel) on the pressure adjustment panel. After preheat is

finished, it will automatically switch from High Preheat to Low Preheat and begin

cutting.

§ When cutting a thicker plate, HIGH PREHEAT can effectively reduce

preheating time.

Cutting Gases：

1. Adjusting High Cutting Oxy

a. Set the low cutting Oxy switch to "0" (closed position) and then open the

cutting oxygen valve on the torch (open all the way).

b. Set the high cutting Oxy switch "1" ( force on position ) and you can adjust the

desired high cutting pressure on the pressure adjustment panel. After

finishing adjusting the pressure, please shut off high cutting Oxy by setting the

high cutting Oxy switch to "0" (closed position).

2. Adjusting Low Cutting Oxy

a. On the EDGE screen, please adjust flame setup data --- " move pierce time "

to 10 seconds.

b. Set the low cutting Oxy switch to "1" position.

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c. Set the High Cutting Oxy switch to "Auto" position and press the CNC starting

switch. It starts to preheat. Before the 10-seconds-conuntdown the time up, the

torch will only have Low Cutting Oxy, you must adjust the Low Cutting Oxy

pressure on the pressure adjustment panel at this time. After the 10 seconds

countdown, the system will switch the pressure from Low Cutting Oxy to High

Cutting Oxy automatically. The operator also has to adjust the " move pierce

time "according to his/her work’s thickness.

§For various cutting parameters, please refer to the cutting data.

11

1.4 TWO STAGE PIERCING

Hi / Low Oxygen Two Stage Piercing with EDGE Pro

1. Piercing method：

This operation needs to be combined with EDGE Pro cutting parameters. When “Oxy Fuel” is selected, the parameters of “Moving Pierce Time” are available to set the Hi/Low Oxy Fuel two stage piercing time.

2. Reference of relevant parameters：

I. Pierce Time：Specifies the amount of delay after the cutting gas is turned on before lowering the torch to the cut position.

II. Moving Pierce Time：Specifies the amount of time that the pierce output remains on while piercing with motion.

III. Creep Time：Specifies the amount of time after piercing the part that the torch travels at Creep Speed. This parameter is helpful in allowing the operator to bring the cutting surface up to temperature and completely pierce the metal before cutting at full speed.

IV. Pierce Torch Up Time：Specifies the amount of time used for torch lift during piercing. This parameter is used to provide distance between the torch tip and metal surface for cutting. This can avoid blocking of the spout due to slag.

V. Pierce Torch Down Time：Specifies the amount of time used for torch

lowering during piercing.

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3. Application：

The major piercing application is to be aimed at thick plates, generally 25mm and

above, however good piercing results is even more manifested if applied on 40mm

and above. During piercing, residue such as slag may likely clog the torch tip. It will

end up a stop on the machine, cleaning up of torch tip, a waste of time and influence

cut quality. Consequently, the “low cutting oxygen” (acts to control half of that high

cutting oxygen pressure) will avoid high cutting oxygen piercing vertically through the

plate and avoid producing too much slag. An optimum result is achieved after using

low-pressured cutting oxygen until it reaches the set time before shifting to standard

“high cutting oxygen” while piercing. For this reason, two-stage piercing combined

with appropriate “Lead-In Length” will further enhance optimum efficiency.

4. Procedures：

I. Adjust high cutting Oxygen/ Preheat Oxygen/Preheat Gas pressure according to cutting torch’s original setup.

II. Adjust two stage low cutting oxygen pressure.

III. It is advisable that “Pierce Time” is set at “0”. It is intended not to stop at cut position as soon as the cutting oxygen is turned on (reaches preheat time), hence, in low cutting oxygen, piercing should start while cutting torch is in motion (This is the same way as that of manual cutting).

IV. Adjust “Moving Pierce Time” about 2 seconds, depending the material thickness you may increase the length of time accordingly.

V. Set “Creep Time” approximately 3 ~ 5 seconds. The purpose is to slow the machine’s speed while piercing. Creep speed is determined by a setup parameter; percentage of the cut speed may be set approximately 25 ~ 50%.

LOW CUTTING

OXYGEN

HIGH CUTTING

OXYGEN

LOW CUTTING OXYGEN DEPTH

HIGH CUTTING OXYGEN DEPTH

13


Example of set up data：

{ Cutting speed：300mm/min, creep speed: 300 x 25% = 75mm/min, Creep Time: 3 sec .}

Thus, base on the above setup, the cutting torch starts to travel at a speed of 75mm/min., 3 seconds later actual cutting speed will increase to 300mm/min.

VI. Example：

{ Material thickness：80mm, Creep time: 5 seconds, Pierce time：2 seconds, Lead-in length: 20mm }.

If creep speed is 75mm/min (or 1.25mm/sec), creep time at 5 seconds will

have 6.25mm length (1.25mm x 5 sec.). Consequently, based on the Lead-in

length of 20mm, distance from 0~6.25mm will have creep speed of 75mm/min

while distance from 7~20mm will increase the cutting speed to 300mm/min.

Two stage piercing from 0 – 2 sec. uses “low cutting oxygen” that will pierce

through the plate about 1/3 ~ 1/2 of its depth. After 2 sec., it uses “high cutting

oxygen” to complete the piercing job at the given lead-in length of 20mm. This

will ensure that before cutting the plate sketch, high cutting oxygen had pierce

thoroughly without wasting the remaining plate sketch. This combination of

cutting mode is inherited through the traditional piercing done manually.

LOW CUTTING

OXYGEN HIGH CUTTING

OXYGEN

14

1.5 FLAME MARKING TORCH

Settings of Pressure Gauges:

Using Propane /Acetylene as preheating gas:

Preheat Oxy:：30 psi / 10 psi

Fuel Gas:：10 psi / 2 psi

Cutting Oxy:：30 psi / 10 psi

Preheating Flame Adjustment:

1. Select FLAME on the control console, and

turn ON the LOW PREHEAT by switching it

to position “1”.

2. Turn ON the powder switch by switching it to

position “1”.

3. Open the fuel valve (3) and ignite at the torch

tip to bring up the fire. Then, open preheat

oxy valve (4) gradually to assist the

combustion.

4. It is advisable that the preheat flame be

adjusted to become an approximately 100

mm-long thin and mild flame.

The Adjustment of Zinc Powder flow rate:

1. Select CUTTING switch on the control console, turn ON the cutting by switching

to postion “1”.

2. Adjust the flow of zinc powder at (1) of the zinc cup. Open the valve slowly, at a

point, a white color bright stream is visible and coming out from the torch tip.

3. Open the valve (2) slowly, this will agitate and blow up the zinc powder in the cup.

The white color bright stream will be turning red-hot due to burning zinc powder.

Use this valve (2) to adjust the width of the marking lines or to shut off the

marking process. Too much oxygen gas may block or clog the torch tip.

15

1.5 FLAME MARKING TORCH

Line Marking：

1. Adjust the torch stand-off distance to be about 30 ~ 50mm between the torch tip and the steel plate.

2. With marking flame on, move the torch, in both directions of X-axis manually. Check the clarity and width of the marked line. If it is inadequate, adjust the flow at. (1) & (2) of the zinc powder cup.

3. Set the machine to its desired marking speed (3M, 4M… ). Adjust the flow at (1) & (2) of the zinc powder cup to match the corresponding machine’s travel speed.

4. Following the above-mentioned adjustments, turn OFF the CUTTING switch by flipping it to position “0” or to position “Auto”, then flip the POWDER switch to position “Auto”.

5. Flip the LOW PREHEAT switch to position “0”(OFF).(If your machine is equipped with the optional auto ignition device, set IGNITE switch to position “Auto”).

Setting EDGE Pro CNC Control’s Marker Parameters: 1. Marking Speed. 2. For marking with auto ignition device, set Ignition to “ON”, Ignition Time at 1 sec.

3. Set Marker Off time at 1 sec. 4. Leave the remaining parameters blank.

Setting Marker Offset Value: 1. Setting the compensation value Offset 1 X, & Y for

its offset value between cutting torch and marking torch.

Marking / Cutting： 1. Load the marking and cutting programmer. 2. Set the parameters for powder marking and flame cutting. 3. Adjust the desired cutting gas pressure and flow rate. Make sure the control

panel’s switches are set properly. 4. Execute the marking process.

16

1.6 POSITIVE ANTI-DUST PRESSURE SETTINGS AND OPERATION

1. Regulator(w/Filter) specification：

Model：FESTO LFR (MIDI) G3/8 Flow rate：3100l/min @6kg/cm sq.

Regulator pressure setting 4kg/cm sq.

Total flow rate require=160L/min. above

2. Positive Anti-Dust Pressure adjustment：

To adjust regulator pressure to 2kg/cm sq, switch Anti-Dust to “ON” while the

solenoid valve is “ON”.

(Air will come out in blow condition, not injection)

When solenoid valve is “OFF”, the regulator pressure will ascend/increase to 2.5kg/cm sq.

17

1.7 GAS CIRCULATING DRAWING

18

1.7 GAS CIRCULATING DRAWING (HIGH/LOW PREHEAT/MARKING)

19

1.8 SEQUENCE DIAGRAM (HIGH/LOW PREHEAT)

20

2.1 TROUBLE SHOOTING GUIDE

1. WHAT HAPPEN? The machine will not move…

PROBLEM (SYMPTOMS) POSSIBLE CAUSE REMEDY

EDGE Pro screen does not

display

1. The DC12V,5V output of

ATX power supply

malfunction?

2. When booting, mother

beeps with speaker

connected but no screen

display?

3. Mother board or CPU

failed?

1. Replace ATX power

supply.

2. Replace RAM on the

mother board.

3.Replace mother board or

CPU.

Cannot log into the main

menu

1. The system could have

experienced an abnormal

shutdown?

2. In Windows the program

for booting failed?

3 .De fec t i ve hard d isk?

1. Press ”Enter” to boot,

don’t press “Start” to

recovery. If press “Enter”

still cannot access the

main menu, replace the

Hard Disk.

2. Use ghost to restore the

booting programs(refer to

EDGE Pro manual under

the subject “diagnostics”).

If Ghost still cannot

restore, replace the Hard

Disk.

3. Replace hard disk.

Displaying Remote Pause You may have pressed

Remote/Pause button, or

having a short circuit.

Reset remote pause, or

replace switch, or check the

circuits.

21


1. WHAT HAPPEN? The machine will not move…


Displaying driver disable 1.Did not press power switch,

or power switch failure.

2.M(magnetic contactor)

has no response after

pressing power switch, the

coil still measured DC 24V.

3.M(magnetic contactor)

has no response after

pressing power switch, the

coil measured no DC 24V.

4.Driver amp displaying error

message, ALXX

1.Press power switch or

replace the switch.

2. M(magnetic contactor)

failure, replace contactor.

3.Blown fuse on relay’s PCB,

replace fuse or replace

relay PCB.

4.Please follow trouble

shooting guide specified in

the driver amp manual.

Screen does not display any

error message

1.EDGE Pro Controller does

not have DC+-10V output

signal.

2.Loose transmission gear

and the rack

3.Loose or worn gear

reducer.

4.Tripped coupling between

the motor and reducer.

5.Driver amp failed.

1.Check IO board, MCC

board, Mother board and

Power Supply in EDGE Pro

Controller, replace any

defective parts.

2.Tighten spring or motor

base plate.

3.Tighten or replace gear

reducer.

4.Tighten or replace the

coupling.

5.Replace Drive amp.

22


2. WHAT HAPPEN? The machine trembling or shaking


The machine trembled along

the rail axis during cutting.

1. Dirty rail or gear racks.

2. Dirty wheels.

3. Worn-out rail scraper

which failed to clean the

rail.

4. The rails are not leveled or

paralleled.

5. Worn out or loosed gear

rack on the rails.

6. Worn out or loosed

transmission gear.

7. Loose transmission gear

and the rack.

8. Loose or worn gear

reducer.

9. Tripped coupling between


10. Adjust or replace the

guide bearing.

11. Reset the gain or

acceleration rate.

1. Clean and lubricate with

SD40/#32 oil.

2. Clean the wheels.

3. Replace rail scraper and

lubricate with SD40/#32oil.

4. Readjust the level and the

parallel of the rails.

5. Replace or tighten the

gear rack.


transmission gear.

7. Tighten spring or motor

base plate.

8. Tighten or replace gear

reducer.

9. Tighten or replace the

coupling.

10. Loose or too tight of the

guide bearing or non

contact of guide bearing

with the rails.

11. Wrong settings of the

gain or acceleration rate

on the CNC control.

23


2. WHAT HAPPEN? The machine trembling or shaking


The machine trembled along

the gantry axis during cutting. 1. Adjust or tighten electric

torch height control

assembly or universal joint.

2. Too tight or failed cross

slide bearing or liner way.

3. Too tight or mis-aligned

cable chain.

4. Too tight of steel belt or

belt rolls.

5. Worn out or loosed gear

rack on the rails.

6. Worn out or loosed

transmission gear.

7. Loose transmission gear

and the rack.

8. Loose or worn gear

reducer.

1. Loose or shaky electric

torch height control

assembly or universal

joint.

2. Adjust, tighten or replace

cross slide or liner way.


cable chain.

4. Adjust or replace steel

belt.


gear rack.


transmission gear.

7.Tighten spring or motor

base plate

8. Tighten or replace gear

reducer.

3. WHAT HAPPEN? The machine move slowly


Slow moving machine No+-10V output after Servo-On

1. Check if EDGE Pro Aux

power+-DC12V output is

normal.

2. Check if EDGE Pro IO board

DC12V and +-10V output

are normal.

3. Check if EDGE Pro MCC

board +-10V output is

normal.

1. Tighten the terminals or

replace the power

supply.

2. Replace I/O board.

3.Replace MMC board.

24


4. WHAT HAPPEN? Full Speed movement


Move only on full speed 1. EDGE Pro will not display

the value of the coordinates,

follow Drive AMP manual

and check if the coordinates

are displayed.

2. EDGE Pro control has+-10V

output, check if MCC and IO

board are functioning

1. Replace the decoder if

Drive AMP does not have

the coordinates output.

2. Replace the failed parts.

5. WHAT HAPPEN? Not a round cut


Start and end cutting points

will not coincide.

1. The spring loaded motor

base plate is not tighten.

2. Loose or too tight of the

guide bearing or non contact

of guide bearing with the

rails.

3. Too tight or failed cross slide

bearing or liner way.

4. Tripped steel belt and the

driving rolls.

1. Tighten the spring.


guide bearing.

3. Adjust, tighten or replace

cross slide or liner way.

4. Adjust and clean the

rolls, add lubricant.

Flat curvature at 6 and 12

o’clock

1. Loose contact between the

transmission gear of the rail

axis and its rack.



3. Too tight of the guide

bearing with the rails.

1. Tighten the spring or the

motor base plate.


coupling.


guide bearing.

Flat curvature at 3 and 9

o’clock

1. Loose contact between the

transmission gear of the

gantry axis and its rack.



1.Tighten the spring or the

motor base plate


coupling.

25


6. WHAT HAPPEN? Incorrect travel


Wrong cutting size 1. The accuracy and

repeatability of the cuts

are good except wrong

size.

2. Loose guide wheel.

3. When torch travel along

the rail axis back and

forth, the two cutting lines

do not coincide, especially

in the midway.

1. Redo the calibration and

rectify the settings of the

control.

2. Adjust the guide wheel.

3. The wheels are not parallel.

Adjust the wheels to

become parallel.

7. WHAT HAPPEN? Wrong cutting dimension


Wrong size flame cutting 1. Heat distortion.

2. The tolerance falls within

the compensation value.

1. Reroute the cutting

sequence.

2. Wrong setting of

compensation value.

8. WHAT HAPPEN? Cannot read the file


Cannot read the file while the

disk drive does flashing.

1. The USB is damaged.

2. Incorrect extension file

name of the NC Code file.

1. Replace a new USB.

2. Reset for a correct

extension file name.

26


9. WHAT HAPPEN? Files from CAM


Actual cutting speed does not

agree with the preset cutting

speed

F Code override is set to “ON” Set F Code Override to

“OFF”

Torch traces the cutting only -

no actual cutting.

1. The cutting path in the CAM

was set to “mark” not cutting.

2. NC code does not comply

with the controller.

1. Reset to “cutting” path.

2. Set the objective

processor to EDGE Pro.

10. WHAT HAPPEN? Plasma operating issues


Plasma Cutting 1. Arc discontinued after cutting

a shape – set with lead out,

work drop, arc stop, display

wait arc on.

2. Machine stop, displaying wait

arc on – no cutting plates or

the torch has traveled out of

the cutting plate.

1. Modify the pattern-

should not set lead out

line.

2. Move the torch to a

cutting plate.

Machine will not move after

pilot arc on

The controller will not respond

when pressing any keys-

plasma interference that shut

down the system.

No proper grounding,

need install grounding bar.

NO Main ARC 1. Work cable is not connected.

2. The plasma system

malfunction – could be caused

by torch parts, gas pressure,

coolant, overheat etc.

3. Poor insulation between the

electrode and tip in the torch

body – insulation deteriorated

by long time running of pilot

arc.

1.Check work cable

connection.

2.Follow plasma system

trouble shooting guide.

3.Replace torch body.

27


10. WHAT HAPPEN? Plasma operating issues


Machine will not move after

main arc on

1. The “ARC ON” signal does

not feed back to the CNC.

2. The “Pierce Time” in the

controller is set too long.

3. The “Cut Speed” in the

controller is set to 0

1. In accordance with the

manual, check the feed

back signal wire.

2. Reset the pierce time

based on the cutting data.

3. Reset the cutting speed.

11. WHAT HAPPEN? Flame Cutting abnormality


Flame Cutting abnormality 1. Cutting continued after

shut off the main cutting

oxygen gas – relief valve

delay closing.

2. MG torch’s interior tip

broken in the torch –

disassemble interior tip

while the torch is still very

hot.

3. MG torch’s rack broken –

have not used two

wrenches to disassemble

a cutting tip.

4. Torch creeping down after

repeated use – In cut

Mode, need to set 1.2

second more on up than

down.

1.Replace relief valve(No.15)

2. Disassemble after the tip

has cooled down.

3. Always use two wrenches

to disassemble the tip.

4. In cut mode, set 0.2 second

more on up than down.

28




All torches have no gas

flowing

1. No gas pressures, or not

enough gas pressures.

2. The pressure regulator on the

machine cannot regulate the

gas pressure - inlet gas filter

is blocked, or inlet gas

connector loose.

3. With gas on/off switch of the

OPC set to on, the solenoid

valve should have 24VAC

input power.

4. When no 24VAC input to the

solenoid, check the voltage

between PIN 1 and PIN 2 of

the main PCB-CN1 in the

OPC, it should read 24VAC.

5. The fuse of the main gas

PCB is blown.


OPC set to on, on the main

gas PCB-CN2, the voltage

between Pin 1&2 ; PIN 2&4;

Pin 5&6 ; Pin 7&8 should

read 24VAC.

1. Open the cylinder valves

or adjust the cylinder gas

pressure regulators to the

appropriate pressures.

2. Clean or replace the

filter, or tighten the hose

connector, or replace the

gas pressure regulator.

3. If 24VAC does exist

indicates the solenoid

valve has failed - replace

solenoid valve.

4. If no 24VAC between PIN

1 and Pin 2, make sure

the contact between the

wire and the terminal is

sound, or check if the

control transformer T1 is

failed - replace when

necessary.

5. Replace fuse.

6. If no 24VAC output, the

main gas PCB have failed

- replace Main gas PCB.

29




Individual torch has no

flowing gas


OPC set to on, gently loose

the individual gas connector

to see if the gas will blow out.

2. If no gas blow out from the

loosed connector, check the

individual solenoid valve, it

should read 24VAC.

3. If no 24VAC reading at the

solenoid valve, check Cut gas

station PCB of the relay box.

The CN1-CN4 terminal board

should supplies 24VAC to the

solenoid.

1. If gas blow out at the

connector when loosen,

check the check valve

and the flow regulator

and the torch body -

replace when necessary.

2. If 24VAC exists, the

solenoid valve failed -

replace the solenoid

valve.

3. If no 24VAC output,

check the fuse of the Gas

station PCB - replace

fuse or replace the Gas

station PCB where is

necessary.

All motorized torch holders

are not working

1.Check the fuse of the

motorized PCB in the relay

box.

2. The reading between Pin1/2

and Pin3/4 of the PCB in the

relay box should read 24VDC.

1.Replace fuse if it is blown.

2. If 24VDC exists, the

motorized PCB failed -

replace the motorized

PCB.

30


11. WHAT HAPPEN? Flame cutting abnormality


Individual motorized torch

holder is not working

1. With individual gas on/off

switch of the OPC set to on,

measure Pin 1 & Pin2 of the

CN4 terminal board of the

PCB of the motorized box,

the reading should be

220VAC.

2. If no 220VAC exists,

measure PIN 1 & PIN 2 of

the CN1,CN4 terminal board

of the PCB of the motorized

box, the reading should be

220VAC.


measure Pin 1 & Pin 2 of the

CN1,CN4 terminal board of

the PCB of the motorized

box, the reading should be

220VAC.

4. If no 24VDC reading at

above procedure B, check

the output voltage to the

relay from the CN1-CN4

Pin3&6 terminal board of the

motorized PCB in the relay

box. It should read 24VDC.

1. If 220VAC exists,

inspect the possible

failure of the motorized

limit switch or motor -

replace where

necessary.


check the fuse that

protect the T1

transformer in the OPC,

or check the possible

failure of T1 transformer -

replace where

necessary.

3. If 24VDC exists, it

indicates a failed PCB in

the motorized box,

replace the PCB of the

motorized box.

4. If 24VDC exists, it

indicates a failed PCB in

the motorized box,

replace the PCB of the

motorized box.

31

TTTHHHIIISSS PPPAAAGGGEEE IIISSS BBBLLLAAANNNKKK

32

3.1.1 OPERATION CONTROL

Fig No. Part No. Description Q’ty. Remark

1 ** 4200-2007 EDGE Pro CNC controller 1 SW1 (Single)

** 4200-2004 EDGE Pro CNC controller 1 SW1 (Dual)

** 4200-2008 EDGE Pro CNC controller 1 SW1 (Dual + STHC)

2 3214-2002 Emergency stop 1 SW2

3214-1005 Contact 1 SW2

3 3212-4001 Select switch with led 1 SW3

4 3213-1001 Toggle switch 9 SW5,7,24~30

5 3213-1006 Toggle switch 8 SW4,6,9~12,14,16

6 3213-1002 Toggle switch 10 SW8,13,15,17~23

7 6631-1101 OPC plasma SW board 1

8 6631-1201 OPC optional SW board 1

9 6631-1301 OPC flame SW board 1

10 6631-1560 OPC station SW board 1

* Recommended spare parts ** Option

33

3.1.1 OPERATION CONTROL

34

3.1.2 CONTROL CONSOLE( INSIDE )


1 ** 3251-2202 Relay 1

** 3256-2004 Relay socket 1

** 3257-0005 Relay clamp 1

** 3422-3001 Terminal stopper 2

2 ** 6631-3120 OPC main gas board 1 Marking

** 6631-3220 OPC main gas board 1 Two plasma

** 6631-3420 OPC main gas board 1 Marking drill

3 * 6631-2112 OPC I/O board 1

4 6631-0011 Power I/O board 1

* Recommended spare parts ** Option

35


36

3.2 SERVO AMPLIFIER BOX


1 ** 3031-2023 Servo amplifier 500w 2 / 3 Ms35s~40s/Ms35~45dual

** 3031-2025 Servo amplifier 1Kw 3 Ms 35~45 High speed

** 3031-2025 Servo amplifier 1Kw 3 Ms 50/60

2 3223-3001 Short circuit breaker 1

3 * 3224-1005 Magnetic contactor 1

4 3332-1001 EMI Filter 1

5 ** 6630-1520 Relay board 1 Single

** 6630-1720 Relay board 1 Dual gantry

6 3422-0010 Terminal 7

7 3422-0006 Terminal block 6

8 3071-3202 Fan 1

9 3422-3001 Terminal stopper 4

* Recommended spare parts

** Option

37

3.2 SERVO AMPLIFIER BOX — LEFT

38

3.2 SERVO AMPLIFIER BOX — RIGHT

39

3.3 RELAY BOX ( STANDARD )

Fig. No Part No. Description Q’ty. Remark

1 5034-5013800-20 Control box 1

2 5034-5013900-20 Gas distribution block /base 1

3 5034-5013400-11 Dust proof plate 2

4 * 6631-5431 Torch motorized board 1 4st


3422-0006 Terminal block 14

6 * 6631-4431 Gas station board 1 4st

7 ** 3722-1901 Bridge diode 1

8 ** 6651-0001 Motor speed control board 1

9 5034-5820700-20 Ring 4

10 0102-0607 Screw 4 M6*20L


**Option

40


1 * 3326-0001 Power supply 1

2 3311-0006 Transformer 1


**Option

3.4 GAS BOX

41

4.1.1 CONTROL SYSTEM

42

4.1.2 MAIN CIRCUIT

43


44

Edge Single Ended I/O Pinout

The single ended I/O offers 12 outputs which are rated at 24VDC for up to 1-amp

loads and

12 inputs rated for 24VDC

Pin I/O Description

1 Input 1 Torch Up sense

2 Input 2 Torch Down sense

3 Input 3 X-Overtravel switch

4 Input 4 Cut / Mark sense

5 Input 5 Torch collision

6 Input 6 Y-Overtravel switch

7 Input 7 Driver disable

8 Input 8 Remote pause

9 Input 9 X Home switch

10 Input 10 X+ Overtravel switch

11 Input 11 Y Home switch

12 Input 12 Y+ Overtravel switch

13 N/C No Connection

14 +24 VDC +I/O Power supply



17 24V Common I/O Power supply common




4.2.1 EDGE SIGNAL ENDED I/O PINOUT

45

4.2.1 EDGE SIGNAL ENDED I/O PINOUT

Pin I/O Description

21 Output 1 Torch Up

22 Output 2 Torch Down

23 Output 3 Ignition control

24 Output 4 Torch height disable

25 Output 5 Pierce control

26 Output 6 Marker 1 enable / Plate marker No.1

27 Output 7 Cut Control

28 Output 8 Drive enable / Marker 2 enable

29 Output 9 Spare / Nozzle contact enable 1

30 Output 10 Preheat control

31 Output 11 Program running

32 Output 12 Plasma select

33 I/O Shield Chassis ground





46

4.2.2 EDGE DRIVE / ENCODER PINOUT

Edge drive / Encoder pinout

Pin Description

2 Encoder power supply input(+5Vor+12V*)

3 Encoder power supply common

7 Encoder power supply shield

X Axis Y Axis Description

4 1 Encoder power output

8 6 Encoder power common

9 5 Encoder channel A Input

14 11 Encoder channel / A Input

15 10 Encoder channel B Input

21 17 Encoder channel / B Input

22 16 Encoder channel Z Input

28 23 Encoder channel / Z Input

13 12 Encoder shields

24 26 Drive enable In (relay contact)

25 27 Drive enable out (relay contact)

37 34 Drive power input (+12 or +15)

33 29 Servo output (±10V)

32 30 Drive power common

36 35 Drive power input (-12 or -15)

20 18 Servo output common

19 31 Drive / Servo shield

47

4.2.2 EDGE DRIVE / ENCODER PINOUT

Edge drive / Encoder pinout (for 3 and 4 Axis units)

2 Encoder power supply input(+5Vor+12V*)

3 Encoder power supply common

7 Encoder power supply shield

Z Axis W Axis Description

4 1 Encoder power output

8 6 Encoder power common

9 5 Encoder channel A Input

14 11 Encoder channel / A Input

15 10 Encoder channel B Input

21 17 Encoder channel / B Input

22 16 Encoder channel Z Input

28 23 Encoder channel /Z Input

13 12 Encoder shields

24 26 Drive enable In (relay contact)

25 27 Drive enable out (relay contact)

37 34 Drive power Input (+12 or +15)

33 29 Servo output (±10V)

32 30 Drive power common

36 35 Drive power Input(-12 or -15)

20 18 Servo output common

19 31 Drive / Servo shield

48

CONTENT：CNC EIA CODE FOR DRILL/MARKING/CUTTING, AS FOLLWING

Cutting： ON：M07

OFF：M08

Marker 1： M36T3(Flame marking process select)

OFFSET ON：M11

Enable Marker 1：M09

Disable Marker 1：M10

Offset Off：M12

Marker 2： M36T4(CENTER DRILL PROCESS SELECT)

Offset ON：M73

Enable Marker 2：M13

Disable Marker 2：M14

Offset Off：M72

Example：G90

G21

G92 X0. Y0.

G00 X-44.5 Y46.7

M36T4

M73

M13

M14

X-94.5

M13

M14

Y96.7

M13

M14

X-44.5

M13

M14

M72

M02

4.2.3 CNC EIA / CODE

49

4.3.1 OPC : OPC I/O BOARD & EDGE I/O INTERFACE

OPC I/O BOARD-P1

EDGE-I/O NAME OPC I/O

BOARD-P2EDGE-I/O NAME

1 1 TUS 1 21 TU

2 2 TDS 2 22 TD

3 3 NX 3 23 IGN

4 4 CS 4 24 THD

5 5 TC 5 25 PC

6 6 NY 6 26 MK

7 7 SO 7 27 CUT

8 8 RP 8 28 DE / MK2

9 9 HX 9 29

SPARE / NOZZLE

CONTACT ENABLE 1

10 10 PX 10 30 PH

11 11 HY 11 31 PROGRAM RUNNING

12 12 PY 12 32 PF

13 33 GROUND

14 14 EVCC-24V 14 34 EVCC-24V

17 17 EVCC-0V 17 36 EVCC-0V

50

4.4.1 RELAY BOX : TB4 INTERFACE

TB4 TORCH MOTORIZED BOARD GAS STATION BOARD

1 AC 24V_1L CN8-3

2 AC 24V_2L CN8-4

3 AC 24V_1N CN8-1

4 AC 24V_2N CN8-2

5 P+_1 CN10-1

6 P+_2

7 P-_1 CN10-2

8 P-_2

9 AC 220V_1L CN9-1,CN9-3

10 AC 220V_2L CN6-1

11 AC 220V_1N CN9-2,CN9-4

12 AC 220V_2N CN6-2

13 M+

14 M-

51

4.4.2 RELAY BOX : GAS STATION BOARD

NO OPC MAIN GAS BOARD GAS STATION BOARD

1 J5-2 J1-2

2 J5-4 J1-4

3 J5-6 J1-6

4 J5-8 J1-8

5 J5-9 J1-9

6 J6-2 J2-2

7 J6-4 J2-4

8 J6-6 J2-6

9 J6-8 J2-8

10 J6-9 J2-9

52

NO TORCH MOTORIZED BOARD OPC STATION SW BOARD

1 J5-1 J16-1

2 J5-2 J16-2

3 J5-3 J16-3

4 J5-4 J16-4

5 J5-5 J16-5

6 J5-6 J16-6

7 J5-7 J16-7

8 J5-8 J16-8

9 J5-9 J16-9

10 J5-10 J16-10

11 J5-11 J16-11

12 J5-12 J16-12

13 J9-1 J15-1

14 J9-2 J15-2

15 J9-3 J15-3

16 J9-4 J15-4

17 J9-5 J15-5

18 J9-6 J15-6

19 J8-1 J14-1

20 J8-2 J14-2

21 J8-3 J14-3

22 J8-4 J14-4

23 J8-5 J14-5

24 J8-6 J14-6

25 J8-7 J14-7

26 J8-8 J14-8

27 J8-9 J14-9

28 J8-10 J14-10

29 J8-11 J14-11

30 J8-12 J14-12

4.4.3 RELAY BOX : TORCH MOTORIZED BOARD INTERFACE

53

4.4.4 RELAY BOX : TORCH MOTORIZED BOARD INTERFACE

TORCH MOTORIZED

BOARD FOR 4ST

MOTORIZED CONTROLBOX #1 CN1

TORCH MOTORIZED

BOARD FOR 4ST


CN1-1 1 CN4-1 1

CN1-2 2 CN4-2 2

CN1-3 3 CN4-3 3

CN1-4 4 CN4-4 4

CN1-5 5 CN4-5 5

CN1-6 6 CN4-6 6

CN5-1 7 CN8-1 7

CN5-2 8 CN8-2 8

TORCH MOTORIZED

BOARD FOR 4ST


TORCH MOTORIZED BOARD FOR

EX 2ST

MOTORIZED CONTROLBOX #5 CN1(OPTION)

CN2-1 1 CN1-1 1

CN2-2 2 CN1-2 2

CN2-3 3 CN1-3 3

CN2-4 4 CN1-4 4

CN2-5 5 CN1-5 5

CN2-6 6 CN1-6 6

CN6-1 7 CN5-1 7

CN6-2 8 CN5-2 8

TORCH MOTORIZED

BOARD FOR 4ST


TORCH MOTORIZED BOARD FOR

EX 2ST

MOTORIZED CONTROLBOX #6 CN1(OPTION)

CN3-1 1 CN2-1 1

CN3-2 2 CN2-2 2

CN3-3 3 CN2-3 3

CN3-4 4 CN2-4 4

CN3-5 5 CN2-5 5

CN3-6 6 CN2-6 6

CN7-1 7 CN6-1 7

CN7-2 8 CN6-2 8

54

4.4.5 RELAY BOX : I/O CONNECTOR INTERFACE

TORCH MOTORIZED

BOARD

OPC MAIN GASBOARD

TORCH MOTORIZED

BOARD J12 GAS STATION

BOARD J6

CN11-1 CN4-1 1 1

CN11-2 CN4-2 2 2

CN11-3 CN3-7 3 5

CN11-4 CN3-8 6 8

HEIGHT

SENSING SW

J9-7 HS-3 PANEL

SW.

J9-8 HS-2 TORCH MOTORIZED

BOARD J13

J9-9 HS-1 1 3

2 4

6 9

TORCH MOTORIZED

BOARD J11 GAS STATION

BOARD J5

1 1

2 2

3 3

4 4

55

4.5 SERVO CONTROL BOX:AMPLIFIER CN1 & SERVO RELAY BOARD INTERFACE

RL-CN10 AMP Z-CN1

RL-CN11 AMP Y-CN1 RL-CN12 AMP X-CN1

1 28 1 28 1 28

2 2 2 2 2 2

5 15 5 15 5 15

8 17 8 17 8 17

9 34 9 34 9 34

10 46 10 46 10 46

11 4 11 4 11 4

12 5 12 5 12 5

13 20 13 20 13 20

14 19 14 19 14 19

15 42 15 42 15 42

16 43 16 43 16 43

17 44 17 44 17 44

18 48 18 48 18 48

20 47 20 47 20 47

22 6 22 6 22 6

23 7 23 7 23 7

24 8 24 8 24 8

25 9 25 9 25 9

56

No Name Value Unit Setting range

PA01 Control mode 0002 0000-0255h

PA02 Regenerative option 0002 0000-71FFh

PA06 Electronic gear numerator(com. pulse

factor numerator)

1 1-1048576

PA07 Electronic gear denominator(com. pulse

factor denominator)

1 1-1048576

PA08 Auto tuning mode 0003 0000-0003h

PA09 Auto tuning response 17 1-32

PA15 Encoder output pulses 4096 pulse/rev 1-100000

PA19 Parameter write inhibit 000C 0000-FFFFh

PB06 Ratio of load inertia moment to servo

motor inertia moment

7.0 times 0.0-300.0

PB07 Model loop gain 24 rad / s 1-2000

PB08 Position loop gain 37 rad / s 1-1000

PB09 Speed loop gain 1350 rad / s 20-50000

PB10 Speed integral compensation 20.0 ms 0.1-1000.0

PB17 For manufacturer setting 0006 0000-031Fh

PC01 Acceleration time constant 0 ms 0-50000

PC02 Deceleration time constant 0 ms 0-50000

PC03 S-pattern acceleration/deceleration time

constant

0 ms 0-1000

PC12 Analog speed command maximum speed 3200 r/min 0-50000

PC26 Function selection C-5 0001 0000-0111h

PC37 Analog speed command offset 0 mV -999-999

PD01 Input signal automatic ON selection 1 0000 0000-0FFFh

PD03 Input signal device selection 1 (CN1-15) 00020202 00000000-003F3F3Fh

4.6 AMPLIFIER PARAMETERS

57

4.6 AMPLIFIER PARAMETERS

No Name Value Unit Setting range

PD04 Input signal device selection 2 (CN1-16) 00212100 00000000-00

3F3F3Fh





PD10 Input signal device selection 8 (CN1-43) 00000A0A 00000000-003F3F3Fh

PD11 Input signal device selection 9 (CN1-44) 00000B0B 00000000-003F3F3Fh


PD13 Output signal device selection 1 (CN1-22) 0004 0000-3F3Fh

PD14 Output signal device selection 2 (CN1-23) 000C 0000-3F3Fh



PD18 Output signal device selection 6 (CN1-49) 0002 0003-0003h

PD20 Function selection D-1 0000 0000-0011h

58

Appendix A : SERIAL COMMUNICATION

59

Appendix B : SIGNAL TOWER

60

Appendix C : TORCH COLLISION INTERFACE

1. COLLISION DEVICE DRY CONTACT OUTPUT

I/O Setup：

1. The output of torch collision device is normal open. Model：090047→Setting value：Input 5 = Torch collision, contact = Open.

2. The output of torch collision device is normal close. Model：090047→Setting value：Input5 = Torch collision, contact = Close.

61

Appendix C : TORCH COLLISION INTERFACE

2 . COLLISION DEVICE NPN OUTPUT

CN4-7：DC24V

CN4-6：NPN Output

CN4-5：DC0V

I/O Setup：

1. When torch collide, the output of torch collision device is ON.

Model：090047→Setting value：Input 5 = Torch collision, contact = Open.

2. When torch collide, the output of torch collision device is OFF.

Model：090047→Setting value：Input5 = Torch collision, contact = Close.

62

Appendix D : PNEUMATIC FLAME MARKING INTERFACE

63

Appendix E : PLASMA SYSTEM COMMAND THC MACHINE INTERFACE

64

Appendix F : PLASMA SYSTEM HPR-260 SENSOR THC INTERFACE

65

Appendix G : TWO COMMAND THC INTERFACE

66

Appendix H: KALIBURN PLASMA & INOVA THC INTERFACE

PS：IF “ Partial raise enable ” not used SW4-3 ( X/Y Raise disable )

should be switched to “ ON ” position

67

Appendix I : SAFETY COLLISION DEVICE INTERFACE

68

Appendix J : BLOWER CONTROL

PS：CNC I/O Setup：Output 8 = Plasma1 enable

69

Appendix K : FUME COLLECTION INTERFACE

1. Process control：

Under Plasma mode，pin ① & ③ of Plastic connector will be

shorted when auto run is started. 2. PS：

Contact：5A 240V ~ AC

5A 28V ~ DC

70

Appendix L : SCRIBER INTERFACE

1. PS：CNC I/O Setup：Output 7=Marker 1 enable

71

Appendix M : HSD-130 & SPHC INTERFACE

72

Appendix N : PLASMA SYSTEM POWER MAX1650 SENSOR THC INTERFACE

73

Appendix O : FLAME VENT OFF

74

OPTION A：RELAY BOX ( 6 CUT )

Fig. No Part No. Description Q’ty. Remark

1 5109-07001501010-10 Control box 1

2 5109-07001501030-10 Gas distribution block /base 1

3 5034-5014100-10 Dust proof plate 2

4 * 6631-5331 Torch motorized board 1 Ex 2st

5 * 6631-5431 Torch motorized board 1 4st


3422-0006 Terminal block 14

7 * 6631-4431 Gas station board 1 4st

8 * 6631-4331 Gas station board 1 Ex 2st

9 ** 3722-1901 Bridge diode 1

10 ** 6651-0001 Motor speed control board 1

11 5034-5820700-20 Ring 4

12 0102-0607 Screw 4 M6*20L


**Option

75

OPTION B：TORCH MOTORIZED BOARD FOR 4ST INTERFACE

NO TORCH MOTORIZED BOARD

FOR 4ST TORCH MOTORIZED BOARD

FOR EX 2ST

1 J7-1 J7-1

2 J7-2 J7-2

3 J7-3 J7-3

4 J7-4 J7-4



FOR EX 2ST

1 J6-1 J6-1

2 J6-2 J6-2

3 J6-3 J6-3

4 J6-4 J6-4



FOR EX 2ST

1 CN10-3 CN10-3

2 CN10-4 CN10-4



FOR EX 2ST

1 CN9-5 CN9-5

2 CN9-6 CN9-6



FOR EX 2ST

1 J10-1 J10-1

2 J10-2 J10-2

3 J10-3 J10-3

4 J10-4 J10-4

5 J10-5 J10-5

6 J10-6 J10-6

7 J10-7 J10-7

8 J10-8 J10-8

9 J10-9 J10-9

76

OPTION B：TORCH MOTORIZED BOARD FOR EX 2ST INTERFACE


FOR EX 2ST GAS STATION BOARD

FOR EX 2ST

1 J12-1 J6-1

2 J12-2 J6-2

3 J13-6 J6-8


FOR EX 2ST GAS STATION BOARD

FOR EX 2ST

1 J11-1 J5-1

3 J11-2 J5-2

77

NO GAS STATION BOARD

FOR 4ST

GAS STATION BOARD

FOR EX 2ST

1 CN9-1 CN8-1

3 CN9-2 CN8-3


FOR 4ST GAS STATION BOARD

FOR EX 2ST

1 J3-2 J1-2

2 J3-4 J1-4

3 J3-6 J1-6

4 J3-8 J1-8

5 J3-9 J1-9



FOR EX 2ST

1 J4-2 J2-2

2 J4-4 J2-4

3 J4-6 J2-6

4 J4-8 J2-8

5 J4-9 J2-9



FOR EX 2ST

1 CN7-1 CN6-1

3 CN7-2 CN6-2

OPTION C：GAS STATION BOARD FOR 4ST INTERFACE

78

REVISIONS

Manual Number Print Data Changed Page Revisions

RD-991E Feb. 06, 2010

RD-991E Mar. 03, 2010 Appendix

3.1.2 (P34)

Revised：Appendix C/D/H/J/K/L/O

Revised Part No.4：6631-0010→6631-0011

Documents

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