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Programming Manual

1. WIDTH DIMENSION HEIGHT DIMENSION HOLE DIAMETER ARC RADIUS KERF DIMENSION SCRAP DIMENSION LEAD IN DIMENSION LEAD OUT DIMENSION VERIFY YES NO SHAPE 23 SQUARE CORNER RADIUS IN REPEAT PATTERNS PLATE SIDE LEFT RIGHT INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS WIDTH OF CUTTING TOOL PATH DISTANCE BETWEEN PARTS IN MM INCHES OR MILLIMETERS INCHES OR MILLIMETERS YES OR NO NOTES If a HOLE DIAMETER of 0 is defined no center hole is cut PART 2 SHAPES 28 AO 73290 SYSTEM OPERATION SHAPES SHAPES324 SHAPE 24 SQUARE CORNER RADIUS REPEAT PATTERNS n PLATE SIDE LEFT RIGHT v AE 2 n 8 V v 2 T5 VER TR gt ei r UR X e e e 4 pee X N gt p gt 3 E L 1 WIDTH DIMENSION INCHES OR MILLIMETERS 2 HEIGHT DIMENSION INCHES OR MILLIMETERS 3 HOLE DIAMETER INCHES OR MILLIMETERS 4 ARC RADIUS INCHES OR MILLIMETERS 5 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 6 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 7 LEAD IN DIMENSION i INCHES OR MILLIMETERS 8 LEAD OUT DIMENSION INCHES OR MILLIMETERS 9 VERIFY YES NO YES OR NO NOTES Ifa HOLE DIAMETER of 0 is
2. Y A J 7 T U A A 3 00 DIA THRU 1 HOLE H AEE LE EEE EEEEEEE EEE EEEESEEEESEESEEEEESBEBEEEEBEEEEEEESEEEEESE LLG 5 0 1 500 1 00 d 10 100 0 67 9 000 10 34 REF SECTION B B 0 281 0 003 0 000 DIA THRU SCALE 1 1 INSTALL PEM P N SO 832 4 FROM OPPOSITE SIDE WITH FLAT OF HEX PARALLEL WITH THE EDGE OF THE FLANGE 8 PLACES E CL SA M E AU AN AT T ET AT AY ANT AT T TL LU LOU T T T TTL LAT TT T LUE LT A nw 2224 6 700 SEE DETAIL A 0 250 0 003 0 000 DIA THRU INSTALL PEM P N B 032 1 CI 3 PLACES F APPLY LAYER OF RIV SILICONE AT ALL SEAMS FROM INSIDE SO THAT CABINET IS DUST TIGHT 9 400 SHERWIN WILLIAMS F63B12 TEXTURED POLYURETHANE CMC P N X09 12455 PAINT TO BE SPECIFIED PER ORDER D03 12697 BLACK PAINT CONDUCTIVE PLATING INSIDE OF CABINET AND PANEL FLANGE GOLD IRIDITE MINIMUM RADIUS ON ALL
3. reet rien 26 SHAPES3 22 gt 222 0 a do tup Ede nte de debi eed tab 27 SHAPES3 23 SHAPE 23 SQUARE CORNER RADIUS IN r 28 SHAPES3 24 SHAPE 24 SQUARE CORNER RADIUS 29 SHAPES3 25 SHAPE 25 SQUARE WITH HOLE cnut hi ee anaa eetas aaa iia aaa aan a aeaa e deei 30 SHAPES3 26 SHAPE 26 OCTAGONAL 31 SHAPES3 27 SHAPE 27 FRAME CORNER RADIUS 32 SHAPES3 28 SHAPE 28 FRAME CORNER RADIUS OUT 33 SHAPES3 29 SHAPE 29 SQUARE 34 SHAPES3 31 SHAPE 31 UNIVERSAL nan 36 SHAPES3 32 SHAPE 32 RECTANGULAR 37 33 SHAPE 33 VERTICAL HOLE L etc et ea 38 SHAPES3 34 SHAPE 34 HORIZONAL 39 SHAPES3 35 SHAPE 35 CIRCULAR HOLE a ae re 40 SHAPES3 36 SHAPE 36 BEAM SUPPORT nn nn 41 SHAPES3 37 SHAPE 37 TRUSS SUPPORT 2444440000nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnannnnnnnnnnnnnnnnnnnnnnnannnnnn 42 SHAPES3 38 SHAPE 38 ANGULAR 085 43 SHAPES3 39 SHAPE 39 TRIANGLE een 44 SHAPES3 40 SHAPE 40 BEVELED
4. 62 SETUP amp CONFIG 4 5 3 SERV32 16 CRU DISPLAY a 62 SETUP amp CONFIG 4 5 4 SERV33 SINGLE BYTE MEMORY DISPLAY 63 SETUP amp CONFIG 4 5 5 SERV34 8 BIT CRU 0404000 63 SETUP amp CONFIG 4 5 6 SERV50 AXIS 00 004 0 2 63 SETUP amp CONFIG 4 5 7SERV51 SPEED 0 04000 2 64 SETUP amp CONFIG 4 5 8 SERV52 MEMORY 0 0406400 65 SETUP amp CONFIG 4 5 9 SERV 54 AUTOMATIC REFERENCE ADJUSTMENT 66 SETUP amp CONFIG 4 5 10 SERV70 CUSTOM AUX TABLES 67 SETUP amp CONFIG 4 5 11 SERV78 LOOP BACK a a 72 SETUP amp CONFIG 4 5 12 SERV97 VARIABLE 5 2 064 0 00 73 SETUP amp CONFIG 4 5 13 SERV98 SYS 2 2 0064004000 74 TYPICAL SETUP EXAMPLE 0004000 74 SERV54 REF ADJUST FOR THE BURNY 2 5 80 INTERFACE
5. 1 MACH 1 MACHINE INTERFACE v 2 2 Bean ae nasser 1 1 1 u a 1 73290 Table of Contents viii TABLE OF CONTENTS MACH 1 2 E STOP 2 MACH 1 3 OXY FUEL CUT SENSE INPUT 3 MACH 1 4 OXY FUEL CUT INTERFACE 3 MACH 2 RELAY CONTACTS tei er a a t vrina 4 MACH 2 5 OXY ENABLE CONTACT 4 MACH 2 6 OXY START 5 MACH 2 7 HI PREHEAT CONTACT eiii eee aite aan sta sapere nr aet haha pasate andauernden dehnen 5 MACH 2 8 PLASMA 6 MACH 2 9 PLASMA ON GO INPUT U 6 MACH 2 10 PLASMA ENABLE 7 MACH 2 11 PLASMA START CONTACT 8 MACH 2 12 PLASMA HEIGHT DISABLE CONTACT L u uu 8 MACH 2 13 CUT CONTROL RELAY OUTPUT SEQUENCING DIAGRAMS 9 MANUAL OXY FUEL CUTTING SEQUENCE 9 OXY FUEL AUTOCUT RELAY 10 PLASMA CUTTING MANUAL RELAY 11 PLASMA CUTTING AUTOCUT RELAY SEQUENCING eene nennen 12 PART ERROR MESSAGES nim ripe EUR npa ae 9 ERROR MESSAGES nudes titer ent ex nai eee sy eter exes
6. ms AUTO MANUAL MA PLATE SIDE N P vi ER 2 2 4 A 5 gt Z Le 60 DEGREE ANGLE TO CENTERS 1 CUT DIRECTION OD CLOCKWISE OR COUNTERCLOCKWISE 2 STARTING POSITION 1 OF 8 POINTS 3 INNER DIAMETER SIZE INCHES OR MILLIMETERS 4 OUTER DIAMETER SIZE INCHES OR MILLIMETERS 5 LEADIN DIMENSION INCHES OR MILLIMETERS 6 LEADOUT DIMENSION INCHES OR MILLIMETERS 7 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 8 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 9 REPEAT MODE AUTOMATIC OR MANUAL POSITIONING IF AUTO REPEAT MODE IF MANUAL REPEAT MODE 10 VERIFY YES NO 10 REPEAT DIRECTION 1 OF 4 POINTS 11 VERIFY YES NO NOTES The CUT DIRECTION prompt defines the outer diameter cut direction The inner direction is always opposite so that the same KERF side LEFT RIGHT can be used for both cuts The STARTING POSITION and REPEAT DIRECTION parameters can be directly entered with the numeric keypad The actual LEADOUT position is determined by the direction of the cut The figure above shows the LEADOUT position assuming a clockwise cutting direction has been selected When running the resulting NC part program position the torches at the CENTER of the first part regardless of the REPEAT MODE selected When performing AUTO REPEAT mode operation parts are shifted to the left and right at a 60 degree angle PART 2 SHAPES 8 AO 73290 SYSTEM OPERATION SHAPES SHAPES3 4 SHAPE 4
7. 45 SHAPES3 41 SHAPE 41 TRAPEZOL D 46 SHAPES3 42 SHAPE 42 QUAD 2 2 22 0000000 000 1 101000 E rani 47 5 5 343 SHAPE 43 5 EAP JOINT u niece t t eee 48 SHAPES3 44 SHAPE 44 SLOTTED PLATE a 49 SHAPES3 45 SHAPE 45 LAMP BASE u envied en ar mi nl 50 SHAPES3 46 SHAPE 406 CAM 5 n riii co eie Ege tiet ee yere 51 SHAPES3 47 SHAPE 47 L BRACKET 1 52 SHAPES3 48 SHAPE 48 ES BRACKET 2 Z a uina ae eai e 53 SHAPES3 49 SHAPE 49 BI 54 SHAPES3 50 SHAPE 50 DAMPER ice ie eroe HL ER ode bt LI IA 55 SHAPES3 51 SHAPE 51 RECTANGLE ves see 56 SHAPES3 52 gt SHAPE 52 ZGIRGLE a ut anteilig 57 53 ZSHAPE 59SZ RING emnt iit ee naeh 58 RUNNING A PROGRAM a 1 RUN 1 PLASMA OXY FUEL SELECTION rettet ettet Cu tet tech o oed eee 1 RUN 2 GEOMETRY MODIFICATION OPTIONS sese 1 SCALING SA um aga u a dle M rM cc DL 2 RUN 22 PART ROTATION et 3 RUN23 X Y AXIS MIRRORS esc a a 3 RUN 3 KNIFE COMPENSATION einen ae een 3 RUN 3 1 DIAL IN KERF ee ee ee
8. Pressing the PART key a second time returns to the start point of the current part The display now shows RETURN START Pressing the PART key a third time will return to the home position on the selected cutting table The display now shows RETURN HOME NOTE Pressing SHF PART RET returns to table 1 0 0 home reference position The BACKUP key can be used in CUT TEST RUN or SINGLE STEP to retrace the cut path either for verifying the positioning or in the case of a lost cut When pressed the part must be running forward first it backs up at a preset speed as long as the key is held When the desired point is reached release the key and restart the cut NOTE BACKUP does not work if STOP CYCLE is pressed To stop the program at any point press the red STOP CYCLE key To continue press the START CYCLE key again After stopping it is possible to jog away from the part to clean a torch tip for instance Then pressing the BACKUP key causes the machine to return directly to the position where it was jogged from Pressing the START CYCLE key continues cutting the part To stop executing the program and return to the top prompting level press the RECYCLE key AO 73290 PART 2 RUN 13 2 5RS OPERATION AND MAINYENANCE MANUAL BLANK PART 2 RUN 14 AO 73290 PART 3 SYSTEM UTILITIES Tab Page Part 3 SYSTEM UTILITIES PROGRAM TEXT ED
9. 14 SETUP amp CONFIG 4 2 13 SD15 ERROR WARNING DISTANCE in mm sem 14 SETUP amp CONFIG 4 2 14 SD16 LOOP GAIN multiple 15 SETUP amp CONFIG 4 2 15 SD17 ARC OFF DELAY seconds eem 16 SETUP amp CONFIG 4 2 16 SD18 SLOWDOWN DISTANCE in mm multiple parameter 16 SETUP amp CONFIG 4 2 17 SD19 HEIGHT SENSOR DISABLE LOOKAHEAD 17 SETUP amp CONFIG 4 2 18 5020 17 SETUP amp CONFIG 4 2 19 5021 ENC ernennen ernennen nennen nenn 17 SETUP amp CONFIG 4 2 20 5022 17 SETUP amp CONFIG 4 2 21 5023 ENCODER DIR eee ener 18 SETUP amp CONFIG 4 2 22 SD24 Y ENCODER DIR 18 SETUP amp CONFIG 4 2 23 5025 DRIVE DIR L L n 18 SETUP amp CONFIG 4 2 24 SD26 Y DRIVE 18 SETUP amp CONFIG 4 2 25 SD27 PLATE 19 SETUP amp CONFIG 4 2 26 SD28 HEIGHT RELAY Norm Rev l eem 19 SETUP amp CONFIG 4 2 27 SD29 SLOWDOWN RADIUS in mm multiple parameter 20 SETUP amp CONFIG 4 2 28 SD30 MIN RAD SPD multiple 20 SETUP amp CONFIG 4 2 29 SD31 PLASMA TB1
10. SHAPES3 18 SHAPE 18 VERTICAL PROJECTION REPEAT PATTERNS 1 PLATE SIDE gt La LEFT RIGHT wu ur 2 lt lt LJ Bee L 4 GE 1 WIDTH DIMENSION INCHES OR MILLIMETERS 2 HEIGHT DIMENSION INCHES OR MILLIMETERS 3 COLLAR HEIGHT INCHES OR MILLIMETERS 4 COLLAR WIDTH INCHES OR MILLIMETERS 5 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 6 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 7 LEAD IN DIMENSION INCHES OR MILLIMETERS 8 LEAD OUT DIMENSION INCHES OR MILLIMETERS 9 VERIFY YES NO YES OR NO NOTES The only difference between parts created with LEFT PLATE or RIGHT PLATE enabled occurs in the traverse move to the first pierce point AO 73290 PARTS 2 SHAPES 23 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 19 1 E 9 2 je BASE WIDTH HEIGHT DIMENSION COLLAR HEIGHT COLLAR WIDTH WIDTH KERF DIMENSION SCRAP DIMENSION LEAD IN DIMENSION LEAD OUT DIMENSION 10 VERIFY YES NO 1 tn SHAPE 19 SLANT PROJECTION REPEAT PATTERNS PLATE SIDE LEFT RIGHT I i A A A A A I L 1 PE 1 ri I INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS WIDTH OF CUTTING TOOL PATH DISTANCE BETWEEN PARTS IN MM INCHES OR MILLIMETERS INCHES O
11. 2 6 ir eta n ata iria eater taa deed dh acea nd 5 ERROR A7 FORMATERROR ttt 5 ERROR 4 8 PROGRAM NUMBER 5 PART 9 RETROFITS sr ER 9 RETROFIT AND RETROFIT INSTALLATION 1 uuu u 1 RETRO 1 GENERAL EXPLANATION OF CNC 1 RETRO 2 GEAR RACK MOUNTING gier ierat ce cheat i neret een ect E a 2 RETRO 3 ENCODER MOUNTING 2 3 RETRO 4 CABLE LENGTH DETERMINATION u 4 PART 10 PRODUCT 8 40044200 11 PRODUCT SPECIFICATIONS rene rire P nennen RD anne eR RO E PE TERRE an Ener Free 1 SPECS 1 PHYSICAL ENVIRONMENT OPERATING LIMITS u 1 SPECS 2 ELECTRICAL SPECIFICATIONS una nahua 1 PART 11 DRAWINGS amp SCHEMATICS 27 AO 73290 Table of Contents ix 2 5RS OPERATION AND MAINTENANCE MANUAL BLANK AO 73290 Table of Contents x WARRANTY WARRANTY AND LIMITATION OF LIABILITY ALL EQUIPMENT IS SOLD SUBJECT TO THE MUTUAL AGREEMENT THAT IT IS WARRANTED BY THE COMPANY TO BE FREE FROM DEFECTS OF MATERIAL AND WORKMANSHIP BUT THE COMPANY SHALL NOT BE LIABLE FOR SPECIAL I
12. sse nennen nennen nennen eerie nennen 20 SETUP amp CONFIG 4 2 30 SD32 MIN SLW ANG degrees multiple 21 SETUP amp CONFIG 4 2 31 5033 SLW ANG degrees multiple 21 SETUP amp CONFIG 4 2 32 5040 MARKER OFFSET 1 in mm u 22 SETUP amp CONFIG 4 2 33 5041 MARKER OFFSET 1 22 SETUP amp CONFIG 4 2 34 SD42 MARKING SPEED Not used in this control ipm MPM 23 SETUP amp CONFIG 4 2 35 SD43 MARKER DELAY Not used in this control seconds 23 SETUP amp CONFIG 4 2 36 SD45 DEFAULT DWELL seconds multiple 23 SETUP amp CONFIG 4 2 37 SD46 MIN OFF DELAY seconds multiple parameter 23 SETUP amp CONFIG 4 2 38 5047 MARKER OFFSET 2 23 SETUP amp CONFIG 4 2 39 5048 MARKER OFFSET 2 in mm m 23 SETUP amp CONFIG 4 2 40 SD49 START DELAY seconds multiple parameter 24 SETUP amp CONFIG 4 2 41 SD50 SERIAL a 24 PROGRAMMING LANGUAGE 5 50 n I Ei a aa 25 CHARACTER FORMAT SPECIFICATION 5 50 26 SETUP amp CONFIG 4 2 42 SD51 PRGM 0 28 PROGRAM FORMAT SDSE u a I ER ER EDER
13. NI ALFILLVSS3SA HO3 ANYA NVO NOILISOd L3 12V88 ONILNNON e AO 73290 PART 9 RETROFIT 8 RETROFIT ANDINHOAL ONILNNOW YACOONA 8 V 1038302 SIXV 55042 8 V LO3HMHOONI SIXV 5030 PART 9 RETROFIT 9 AO 73290 2 5RS OPERATION AND MAINTENANCE MANUAL 961 09 ONILNNOW S3GOON SIXV LNOYSs I3 0VvH8 31SNV Ov AONAL UALSVIN MIIA dOL MAIA 3GIS AO 73290 PART 9 RETROFIT 10 RETROFIT ONILNNOW H3GOON SIXV SSOHO MAIA Adis 1 3MOV88 3 19NV MOV uvdo LINN SAIC SIXV SSOSHO dOL PART 9 RETROFIT 11 AO 73290 2 5RS OPERATION AND MAINTENANCE MANUAL dO L AT8W3SSV 14 YSACOONA GPESO LIX I 80 1 NO av X Ad 031519395 29191 80 ET AL ONDIOOT SI M3SOS 138 SSIINN MINOS 138 5 SIHL X007 OL MIYOS LAS TIVLSNISY M3SOS LAS 9 UV39 TIO JAON3SMH ggzpgso0x SpL1067X I sorivove TTT TIL Z60SL LOV 2 GOAN Z LLLSLETX I Z ZULSLZIX m Z 0000 1 8E000 01x A 0800 CLX TVO00 0LX 80000 21X P 0Z0ZL OLX 0 1980 0 GOX 268 0 1 Z LLOOO ZIX el 134949 3H NI LIH 55644 ONIMVIUE
14. a la ana ana qana 6 2 8 2 nisi ern neben E the entente BAR UN UR 7 SHAPES3 3 SHAPE 3 RING sss tette nennen a aaa 8 SHAPES3 4 SHAPE 4 CHAIN RECTANGLE 1 9 SHAPES3 5 SHAPE 5 CHAIN RECTANGLE 2 10 SHAPES3 6 SHAPE 6 CHAIN CIRCLE a aaa ttt 11 SHAPES3 7 SHAPE 7 RIP MODE ttt ttt nennen 12 SHAPES3 8 SHAPE 8 FLANGE ananas tert nennen 13 SHAPES3 9 SHAPE 9 zoe ettet ett ita aee tao Mt te ed a adele de 14 SHAPES3 10 SHAPE 10 RING DEGREES seete ettet 15 SHAPES3 11 SHAPE 11 STRAIGHT 16 SHAPES3 12 SHAPE 12 LUG FRAME ttt ttt ttt 17 SHAPES3 13 SHAPE 13 SLANT 18 SHAPES3 14 SHAPE AA E A 19 73290 Table of Contents iii 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 15 SHAPE 157s WEDGE PAIR antun C Rb REEL ann 20 SHAPES3 16 SHAPE 16 STRAIGHT PIPE 21 SHAPES3 17 SHAPE 17 SLANT PIPE 22 SHAPES3 18 SHAPE 18 VERTICAL PROJECTION nn 23 SHAPES3 19 SHAPE 19 SLANT 24 SHAPES3 20 SHAPE 20 VERTICAL SLE OT xc Ha an 25 SHAPES321 SHAPE 21 gt SLANT SEO Wo
15. 11 FLOPPY DRIVE OPERATION u eee ee tee neck e tabe Dor eren ERE re 1 FLOPPY 1 EEOPPY DRIVES x iter rhet mete ee kaz ha rade 1 FLOPPY 2 ELOPPY UTIEITIES DISK eri uti ee S Sa um as a Recent u 2 FLOPPY 3 SERIAL CONNECTION m rea 2 FLOPPY 4 LOADING FILES FROM THE 2 3 FLOPPY 5 SAVING FILES TO FLOPPY DISK esses 0 4 PARIA4PARTPROGRAMMING inopi an 5 PROGRAMMING THE NC CONTROL I 1 WORD ADDRESS PROGRAMMING LANGUAGE U U U u uu 1 WADR 1 WORD ADDRESS L u ana 1 WADR 1 1 WORD ADDRESS DATA BLOCK SPECIFICATION sese 1 AO 73290 Table of Contents v 2 5RS OPERATION AND MAINTENANCE MANUAL WADR 1 2 5 ee ne 2 WADR 1 3 TP PROGRAM NUMBER 2 WADR 1 4 X DIMENSION FOR LINES OR ARCS L u 2 WADR 1 5 Y DIMENSIQON uu M 3 WADR 1 6 I DIMENSION FOR ARGS 4 WADR 1 7 J DIMENSION FOR ARCS 5 WADR 1 8 SPECIAL NOTE ON PROGRAMMING 5 WADR 1 9 G PREPARATORY 6 WADR 1 10 AUXILIARY 0 7 WADR 1 11 DWELL TIME naisissa eene metre de r
16. 73290 2 5RS OPERATION AND MAINTENANCE MANUAL BLANK PART 9 RETROFIT 14 AO 73290 PART 10 PRODUCT SPECIFICATIONS TAB PAGE PART 10 PRODUCT SPECIFICATIONS PRODUCT SPECIFICATIONS SPECS 1 PHYSICAL ENVIRONMENT OPERATING LIMITS Temperature 5 to 40 C Relative Humidity 5 to 85 1 g m3 to 25 g m3 Atmospheric pressure 86 kPa to 106 kPa Climatic Class 3K3 SPECS 2 ELECTRICAL SPECIFICATIONS The Burny 2 5RS 2 5 Plus is intended for use in heavy industrial environments It is not intended for use in commercial or light industry environment The electrical specifications for the various configurations of the 2 5RS can be found in the tables below At the end is the table of electrical specifications for the encoder electronics 2 5RS for REPLICATORT 900 using MO 09489 0 1 or 2 INTERFACE CARD See pins 31 and 32 below MO 02643 POWER OXY PIGTAIL And either MO 09498 010 DRIVE CABLE for 230 V Or MO 09499 010 DRIVE CABLE for 115 V DESCRIPTION RATINGS open dry contacts 2 A 230VAC maximum contacts Start Cut contact These contacts can be 32 27 configured as normally open or normally closed by jumper settings 177 and 18J on the 2 230V AC maximum interface card These are dry contacts 3 30VDC maximum 37 28 This is the other half of the Start Cut contact Stop Cut contact These contacts can be configured as normally open or normally 4 29 closed by jumper settings 22J and 237 2
17. amp 4 4 10 V13 Y ABS an sarah 57 SETUP amp CONFIG 4 4 11 V14 Y ENC 57 SETUP amp CONFIG 4 4 12 V15 Y ERROR a a a a 57 SETUP amp CONFIG 4 4 13 V16 YERSCL SETUP amp CONFIG 4 4 14 V17 Y HOME SETUP amp CONFIG 4 4 15 V20 RADERR 58 SETUP amp CONFIG 4 4 16 V21 RADSCL a a a 58 SETUP amp CONFIG 4 4 17 VARIABLES 22 49 a a a 58 SETUP amp CONFIG 4 4 18 50 INPUT a 59 SETUP amp CONFIG 4 4 19 V54 XCNTR 59 SETUP amp CONFIG 4 4 20 55 20 64 50000000 0 59 SETUP amp CONFIG 4 4 21 60 02 0060000 00 59 SETUP amp CONFIG 4 4 22 V72 X BACKLASH uu un uC E 60 SETUP amp CONFIG 4 4 23 V73 Y BACKLASH a a 60 SETUP amp CONFIG 4 5 MEMORY DISPLAY UTILITIES 60 SETUP amp CONFIG 4 5 1 SERV30 SINGLE WORD MEMORY DISPLAY 61 SETUP amp CONFIG 4 5 2 SERV31 DOUBLE WORD MEMORY DISPLAY
18. 2 DISPLAY 5 DSPYS80 CONFIG erii ertet cider ade di 3 SPECIAL F NGCTIONS 5 ee ELEC DE E 1 MANUAL CONTROL MOBDBE I I Re ie eror RE Rec Re 1 SPECFUNC 1 MANUAL CONTROL 1 SPECFUNC 2 PLASMA OXY FUEL CUTTING 2 SPECFUNC 2 1 OXY FUEL MANUAL CONTROL 3 SPECFEUNG 2 14 OXY PRHT GUT iiec tee 3 SPECFUNC 2 1 2 OXY ENABLE erinnert rennen tere ceti tin tan dika aree E rata Er 3 SPEGEUNG 2 1 3 OXY START inito ie tides tee eset et ema enden 4 SPECFEUNG 2 1 4 PREHERT Heer ee eb Eat esee Rap 4 SPECFUNC 2 2 PLASMA MANUAL CONTROL 8 a 4 SPECFUNG 2 2 1 PLASMA GUT ceret nitet p ae tiber doses 5 SPECFUNG 2 2 2 PLASMA CUT 406 5 SPECEUNG 2 2 3 PLASMA ENABLE 6 SPECFUNG 2 2 4 PLASMA START 02 6 SPECFUNG 22 5 HEIGHT DISABLE ee 6 SPECFUNC 3 FNC15 GO HONB X 7 SPECFUNC 2 1 GO HOME MENU 5 8 SPECFUNC 2 2 GO TO TABLE HOME FROM PART PROGRAMS sse 9 SPECEUNC 3 16 SET HOME 10 SPECFUNC 3 1 SETTING TABLE 1 HOME 10 SPECFUNC 3 2 SETTING TABLE 1 HOME
19. MACHINE INTERFACE SENSING INPUT Chassis Ground OVAC 0 25 A 115VAC 0 25 A 230VAC 0 110 A PART 10 SPECIFICATIONS 17 2 5RS OPERATION AND MAINTENANCE MANUAL 2 5RS with MNJ 10380 using MO 03502 X INTERFACE CARD MO 03561 CABLE SEE RATINGS OF PINS 31 AND 32 FOR THE DIFFERENT SUFFIXES 0 1 2 OF THE MO 03502 X INTERFACE CARD 2 5RS BACK PANEL 37 PIN EXT DRIVE CONNECTOR EXT DRIVE CONN ECTOR PIN NO DESCRIPTION RATINGS Speed reference input from customer potentiometer Speed Reference input Burny speed reference output Override output Hi true output signals that Burny 2 5 reference signal is being used not the customer reference signal Y drive reference output Y drive reference input X drive reference output X drive reference input Preheat Gas solenoid power contacts These are normally open dry contacts Start Cut contacts These are dry contacts Enable Cut contacts These are dry contacts Sense return for pins 32 and 33 Input PART 10 SPECIFICATIONS 18 Nominal 0 to 8 1V peak Maximum 5 4 to 10 8V peak 0 025 mA Maximums 30VDC 2 A or 60VDC 0 5 A 120VAC 8 2 7 2VDC 15 mA if Burny reference is used If customer signal is selected see pin 10 for specifications Pin 12 can sink 500 mA maximum a 50V maximum 23 4VDC 1 A Output If Burny signal selected output is 1 ma 15V If signal sele
20. To force the selection of a particular table for testing when the CURRENT TABLE display is showing enter a new index number 0 4 The appropriate table is copied into the running table area and immediately affects the operation of the machine Then pressing ENTER accesses the new table for adjusting AO 73290 PART 7 SETUP AND CONFIG 53 2 5RS OPERATION AND MAINTENANCE MANUAL Parameters which are not in the overlay tables can only be accessed and adjusted by using the SERV10 procedure Note that if SER V40 is used to access the 0 table only the overlayed parameters are displayed so that the 0 table appears the same as 1 4 Accessing the 0 table through SERV 10 allows all the parameters to be accessed Due to the additional memory required to store the multiple setup tables there is not sufficient RAM available to keep all the parameters available for access at any time Therefore when the machine is not running the RAM used to store the multiple tables is re used for other system purposes The parameters are recalled from the Non Volatile memory back to the operating RAM when a part is selected for running The parameters are also recalled to operating RAM when the RECYCLE key is pressed Therefore the parameters can only be entered or displayed either in the RECYCLE state or after a part has been selected for running and the Kerf Accel Decel and Part Rotation software has finished The parameters can be adjusted all the
21. DISTANCE BETWEEN PARTS IN MM 9 LEAD IN DIMENSION INCHES OR MILLIMETERS 10 LEAD OUT DIMENSION INCHES OR MILLIMETERS 11 VERIFY YES NO YES OR NO NOTES The only difference between parts created with LEFT PLATE or RIGHT PLATE enabled occurs in the traverse move to the first plerce point AO 73290 PARTS 2 SHAPES 31 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 27 SHAPE 27 FRAME CORNER RADIUS IN REPEAT PATTERNS 1 PLATE SIDE 10 a XE LEFT RIGHT 2 O 4 a s gt mE x EM gt 1 OUTSIDE WIDTH INCHES OR MILLIMETERS 2 OUTSIDE HEIGHT INCHES OR MILLIMETERS 3 INSIDE WIDTH INCHES OR MILLIMETERS 4 INSIDE HEIGHT INCHES OR MILLIMETERS 5 INSIDE RADIUS INCHES OR MILLIMETERS 6 ARC RADIUS i INCHES OR MILLIMETERS 7 KERF DIMENSION 2 WIDTH OF CUTTING TOOL PATH 8 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 9 LEAD IN DIMENSION INCHES OR MILLIMETERS 10 LEAD OUT DIMENSION INCHES OR MILLIMETERS 11 VERIFY YES NO YES OR NO NOTES The only difference between parts created with LEFT PLATE or RIGHT PLATE enabled occurs in the traverse move to the first pierce point as shown PART 2 SHAPES 32 AO 73290 SYSTEM OPERATION SHAPES SHAPES3 28 SHAPE 28 FRAME CORNER RADIUS OUT OUTSIDE WIDTH OUTSIDE HEIGHT INSIDE
22. E B E E 8 The sixth digit D6 only affects programs loaded using WADR3 or ESSII This digit allows the axis definitions of the incoming program to be changed to match the standard X Y axis definitions used by the 2 5RS Forced Auxiliary Code Priority In Word address programming it is possible to include auxiliary functions M and G codes in the same block as an X Y move or an Arc The 2 5RS follows the RS 274 specifications which specifies certain functions should be executed before the movement while others are done after the movement programmed in the same block is complete However some other NC controls assume that all auxiliary functions are done before any movement when they are contained in the same block So that these programs can be read without re programming the software has the ability to force all auxiliary codes to operate before the movement in the same block AO 73290 PART 7 SETUP AND CONFIG 31 2 5RS OPERATION AND MAINTENANCE MANUAL oi ws o os os os o os IF D6 IS EQUAL TO 0 X gt X Y gt Y Standard 1 gt X gt Y 2 X gt X Y gt Y 3 X gt X Y gt Y 4 X gt Y Y gt X 5 X gt Y Y gt X 6 X gt Y Y gt X 7 X gt Y Y gt X 8 X gt X Y Y and all Aux Codes Forced to High Priority 9 X gt X Y gt Y and all Aux Codes Forced to High Prior
23. ERROR 4 6 DATA COMM ERROR This error indicates that the handshaking controlling the communication did not work and that data was lost ERROR 4 7 FORMAT ERROR During a LOAD operation if the program being received does not match the specified program format type ESSI WORD ADDR ETC this error message is displayed ERROR 4 8 PROGRAM NUMBER WARNING When a program LOAD operation is complete the program number contained in the transmitted data is compared to the number requested by the operator Ifthese two do not match this warning occurs however the program is loaded as the number requested AO 73290 PART 8 ERROR 5 2 5RS OPERATION AND MAINTENANCE MANUAL BLANK PART 8 ERROR 6 AO 73290 PART 9 RETROFITS Tab Page Part 9 RETROFIT RETROFIT AND RETROFIT INSTALLATION RETRO GENERAL EXPLANATION OF A CNC RETROFIT The main reason to add a 2 5RS control to a cutting machine is to increase productivity The 2 5RS eliminates the need to use a template The 2 5RS also adds accuracy to the shape being cut and makes the operator s job of cutting easier The objective of the installation section is to graphically explain the mounting of necessary hardware utilized by the 2 5RS to run the cutting machine A 2 5RS can be installed on almost any cutting machine with an X Y coordinate drive system The 2 5RS provides NC control with the capability of switching back to photocell control if it is desired At the end
24. INCHES OR MILLIMETERS INCHES OR MILLIMETERS WIDTH OF CUTTING TOOL PATH DISTANCE BETWEEN PARTS IN MM INCHES OR MILLIMETERS INCHES OR MILLIMETERS YES OR NO NOTES The slot pattern defined is automatically centered on the part from top to bottom and left to right The operator must determine that the height and width specified can contain the slots AO 73290 PARTS 2 SHAPES 49 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 45 SHAPE 45 LAMP BASE th 9 91 el N MT 1 gt 6 11 F 10 WIDTH DIMENSION HEIGHT DIMENSION BOLT HOLE DIAMETER X BOLT HOLE CENTER Y BOLT HOLE CENTER CENTER HOLE DIAMETER CORNER RADIUS KERF DIMENSION 9 SCRAP DIMENSION 10 LEAD IN DIMENSION 11 LEAD OUT DIMENSION 12 VERIFY YES NO tn gt PATTERNS PLATE SIDE LEFT RIGHT INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS WIDTH OF CUTTING TOOL PATH DISTANCE BETWEEN PARTS IN MM INCHES OR MILLIMETERS INCHES OR MILLIMETERS YES OR NO NOTES The hole pattern defined is automatically centered on the part from top to bottom and left to right If a CENTER HOLE DIAMETER of 0 is defined no hole is cut If a COR
25. OL SIHL ONIN 104 LON 5300 UNS JAVA A 1343234 Z 906001 SL34OY amp 4 JHL S43HM INIO4SHL OL 1 INN NIS001 AllS a LON SISMOVeJS dH1 ULNA LAN SHE N3IHOLL ONINSNL Wows 1109 3H1 AO QV3H 3HL OL HONSYM NY 3SN SV SONIAY3E LSN AY X SprLO ON 0 0 X CG6 0 ON S vL 8CX LON AO 73290 RETROFIT 12 PART 9 RETROFIT c JOc ZELZL OO NOILVOO 1 ONIAIS 8 NOILISOd ONILNNOW H3OOON3 QNHVONVIS ONIdS JO NOLLOSIO 3H1 S31VOIONI Z S3NI HOVI A LIHOP VIN IHL H3AOO CINOHS S3SVO NI HOM LON AVI 1 ONIHdS SIHLSTIHM SNOLLISOd 9 TTV NI S4dO4d JHL ONISIS JHL 9NINOLLISOd3H Ag SNOLLWUNOIANOO SNI LANON OISV8 9 AINO Suv YOYA JHL OL TaTTWavd s3d09N3 ANY 1108 10Ald 3HL 1VH1 OS ish LaMOWNE 83009N3 32 6 411934009 N3HM 30304 SONNOd p AHLYNIXOYddY SACIAONd ONIX dS JHL OVE JHL OLNI HV3 NOINId OL ONIMdS Wv38 OSIV 591035 OZH SHL ONISN ISW3SSV ISYOVYE SCOONS ANANA JHL CL NOLLdI4OS3Q ONIAIS Wad L330V38 YSCOONS 3LON RETROFIT 13 9
26. u 8 as i a f 7 2 1 BASE WIDTH INCHES OR MILLIMETERS 2 TOP WIDTH INCHES OR MILLIMETERS 3 LEFT HEIGHT INCHES OR MILLIMETERS 4 RIGHT HEIGHT INCHES OR MILLIMETERS 5 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 6 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 7 LEAD IN DIMENSION INCHES OR MILLIMETERS 8 LEAD OUT DIMENSION INCHES OR MILLIMETERS 9 VERIFY YES NO YES OR NO NOTES Like others this part is cut with the BASE at the upper position As a result the prompts used to label the top and sides assume the part is rotated 180 degrees The only difference between parts created with LEFT PLATE or RIGHT PLATE enabled occurs in the traverse move to the first pierce point as shown AO 73290 PARTS 2 SHAPES 45 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 41 SHAPE 41 TRAPEZOID REPEAT PATTERNS 1 PLATE SIDE LEFT RIGHT i NZ 4 4 2 1 BASE WIDTH INCHES OR MILLIMETERS 2 TOP WIDTH INCHES OR MILLIMETERS 3 HEIGHT DIMENSION INCHES OR MILLIMETERS 4 LEFT OFFSET INCHES OR MILLIMETERS 5 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 6 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 7 LEAD IN DIMENSION INCHES OR MILLIMETERS 8 LEAD OUT DIMENSION INCHES OR MILLIMETERS 9 VERIFY YES NO YES OR NO NOTES Like others this part is cut with the BASE at the upper position and the TOP at the lower position However the LEF
27. when the correct response is displayed Ifa start point or repeat direction is requested use the outside row of keys on the numeric keypad 1 9 to indicate the correct corner or direction Once the correct direction is indicated on the readout press ENTER Invalid entries for a particular prompt are ignored Start point or repeat direction TOP RIGHT TOP UP BOT DN Once all the prompts are answered a verification prompt appears YES VERIFY NO To verify the input data which starts the prompting over again press the key one time causing the YES to begin flashing Then press the ENTER key to review the input data Use the ENTER key to step through the prompts and correct any values as needed After all prompts have been answered correctly the 2 5RS creates the part program The following prompts are displayed COMPUTING The input data is being processed PROGRAM LOADED The program has been created Press RECYCLE to return the MAIN FUNCTION MENU Go to RUNNING THE PART in this manual for directions on actually running the program PART 2 SHAPES 2 AO 73290 SYSTEM OPERATION SHAPES SHAPES 2 DIMENSIONS COMMON TO MOST SHAPES In addition to the actual dimensions of the part most of the 53 SHAPE PROGRAMS also prompt for the following KERF SCRAP LEADIN LEADOUT The standard shapes also prompt for a KERF value along with the part dimensions Since all controls are no
28. 01617 4107 40425 48510 52552 5 3901 re ee Deren BEER ee ee eee oh SP 360 W ENCODER INLINE MO 11784 321 MO 11343 321 MO 09201 350 8 9 MT 3528 297CF 34 0 28 24 2165 29 14286 0 1617 4 107 4 0425 22 66667 5 281 8 2165 20 40000 0 230999 5 867 pcc Eu 250 6 4 4257 138 47 87 2857 71 8050 4237 158 1 8050 EN Be TE 4237 138BF SP 150 W ENCODER INLINE MO 11783 321 11344 321 MO 08934 1 MT 2630 141AF 191 20 30 1824 28 65000 0 164481 4 178 4 1120 4 9344 5 3456 5 4828 SP 150 W ENCODER INLINE 11783 421 NONE MO 09501 0 MT 2630 141AF 2158 22 6000 0 208513 5 296 4 1703 5 0043 5 4213 5 5605 SP 150 W ENCODER INLINE MO 11783 521 11344 521 MO 08794 1 MT 2630 141AF 19 1 24 28 2364 22 28333 0 211476 5 371 4 2295 5 0754 5 4984 5 6395 SP 150 W ENCODER INLINE 0 11783 821 11344 821 0 09267 MT 2630 141AF 19 1 30 20 2162 12 73333 0 370083 9 400 4 6260 5 551 6 0139 6 1682 m i 23 es meer TN Bez Bere 1 8050 p 2857 71 80500 0 087503 2 223 Bere 2857 71 80500 0 087503 2 223 KIN 2857 71 80500 0 087505 2 N N olo 4 SI CA C4 gt R
29. 12 VERIFY YES NO NOTES The CUT DIRECTION prompt defines the outer diameter cut direction The inner direction is always opposite so that the same KERF side LEFT RIGHT can be used for both cuts The STARTING POSITION and REPEAT DIRECTION parameters can be directly entered with the numeric keypad The actual LEAD OUT position is determined by the direction of the cut The figure above shows the LEAD OUT position assuming a clockwise cutting direction has been selected When running the resulting NC part program position the torches at the CENTER of the first part regardless of the REPEAT MODE selected When performing AUTO REPEAT mode operations parts are shifted to the left and right at a 60 degree angle LEAD OUT TYPE 0 is 10 degrees to tangent LEAD OUT TYPE 1 follows LEAD IN path PART 2 SHAPES 58 AO 73290 SYSTEM OPERATIONS RUNNING A PROGRAM RUNNING A PROGRAM This section of the manual describes the procedures used to actually cut the desired shape This occurs after the shape has been selected and all necessary data entered or after a new part has been constructed or taught RUN 1 PLASMA OXY FUEL SELECTION Many of the machines equipped with a 2 5RS control will only use one type of cutting process either plasma or oxy fuel In these cases the setup parameters can be set so that the correct cutting mode is selected automatically However if the machine has both cutting systems a prompt will appea
30. 2 5RS OPERATION AND MAINTENANCE MANUAL The SCRAP value provides the spacing between parts as they are repeated down the plate The accuracy of this scrap dimension is just as good as the actual part itself therefore the value can be set fairly small with good results Typical SCRAP value for OXY FUEL CUTTING can be anywhere between 1 to 5 2 5 mm to 12 mm Note that the SCRAP dimension must allow for the anticipated cutting kerf if the Dial in Kerf feature is to be used when the part is cut see KERF description above The LEADIN dimension is the distance from the part to the pierce point Since the piercing operation is sometimes unpredictable the leadin dimension should be set so that the plate is pierced and the cut has stabilized before it reaches the actual part Normal values range from 25 to 1 00 6mm TO 25mm The LEADOUT dimension is programmable for each of the standard shapes and causes the torch to cut away from the part before the cutting oxygen is turned off This prevents any damage to the cut part due to the bleed off characteristics of the torch In addition on heavy plate cutting the leadout move guarantees that the bottom of the part has been cut completely before the oxygen is turned off Normal values are from 5 to 1 12mm to 25mm For plasma systems the LEADOUT should be adjusted to properly time the turn off of the arc If the leadout is too long cut parts will fall out of the
31. If Burny signal selected output is 1 ma 15V If signal selected is customer signal from pin 18 then maximums are the same as for pin 15 z Maximums 30VDC 2 or 6 X drive reference input 0 5 A 120VAC 2 A 25 26 Preheat Gas solenoid power contacts These 2 230VAC maximum or are normally open dry contacts 2 30VDC maximum 2 A 230VAC maximum or 27 28 Start Cut contacts These are dry contacts 2 30VDC maximum PART 10 SPECIFICATIONS 24 AO 73290 X drive reference output 29 30 PRODUCT SPECIFICATIONS 2 230V AC maximum or Enable Cut contacts These are dry contacts 2 30VDC maximum 115VAC 15 mA See the operator 31 32 5 2 the 2 5RS that the section MACHINE INTERFACE cutting oxygen is operating SENSING INPUT Protective ground from machine power source Chassis Ground Neutral conductor of machine s power source 0 25 A 36 AO 73290 Input pin for powering the 2 5RS from a 115VAC machine power source eas BACK PANEL AND CENC 9 PIN ENCODER CONNECTORS DESCRIPTION RATINGS Analog Ground This output is derived from the customer s 12 Volt supply that is connected to the 2 5RS 12VDC output 37 pin back panel Ext Drive connector pin 4 It is not normally used but is for special installations where encoders require 12 Volt power c l s input from encoder 15V
32. NOTES The only difference between parts created with LEFT PLATE or RIGHT PLATE enabled occurs in the traverse move to the first pierce point as shown PART 2 SHAPES 34 AO 73290 SHAPES3 30 1 O Q Q LS Re 7 8 A 4 OUTSIDE WIDTH OUTSIDE HEIGHT INSIDE WIDTH INSIDE HEIGHT KERF DIMENSION SCRAP DIMENSION LEAD IN DIMENSION LEAD OUT DIMENSION VERFY YES NO SYSTEM OPERATION SHAPES SHAPE 30 RECTANGULAR FRAME REPEAT PATTERNS PLATE SIDE LEFT RIGHT x s 7 x INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS WIDTH OF CUTTING TOOL PATH DISTANCE BETWEEN PARTS IN MM INCHES OR MILLIMETERS INCHES OR MILLIMETERS YES OR NO NOTES The only difference between parts created with LEFT PLATE or RIGHT PLATE enabled occurs in the traverse move to the first pierce point as shown AO 73290 PARTS 2 SHAPES 35 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 31 SHAPE 31 UNIVERSAL FRAME REPEAT PATTERNS PLATE SIDE LEFT RIGHT 7 HM e 15 BAR 9 10 2 20 8 11 quu 7 oy 5 FOOT O EXAMPLE SHAPES RIGHT THICKNESS B LEFT INNER RADIUS 9 T LEFT IN
33. PART 7 SETUP AND CONFIG 50 AO 73290 SETUP AND CONFIGURATION SETUP amp CONFIG 4 2 57 SDA0 X LASH inches Amount of backlash in the Y axis SETUP amp CONFIG 4 2 58 SDAI Y LASH inches Amount of backlash in the Y axis SETUP amp CONFIG 4 2 59 SDA2 LASH RATE inches The desired maximum physical increment of backlash compensation to be applied each 8 ms scan position cycle This parameter can be used to control how fast backlash is compensated For example if 050 inches is entered and the lash is 100 the lash would be corrected with two steps of 050 inches and would take two position scan cycles or 16 ms If 025 inches was entered for the lash rate the same lash compensation would take four steps of 025 inches and 32 ms SETUP amp CONFIG 4 3 MULTIPLE SETUP PARAMETER TABLES Due to the different types of cutting tools which may be included on the same machine router water jet plasma etc the setup parameters need to be set differently for each type of tool The 2 5RS has the ability to do this and get optimum performance out of the tool being run This ability is accessed through Service Mode 10 SYSTEMS DATA which has 4 additional overlay tables selectable by a code followed by a select number in the part program Each table can be setup to provide optimum performance for a particular tool and then called by the program before the cutting begins The overlay tables do not contain the entire list
34. Preheat relay contacts PART 10 SPECIFICATIONS 8 AO 73290 PRODUCT SPECIFICATIONS 115VAC 15 mA Input With jumper 157 installed this input is designed for 24VAC or DC 12 ma Resistors IR and 5 R on interface card should be scaled accordingly Cut sense input to signal the 2 5RS that cutting oxygen is operating 2 5RS for RETROFIT with MNJ 10380 MO 07542 INTERFACE CARD MO 05376 CABLE MO 07422 PIGTAIL PIGTAIL MO 07422 PIGTAIL WIRE DESCRIPTION RATING NUMBER Signal Ground Positive supply power output 24VDC 40 mA Output encoders for encoder setup Bad C Analog Ground Speed reference input from customer s speed Nominal 0 to 9 16V peak If Burny signal selected output is 1 ma 15V If signal selected is customer signal from pin 15 then maximums are the same as for pin 15 zs Maximums 30VDC 2 A or 60VDC 0 5 This is the Y drive reference input 120VAC Q2 A Sandy Dave ee 0 to 1 35VDC High 4 4 to If Burny signal selected output is 1 ma 15V If signal selected is customer signal from pin 15 then maximums are the same as for pin 15 pa Maximums 30VDC 2 A or 60VDC 0 5 This is the X drive reference input 120 2 A 25 26 Preheat Gas solenoid power contact These are 2 A 230VAC maximum or normally open dry contacts 2 30VDC maximum 2 230V AC maximum or 27 28 Start Cut contact These are dry conta
35. SD62 SYSTEM CONFIGURATION 2 D5 enables or disables deceleration for the pressing of or the release of the backup button and also swaps offsets 1 and 2 with offsets 3 and 4 if plasma is selected The selection of the accel decel for the Backup button was added based on customer requests The normal operation of the backup button is to decel to a stop and then reverse direction Similarly when the button is released the machine would again decel to a stop and then change directions and resume motion along the cut path Some customers preferred that there is no accel decel when this button is pressed or released to give them finer control over the machine by changing directions as soon as the button is pressed or released WARNING With no accel decel the machine will change directions abruptly which could cause damage to the drive system It is recommended that if this bit is set that the SD06 BACKUP SPEED parameter is set to a very slow setting and that the operator use caution when pressing this button when the machine is traveling at higher speeds The selection to swap the marker offsets allows the programmer to use the same offset number to select the same marking device whether the machine is cutting with Oxy Fuel or Plasma Without this function the programmer would have to use Offset 1 for example to move from the Oxy Fuel Torch to Marker 1 but would have to use a different offset Offset 3 to move from the Plasma torch
36. TERMINAL BLOCK LABELED V 09 AND RED WIRE TO CTI 2 or 1 2 CONNECT EXTENSION m IRE CABLE TO RIBBON FROM 7 THREAD ALL WIRES AND RIBBON CABLE FROM MO 06354 ADAPTER THROUGH BEEPER HOLE IN BACK OF CABINET RECONNECT BEEPER HARNESS TO NEW PLUG STEP REMOVE 4 MOUNTING 1 BEFORE INSTALLING UNIT REMOVE SCREWS HOLDING CARDS GASKET AND SET SELECTOR SWITCH TO FRONT PANEL FOR R5 3 OR RS422 OPERATION INTERNAL VIEW OF MO 06354 AFTER GASKET IS REMOVED INTERFACE CARD GP _ Hm d rr PROCESSOR 2 3 CARD FRONT PANEL R5422 R5232 SET ALL THREE SWITCHES TO SAME DIRECTION CAREFULLY REMOVE KEYBOARD PLUG FROM PINS ON MAIN PROCESSOR CARD RE CONNECT KEYBOARD PLUG 10 INSTALL 10 PIN RIBBON CABLE PINS ON MAIN PROCESSOR EXTENSION IN YZRCA ON RE INSTALL 4 MOUNTING SCREWS ee Pree eee abu ASSEMBLY FINAL B2 5 TO ATTACH BOARDS TO FRONT PANEL FOLD CABLE AT AND ROUTE BETWEEN PROCESSOR CARD RS232 422 ADAPTER RE ASSEMBLE REMAINDER OF UNIT AND FRONT PANEL 2271 er aa C0 73153 EXCEPT AS NOTED DECIMAL BLANK 0 4 5 400 4 700 0 350 0 350 7 FINISH DO_NOT PAINT INSIDE OF CABINET SEE DETAIL A PAINT ALL OVER BLACK POLANE WITH SPATTER FINISH 3 17 4 000 0 281 DIA THRU 4 HOLES D 2 000 AP AP
37. When the alternate language feature is enabled the control switches to the new language automatically at power up However for service personnel and in cases where the translation is not clear the prompts may be switched back to ENGLISH On older front panels this may be done by pressing the DOT key which is directly above the RECYCLE key on the panel On newer front panels the SHF and DSP Y keys should be pressed within two seconds of each other Pressing these keys toggles the display between English and the alternate language OPSUMMARY 3 AXIS DEFINITIONS Several places in this manual refer to the X and Y axis of the machine These are defined as X AXIS The main longitudinal rail axis of the machine The direction away from the operator is defined as X and toward the operator is defined as X Y AXIS The cross or traverse axis of the machine The direction to the left is defined as Y and to the right as Y AO 73290 PART 1 OPSUMMARY 3 2 5RS OPERATION AND MAINTENANCE MANUAL OPSUMMARY 4 CUTTING SPEED CONTROL The cutting speed is controlled by the operator using the speed dial and the HI LO OFF selector switch or by the NC programmer with the insertion of feedrate commands in the actual part program The traverse speed used to get from one cut to the next is preset during installation This allows the speed dial to be set at a slow speed for the cutting process and still move at a high speed to get from
38. Allow enough cable for proper routing with existing machine cables PART 9 RETROFIT 4 AO 73290 RETROFIT c869 70V OV ddV3S JO ONILNNOW S3HONI SNOISNAWIG T1V ALON dV L 9 ONIOWdS 310H Q3aN3WINOO3 HV39 UNdS 14 9 S39V 1d Z NIN I2 0 dvi 9 dd XVN 8270 UA 9901 9 sN 0022 319NV 35055348 02 49V4 YVAN YNdS dd 01 1 dd 6SIt l PART 9 RETROFIT 5 AO 73290 2 5RS OPERATION AND MAINTENANCE MANUAL AT8IN3SSV L33VH8 MOVH HV39 AO 73290 SNOILI3S 2 HV39 H9 OML 30 LNIOd NOILONAL NOILD3S MOVE HV39 H9 SNOILOSS H9 N33ML38 HS3W H3dOHd NOLLINNAF JHL SSOHOV Q3LU3ANI Q30V ld MOVE 8 39 30 35314 LYOHS Yu M V L3Q d62 sN SAVITI1IM 8810 621 621 WNNINNIY STONY 310 335 MOVE Vu 71 130 335 NOILOSS 2VH uv39 H9 a3sn SI GOHLAW 31 3HVO 3W341X3 SASIONAXS 319 OL 03073M WOVL HO 8 0311180 38 NV2 2vH NV39 310N PART 9 RETROFIT 6 RETROFIT LL96L OV SLAMOVY ATONV ONIZIILLN ONILNNOW L330V88 MOVE HV39 LSNA ONILVINNNDOV V39 JHL IN3A34d OL INOQ SI d 9NIOV3 U3A3N LHOTH YO 14 1 OL HO NMOG GINOHS HLASL MOV HV39 L3s40vi8 NO NOVY UV39 ONILNNOW TWOIdAL CL 3LON PART 9 RETROFIT 7 AO 73290 2 5RS OPERATION AND MAINTENANCE MANUAL 81 96L Og8 ATEWASSV LIMDVAI H3QOOON3
39. FOR STARTS PURGE OR IF PLASMA DELAY CYCLE TIME STOP IS WAIT TILL SD01 PRESSED ARC ON IS SENSED GOTO 4B OPEN BACKU OPEN BACKU PLASMA OPEN OPEN DISAB NOTE BACKU Assumes plasma cutting has been selected either by the combination of setup parameters or by the operator selecting plasma cut mode before the part is run NOTE HEIGHT DISABLE CONTACT remains closed until machine accelerates to cutting speed It then opens to allow height sensor operation The contact will close again if machine slows for a corner in the part program or if the HEIGHT SENSOR DISABLE function code is read from the part program AO 73290 PART 7 INTERFACE 11 2 5RS OPERATION AND MAINTENANCE MANUAL PLASMA CUTTING AUTOCUT RELAY SEQUENCING CUTTING BACKUP PATHIS PRESSED COMPLET E OR IF CYCLE STOP IS PRESSED GOTO 4B OPEN OPEN OPEN CLOSE CLOSE CLOSE CLOSE OPEN OPEN ENABLE 7 pun OPEN OPEN OPEN OPEN CLOSE CLOSE CLOSE OPEN OPEN PLASMA OPEN HEIGHT OPEN OPEN OPEN OPEN CLOSE CLOSE CLOSE OPEN OPEN DISABLE NOTE NOTE HEIGHT DISABLE CONTACT remains closed until machine accelerates to cutting speed It then opens to allow height sensor operation The contact will close again if machine slows for a corner in the part program or if HEIGHT SENSOR DISABLE function code is read from the part program PART 7 INTERFACE 12 AO 73290 PART 8 ERROR MESSAGES Tab Page Part 8 ERROR MESSAGES ERR
40. If there is no internal floppy the RS232 port can be used to send the programs out to a host computer This requires software in the host computer that is capable of accepting the programs from the 2 5RS and storing them to a disk file After the programs are sent to the computer Back up copies of the computer programs should be made and stored AWAY from the computer Finally there are portable floppy disk systems available which can accept programs from the 2 5RS RS232 port and store them directly to a floppy disk Again more than one copy is advised IT IS THE CUSTOMER S RESPONSIBILITY TO MAINTAIN BACKUP COPIES OF ALL IMPORTANT PROGRAMS AND TABLES ALL PROGRAMS MUST BE BACKED UP BEFORE ANY SERVICE WORK OR NEW SOFTWARE UPDATE IS DONE TO THE CONTROL THIS WILL PREVENT ANY LOSS OF PROGRAM INFORMATION SERVICE 6 REPLACING THE BURNY 2 5RS MEMORY BATTERY The battery should be replaced every five years to ensure proper operation of the battery backup system A replacement battery can be obtained from Burny To replace the battery l Ensure that all files and tables are backed up as in the section of this manual Backup of Programs and Tables Stored in Burny Controls 2 Disconnect the unit from all cables and wires keeping notes as to the proper method of reconnecting the cables and wires Open the 2 5RS by removing the screws visible on the front panel 4 The circuit boards mounted to the front panel should be removed
41. PART 7 INTERFACE 8 AO 73290 SETUP AND CONFIGURATION INTERFACE MACH 2 13 CUT CONTROL RELAY OUTPUT SEQUENCING DIAGRAMS 1A 1B 1 POWER OFF AFTERPOWERUP PRESS RECYCLE OXYGEN ENABLE OXYGEN START CONTACT OPEN OPEN OPEN HIGH PREHEAT CONTACT OPEN OPEN OPEN MANUAL OXY FUEL CUTTING SEQUENCE This sequence will be followed when oxy fuel cutting is selected either by the combination of setup parameters or by the operator selecting oxy fuel cutting when the part is run WAIT FOR OXY SENSE OXY SW INPUT ATANY SENSE To TIME INPUT SENSE CUTTING IF CYCLE OFF PATHIS SUR COMPLETE IR OXYGEN PUSHED ISON GOTO ae GO TO2B START CUT MOTION ENABLE OXY CUT CIRCUIT IF BACKUP IS PRESSED DURING THIS TIME GO TO 2C OXYGEN ENABLE OPEN OPEN OPEN CLOSE CLOSE OPEN OPEN OXYGEN START OPEN OPEN OPEN CLOSE CLOSE OPEN OPEN HIGH PREHEAT OPEN OPEN OPEN OPEN OPEN OPEN OPEN AO 73290 PART 7 INTERFACE 9 2 5RS OPERATION AND MAINTENANCE MANUAL OXY FUEL AUTOCUT RELAY SEQUENCING Tr I CUTTIN G IF OPEN OPEN OPEN OPEN OPEN CLOSE CLOSE FOR OPEN BACKUP OPEN OPEN OPEN OPEN OPEN CLOSE CLOSE FOR OPEN BACKUP OPEN OPEN OPEN CLOSE OPEN OPEN OPEN OPEN PART 7 INTERFACE 10 AO 73290 SETUP AND CONFIGURATION INTERFACE PLASMA CUTTING MANUAL CUT RELAY SEQUENCING CUTTING CUTTING 5 MOTION COMPLETE OPERATOR
42. RUNNING A PROGRAM RUN 2 2 PART ROTATION If the part rotation option is enabled a prompt will appear for the desired rotation angle ROTATE XXX XX Enter the desired rotation degrees 0 00 is the original programmed position A positive angle indicates a counter clockwise rotation A negative angle may also be entered for a clockwise rotation however it will be converted to its equivalent positive angle position If the part is re run the positive equivalent angle will appear not the negative Example If 45 00 degrees is entered for the rotation it will be stored as 315 00 RUN 2 3 X Y AXIS MIRROR If the MIRROR IMAGE OPTION is enabled two prompts will appear The first is for the X axis X MIRROR NO Pressing the key will toggle the flashing response between NO and YES Press the ENTER key when the desired response is shown A NO response causes the X axis to be cut as programmed The YES response causes the X axis to be inverted so the part appears UPSIDE DOWN on the plate After the X mirror selection is entered the prompt will change to Y MIRROR NO Again toggle the selection with the key and enter the desired choice As before the response causes no change in the part while the YES response will mirror the Y axis which reverses the left to right appearance of the part RUN 3 KNIFE COMPENSATION The KNIFE COMPENSATION option allows a spec
43. SD82 SD83 It was normally used to offset for plate marker 2 Once the marker 2 portion of the program is done the offset is canceled by using the OFFSET 2 OFF COMMAND Note that this function could also be programmed by using M71 T2 as described above PART 4 WADR 12 AO 73290 PART PROGRAMMING WORD ADDRESS M71 OFFSET 1 ON Causes the machine to offset from it s current position based on the values in the setup parameters described later One use of this function is with a plate marking device This command is used to offset the machine position so that the marking device is now aligned where the cutting torch used to be This allows the dimensions for the marking portion of the program to be programmed the same as the cutting moves since the marker has been shifted into the same position that was previously occupied by the torch After the marking moves are done the corresponding offset off command is used shift the cutting torch back to the proper position so that the program can continue with the torch now at the programmed coordinates Ifthe M71 is used alone in a data block it will cause the machine to offset based on the setup parameter values SD40 SD41 also SD80 SD81 This supports existing programs where the M71 command was desiginated as the OFFSET 1 ON function code Note that the following parameters specify the same offset dimensions The lower numbers are retained for compatibilty with older software SD40 Same
44. SPECIAL FUNCTION mode To enter this mode the control must be in the RECYCLE state RECYCLE key was just pressed Then press the key to enter the SPECIAL FUNCTION menu Use the SCROLL keys or enter the desired number directly to select from the following menu FNC00 EXIT MODE Exits back to main menu FNC01 MANUAL CUT Manual control of cutting outputs or stripping cutting up remnants and testing cut control outputs FNC15 GO HOME Return to one of 4 fixed home reference positions FNC16 SET HOME Reset machine Reference 0 0 position after power failure MANUAL CONTROL MODE SPECFUNC 1 MANUAL CONTROL MODE The MANUAL CONTROL MODE in the 2 5RS gives the operator direct control of the cutting control relay outputs This permits several types of operation Cutting processes Plasma or Oxy Fuel can be turned ON OFF and used in conjunction with the JOG controls to cut up scrap material or for stripping plate Cutting processes can be turned on before a part program is cut to check gas pressure and cut quality Individual control relays can be turned ON OFF to aid in installation and troubleshooting AO 73290 PART 3 SPECIAL FUNCTIONS 1 2 5RS OPERATION AND MAINTENANCE MANUAL SPECFUNC 2 PLASMA OXY FUEL CUTTING SELECTION As was described in the section on RUNNING THE PROGRAM there are only 3 relays in the 2 5RS for controlling the cutting process If both OXY FUEL and PLASMA are used on a machine the
45. extension is set by SD53 FILE EXTEN See INSTALLATION amp SETUP FLOPPY 1 FLOPPY DRIVES The 2 5RS DISK DRIVE is able to load and store part programs to 3 720K or 1 4 Meg floppy disk The floppy drive is treated as a serial device This gives the user flexibility to use available features such Auxiliary Code Table Decimal Shift and Axis swap Programs that are loaded from and stored to the floppy disk are treated the same as they would be if loaded or stored through the serial port The 2 5RS EXTERNAL DISK DRIVE is available in 2 configurations 1 2 5RS DISK DRIVE PORTABLE It allows loading and storing of programs from the 2 5RS 2 2 5RS DISK DRIVE PORTABLE with KEYPAD and LCD Display This version allows loading and storing of programs from the 2 5RS control It also has a keypad and LCD display which allows for manual operation of the unit The manual operation allows the flexibility to use the unit with other controls that support RS232 serial communications The 2 5RS DISK DRIVE is 10096 compatible with the MS DOS and PC DOS floppy disk format Files may be copied to and from a 2 5RS DISK DRIVE diskette by using the DOS COPY command AO 73290 PART 3 FLOPPY 1 2 5RS OPERATION AND MAINTENANCE MANUAL NOTE The 2 5RS DISK DRIVES are only compatible with the United States versions of MS DOS and PC DOS operating systems FLOPPY 2 FLOPPY UTILITIES DISK The FLOPPY UTILITIES amp TEST PROGRAMS disk that is s
46. gt mode and begin tracing the template In the lt lt CUT ON gt gt mode the actual path or CONTOUR of the part will be stored for playback later When the cutting path is complete the operator should leadout away from the template and then switch back to the lt lt CUT OFF gt gt mode before moving to the next pierce point Use the CYCLE START AND CYCLE STOP buttons to turn the teach cut on and off Pressing the CYCLE START will switch to the CUT ON CONTOUR mode while pressing the CYCLE STOP will go back to the CUT OFF POINT TO POINT positioning mode This will work for either Plasma or Oxy Fuel cutting systems The remainder of this description refers only to lt lt CUT ON gt gt or CUT OFF gt gt and does not specify the method used to make the selection The unit will BEEP any time the mode is changed and the display will indicate the cutting status along with other information When the CUT OFF gt gt mode is selected the display will first show CUT OFF PT TO PT then the X Y position data will return with a flashing minus sign in the center of the screen to indicate the CUT OFF state About every 7 seconds a second message will appear which shows the amount of memory remaining for storing the part During the lt lt CUT OFF gt gt mode the path of the machine is not stored only the last position before the cut is turned ON again Thus from the end of one cut segment
47. pe paka ESA kuskay 1 ERROR 1 ERRORS FROM PROGRAM OPERATIONS 1 ERROR 1 1 DUPLICATE PROGRAM 2 1 ERROR 1 2 _ PROGRAM LIST EMPTY iiaee aena ti tee ehe tete eer dee tne od ren na 1 ERROR 1 3 ENTER PROGRAM 1 ERROR 1 4 NO PROGRAM FOUND e taeda di Fas 2 ERROR 1 5 4 MEMORY DISABLED 4 2 ERROR 1 6 PROGRAM MEMORY 2 ERROR 1 7 END OF LIST nente mee lan LEE 2 ERROR 8 0 BYTES IN PROGRAM iecore 2 ERROR 1 9 RECYCLE ERROR nte sasa ce rear Laden Rd ede aa ch RR nenn 3 ERROR 1 10 DATA ERROR RESET 3 ERROR 1 11 RESET MODE ONLY uu 3 ERROR 2 RUN TIME ERROR Suiriri rinasa usa ansa na ul ss S u 4 ERROR 2 1 MEMORY TRIP WHILE 4 ERROR 22 BATHFERROR u a amu m a 4 ERROR 3 TEACH MEMORY L L L n SSS 4 ERROR 4 ERRORS DURING SERIAL I O OPERATIONS u 4 ERROR 4 1 READ TIMEOUT 4 ERROR 4 2 WRITE TIMEOUT 5 3 PARITY ERROR eet ett eer Na usa 5 ERROR 44 OVERRUN ERROR tee ed eie Alea dete rn el 5 ERROR4A 5 FRAMING ERROR tetti toten tc antenne con Ede da depo 5 ERROR 4 6
48. required to extend the distance of the transmission it is recommended that some sort of modem or transient protection device be installed at the host computer to protect it from line induced noise Most computers have only RS 232 level serial ports Therefore most computers will require an RS 422 to RS 232 converting modem This has two benefits First it provides the long distance transmission capability of the RS 422 signals Second if the proper type of modem is selected it will provide complete electrical isolation between the long transmission wire and the computers sensitive serial port The 2 5RS has such a modem available as an accessory item Part number MO 06707 0 includes a 115VAC adapter while MO 06707 1 includes a 230V AC 50 60HZ adapter This modem provides the proper electrical isolation to protect the host computer port Since the 2 5RS RS 422 port only supports the TRANSMIT and RECEIVE lines Hardware RTS CTS handshaking isn t possible Therefore the host computer must use SOFTWARE HANDSHAKING XON XOFF characters to control the data flow between the 2 5RS and the host computer SIGNAL LEVELS ARE RS 422 COMPATIBLE ONLY THE FOLLOWING SIGNALS ARE USED IN THE RS 422 MODE SIGNAL UO NAME PORT A DESCRIPTION SHIELD PIN 1 PROTECTIVE SHIELD DO NOT CONNECT TO SIG GND 2 B RECEIVED DATA INPUT FROM 2 5RS PIN 3 B TRANSMITTED DATA OUTPUT FROM 2 5RS PIN 4 5 VDC 25mA PIN 5 12 VDC 25mA PIN 6 12 VDC 25
49. these specific tests must be performed on the completed installation Non accessibility Test Performance Test Insulation Resistance Test greater than 0 5 MOhm measured from AC input to chassis Here is a list that should be checked after any installation is complete If possible these types of checks should be assisted by a qualified person other than the persons that performed the installation e All holes in bottom of 2 5RS cabinet have been sealed to dust obtrusive objects and fingers Unused wires have been protected and insulated according to local standards Electrically live parts are all protected from access by enclosures or barriers No loose parts including screws especially 2 5RS front panel screws Burny has been informed of all problems with the hardware Environment within Burny operation specifications Away from sources of moisture Equipment away from combustible vapors and gasses Equipment is not too close to source of high heat Area dust and particulate level satisfactory Operator and equipment away from areas where objects fall slide roll etc Operator s view of work and equipment satisfactory Operator and equipment out of way of travel Cables routed so as to avoid damage after the installation Cables not unduly cramped or stretched Rear panel of unit accessible enough to see and to change cables Operator not subjected to unsafe or unnecessarily stressful conditions Wire size for AC and
50. 0 5 A 120VAC 2 Logic HI is 4 90 V minimum 24V maximum Logic LO is 1 35V maximum 0 V minimum 1 mA maximum If Burny signal selected output is 1 ma 15V If signal selected is customer signal from pin 15 then maximums are the same as for pin 15 Maximums 30VDC 2 A or 60VDC a 0 5 A 120VAC 62 2 230V AC maximum or 2 30VDC maximum 2 230V AC maximum or 2 30VDC maximum 2 230V AC maximum or 2 30VDC maximum 230VAC 15 mA 230VAC 15 mA See operator manual MACHINE INTERFACE SENSING INPUT 230VAC 15 mA maximum See manual for other voltages See operator manual section SD61 SYSTEM CONFIGURATION and MACHINE INTERFACE SENSING INPUT 34 Protective ground from machine power source Chassis Ground 35 Neutral conductor of machine s power source 0 25 A 36 37 Input pin for powering the 2 5RS from a 115V machine power source Input pin for powering the 2 5RS from a 230V AC machine power source PART 10 SPECIFICATIONS 12 115VAC 0 25 A 230VAC 0 110 A AO 73290 PRODUCT SPECIFICATIONS 2 5RS with MNJ 10380 using MO 03541 0 INTERFACE CARD FOR 115 VAC Cut Sense MO 03541 2 INTERFACE CARD FOR 230 VAC Cut Sense MO 03561 CABLE AO 73290 2 5RSBACK PANEL 37 PIN EXT DRIVE DESCRIPTION Signal Ground Power Ground Positive supply power output Input to supply power to 12VDC powered encoders Neg
51. 7 DATA BITS OP7D ASCII ODD PARITY 7 DATA BITS OP8D ASCII ODD PARITY 8 DATA BITS EIA RS244 ODD PARITY FORMAT PART 7 SETUP AND CONFIG 26 AO 73290 SETUP AND CONFIGURATION CHARACTER FORMAT SPECIFICATION SD50 oa os D4 selects the BAUD RATE s2kpaud d I poema SSIS Note 1 2 5RS Baud rate of 9600 should only be used under perfect transmission conditions If any trouble is experienced with transmission at 9600 Baud a slower rate should be used until the trouble is diagnosed Note 2 2 5Plus Settings in the shaded area apply only to the 2 5 Plus For now 19 2 BAUD may be the setting for maximum transfer rate because faster settings could cause the control to spend more time starting and stopping the communication In the following sections this manual explains numbers used to specify various characteristics of the 2 5RS AO 73290 PART 7 SETUP AND CONFIG 27 2 5RS OPERATION AND MAINTENANCE MANUAL SETUP amp CONFIG 4 2 42 SD51 PRGM FORMAT Each digit in this 8 digit number is used to select a particular option for the programming formats of RS 232 or paper tape loaded programs The programming description described in section PROGRAMMING only describes the STANDARD format used by the 2 5RS not the various option possibilities Most customers can use the standard ESSI or WORD ADDRESS formats as is and do not require the special features set by this variable In these cases
52. BY STORAGE COMPUTER TO 2 5RS M30 lt CR gt lt LF gt Z lt CR gt lt LF gt SIGNAL FOR END OF PROGRAM DATA lt ESC gt QQ0 lt CR gt lt LF gt PROGRAM COMPLETED NO ERRORS NOTE One digit of 0 is returned on a successful completion with no errors All other status codes are 3 digits PART 5 SERIAL 22 AO 73290 SERIAL COMMUNICATIONS SERIAL SERIAL 8 11 THREE DIGIT STATUS CODES NORMAL COMPLETION 000 No error LOAD PROCESS ERRORS 102 SYSTEM ERROR 104 SYSTEM ERROR 106 SYSTEM ERROR 108 SYSTEM ERROR 110 112 DATA FORMAT ERROR PGM SYNTAX ERROR END OF FILE ERROR NO END OF PROGRAM CODE PROGRAM MEMORY ERRORS 202 204 206 208 210 264 MEMORY DISABLED SYSTEM ERROR PROGRAM SIZE ERROR exceeds 128k bytes MEMORY INVALID MEMORY FULL CUSTOM AUX CODE TABLE ERROR I O OPERATION ERRORS AO 73290 302 304 306 308 310 312 314 316 318 320 SYSTEM ERROR RECYCLE KEY ABORT DEVICE OFF LINE DEVICE NOT READY READ TIMEOUT WRITE TIMEOUT PARITY ERROR OVERRUN ERROR FRAMING ERROR DATA HANDSHAKE ERROR PART 5 SERIAL 23 2 5RS OPERATION AND MAINTENANCE MANUAL BLANK PART 5 SERIAL 24 AO 73290 PART 6 SERVICE Tab Page Part 6 SERVICE SERVICE SERVICE 1 INSTALLATION OF THE BURNY 2 5RS The 2 5RS should be installed in accordance with the National Electrical Code in the United States and with IEC 364 4 41 in European Community countries Additionally the system must always be
53. CHAIN RECTANGLE 1 1 X DIMENSION 2 Y DIMENSION 3 LEADIN DIMENSION 4 SCRAP DIMENSION 5 KERF DIMENSION 6 VERIFY YES NO REPEAT PATTERNS PLATE SIDE LEFT RIGHT EEE gt INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS DISTANCE BETWEEN PARTS IN MM WIDTH OF CUTTING TOOL PATH YES OR NO NOTES All chain cut parts start from the plate corner closest to the operator The PLATE SIDE is defined through SYSTEM SETUP DATA KERF dimension must be entered here There is no DIAL IN KERF at run time for this shape AO 73290 PARTS 2 SHAPES 9 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 5 SHAPE 5 CHAIN RECTANGLE 2 REPEAT PATTERNS PLATE SIDE LEFT RIGHT 1 nn aM 4 3 314 ol lo rn IS m E 2 1 2 1 X DIMENSION INCHES OR MILLIMETERS 2 Y DIMENSION INCHES OR MILLIMETERS 3 LEADIN DIMENSION INCHES OR MILLIMETERS 4 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 5 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 6 VERIFY YES NO YES OR NO NOTES All chain cut parts start from the plate corner closest to the operator The PLATE SIDE is defined through SYSTEM SETUP DATA The part cutting order also depends on the PLATE SIDE value The part closest to the corner of the plate is always cut first as shown under REPEAT PATTERN
54. COMBO INTERFACE CARD These relays and sensing inputs are used for the interface to the cutting machine All the connections are made to 6PL on the interface card See the Electrical Specifications section of this manual for the exact connection points available to the user for the inputs and outputs described below The 2 5RS may also be ordered with interface cards that are not based on the COMBO CARD Always refer to the Electrical Specifications section of this manual for connection points and electrical specifications for those cards MACH 1 1 SENSING INPUTS CAUTION To ensure proper operation of the E STOP or OXY SENSE and also the CUT SENSE inputs and to avoid damage to the 2 5RS use the following information The sensing inputs are each isolated and are each set up for a two wire hook up These inputs will respond to either AC or DC voltages On the interface circuit card a 5 Watt resistor is connected in series with the input line Check the value of this resistor to be sure that it matches the voltage of the circuitry on the machine The values for the resistor are 24 VAC or DC machine circuits use a 2 ohm 5 Watt resistor on the card Some cards require a jumper to bypass another resistor so that only the 2 kOhm resistor is actually used 120 VAC or DC machine circuits use a 10 K ohm 5 Watt resistor on the card There should not be a jumper across this resistor 240 VAC or DC machine circuits use a 18 ohm 5 Watt r
55. CONFIG 4 2 55 5096 HOME INDEX SWITCH in mm 50 SETUP amp CONFIG 4 2 56 SD97 Y HOME INDEX SWITCH in mm 50 SETUP amp CONFIG 4 2 57 SDAO X LASH nnne 51 SETUP amp CONFIG 4 2 58 SDA1 Y LASH 51 SETUP amp CONFIG 4 2 59 SDA2 LASH RATE 51 SETUP amp CONFIG 4 3 MULTIPLE SETUP PARAMETER TABLES 51 SETUP amp CONFIG 4 4 SYSTEM VARIABLE DISPLAY 54 SETUP amp CONFIG 4 4 1 VO1 X DRIVE a a a 55 SETUP amp CONFIG 4 4 2 02 064000000 0 0 55 SETUP amp CONFIG 4 4 3 03 ABS 55 SETUP amp CONFIG 4 4 4 04 u ee dail ce 56 SETUP amp CONFIG 4 4 5 VO05 X ERROR 2 200 000 n u 56 SETUP amp CONFIG 4 4 6 V06 XERSCL 56 SETUP amp CONFIG 4 4 7 V07 X HOME 57 SETUP amp CONFIG 4 4 8 V11 Y DRIVE 57 SETUP amp CONFIG 4 4 9 V12 YDAOU T ea a 57
56. ENCODER TO MOTOR LIFT THE DISK HUB ASSEMBLY TO INSURE THAT IT MOVES FREELY UP AND DOWN THE MOTOR SHAFT WITHIN THE CON STRAINT OF THE MAIN ASSEMBLY IF THE DISK HUB ASSEMBLY DOES NOT MOVE FREELY DO NOT PROCEED AS DAMAGE COULD RESULT STEP 3 GAPPING LIFT AND ROTATE THE DISK HUB ASSEMBLY ALIGNING ONE OF THE TWO HUB SET SCREWS WITH THE ACCESS CHANNEL SEE FIGURE 2 WHICH IS LOCATED RIGHT NEXT TO THE L E D MOUNTING LOCATION THE ACCESS CHANNEL PROVIDES A MEANS OF ACCESS TO THE HUB SET SCREWS USING THE 4 48 HEX WRENCH PROVIDED APPLY A VERY LIGHT PRESSURE TO THE TOP OF THE HUB WHICH WILL ENGAGE THE DISK WITH THE GAP GAUGE MYLAR SHIM USING THE HEX WRENCH LIGHTLY TIGHTEN ONE OF THE TWO SET SCREWS ROTATE THE MOTOR SHAFT BY HAND TO EXPOSE THE SECOND HUB SET SCREW WHICH IS 90 DEGREES FROM THE FIRST SET SCREW AFTER YOU HAVE TIGHTENED BOTH HUB SET SCREWS ROTATE THE MOTOR SHAFT BY HAND USE THE GAP GAUGE MYLAR SHIM TO INSURE THAT THERE IS CONSISTENT SPACING THROUGHOUT THE ENTIRE ROTATION OF THE MOTOR SHAFT SHOULD THERE BE ANY BINDING LOOSEN THE HUB SET SCREWS AND REPEAT THE PROCEDURE DO NOT REMOVE THE GAP GAUGE MYLAR SHIM UNTIL SATISFIED THAT A CONSISTENT AIR GAP EXISTS REMOVE GAUGE DO NOT DISCARD AS GAUGE MUST BE USED IF UNIT IS TO BE REMOVED AFTER REMOVING GAP GAUGE MYLAR SHIM FURTHER TIGHTEN THE HUB SET SCREWS TO INSURE THAT THEY REMAIN SECURE REPLACE COVER REMOVED IN STEP 1 BY REVERSING PROCEDURE DISK HUB ASSY HUB
57. END W REWIND This is also true if the parts are being loaded through the serial port The last program to be loaded can use the M30 command to stop the loading process and start the tape rewind M04 CUTTING ON M21 Initiates CUTTING START SEQUENCE for selected cutting system While the cut is on the machine moves at the speed set by operators speed dial M03 CUTTING OFF M20 Turns OFF CUTTING PROCESS after performing any cut off sequencing the machine moves at high TRAVERSE SPEED to next pierce location M14 HEIGHT SENSOR DISABLE Disables height sensor contact M15 HEIGHT SENSOR ENABLE Enables height sensor contact M70 OFFSET 71 OFF This function acts exactly opposite the M71 command and has the same abilty to either be used alone to specify OFFSET 1 or be followed by a T1 to T8 to specify one of the 8 offset pairs When it is used it causes the machine to offset in the negative direction from the programmed parameters The OFFSET OFF command is normally used to cancel an OFFSET ON command so that the machine is returned to the original position Use the table for M71 to determine the offset parameters referenced by this command Where the table indicates M71T2 to cause offset 2 on a M70T2 would cause an offset 2 off M73 OFFSET 2 ON M 73 OFFSET 2 ON This command is maintained for compatiblity with older software It causes the machine to offset based on the dimensions specified in parameters SD47 SD48 same as
58. FREEZE at the current height Once the machine has re accelerated this relay turns off and allows the HEIGHT SENSOR to function normally Depending on the PLASMA SYSTEM used the contact must either CLOSE or OPEN in order to perform the disable function If this parameter is set to NORM the output contact is normally OPEN and closes to disable the HEIGHT SENSOR If set to REV the output contact is normally CLOSED and opens to disable the sensor Use the key to toggle the indicator to select the desired operation AO 73290 PART 7 SETUP AND CONFIG 19 2 5RS OPERATION AND MAINTENANCE MANUAL SETUP amp CONFIG 4 2 27 SD29 SLOWDOWN RADIUS in mm multiple parameter The SLOWDOWN RADIUS parameter is used by the Accel Decel routine to determine if a certain radius arc can be cut at the current machine speed or if the speed needs to be reduced due to a small radius When an arc is cut it s radius is compared to this parameter and causes a slowdown proportional to the ratio of the two radii Typically set to 2 3 inches 50 80 mm SETUP amp CONFIG 4 2 28 SD30 MIN RAD SPD in mm multiple parameter This speed value is used as the minimum cutting speed for small Radii even if the corner speed is lower In this way the corner speed can be adjusted to give the best decel to a full corner without the small radii such as the fill in blocks created by kerf running at an unacceptably slow rate Normal values are probably between 1
59. If only OXY FUEL is used set this value to 0 00 SETUP amp CONFIG 4 2 16 SD18 SLOWDOWN DISTANCE in mm multiple parameter This value sets the deceleration distance used when slowing for a corner in the part program See the description in SD07 for an explanation of the SLOWDOWN PARAMETERS and their interaction PART 7 SETUP AND CONFIG 16 AO 73290 SETUP AND CONFIGURATION SETUP amp CONFIG 4 2 17 SD19 HEIGHT SENSOR DISABLE LOOKAHEAD in mm multiple parameter This distance value is only used during PLASMA cutting operations It affects the operation of the Plasma Height Sensor Disable Relay output from the control Normally the relay energizes when the corner slowdown software reduces the speed of the machine before going around a corner This parameter adds an additional condition for causing the Height Sensor Disable Relay to energize by setting a lookahead distance for disabling the height sensor before the end of cut or before a Plasma Height Sensor Disable auxiliary function in the part program is executed This is especially useful when the part program contains either a leadout or a cross or intersection in the cutting path Both of these conditions can cause the plasma torch to dive into the plate In the case of the leadout many times the part being cut will fall out of the plate before the end of the leadout move The plasma height sensor would detect the plate moving down and attempt to follow it possibly causing
60. Ifthe G97 is omitted from the program the repeat pointer is automatically set to the first data block For the overall repeat function to cause the automatic repeat of the part program G98 is programmed at the end of the program When this code is read it causes the program to jump back to the point where the G97 was programmed and continues with the program from that point Note that the G98 should be programmed in a data block by itself and that no commands following the G98 will be executed since the program will always jump back to the G97 location If a G98 is programmed but there was no G97 at the beginning the program will repeat starting at the first data block WADR 1 14 LOOP PROGRAMMING This function allows portions of a part program to be repeated a specified number of times to reduce the size of the part program For example if 100 equally spaced holes need to be cut in a straight line and 4 data blocks are required to cut each hole standard programming would require 400 data blocks By using loop programming it would require only 6 data blocks This is the most common use for this type of loop programming To program a loop a data block containing G97 Txxxx is programmed at the start of the portion of code to be repeated The xxxx following the T data word specifies the number of times the loop is to be executed Ifa value of 1 is programmed it is the same as not having the loop at all since the code would be done 1 ti
61. MARKER OFFSET 1 ON EXAMPLE M71 TI WHERE T CAN BE 1 2 3 4 5 6 7 OR 8 OFFSET 2 OFF OFFSET 2 ON GO TO TABLE HOME INDICATED VALUE EXMAPLE M79 T2 GO TO TABLE 2 0 0 HOME POSITION AO 73290 PART 4 WADR 7 2 5RS OPERATION AND MAINTENANCE MANUAL WADR 1 11 DWELL TIME The G04 command along with the F key character and numeric value immediately following it sets the time that a dwell occurs This dwell time is in effect for that block and all subsequent G04 blocks until a new F DWELL time is included in another G04 block Time is in seconds For example N12G04 F22 5 BLOCK 12 DWELL FOR 22 5 SECONDS The maximum value for the F key character when describing a dwell time is 999 99 seconds WADR 1 12 F FEEDRATE When no G04 preceeds the F value the F key character immediately followed by a numeric value is used for programmable feedrate The feedrate value must be in a block by itself NOTE The PROGRAMMABLE FEEDRATE option must be enabled for proper operation For example N12 F100 causes a BLOCK 12 FEEDRATE of 100 inches mm depending on the operating system selected PART 4 WADR 8 AO 73290 PART PROGRAMMING WORD ADDRESS CODE DESCRIPTIONS WADR 1 13 CODE DESCRIPTIONS G02 These two functions are used to define the G03 Direction for arc data blocks as either CW or CCW respectively Once either of these functions
62. NOTE An A is selected by first pressing the SHF key and then pressing the zero key is selected by first pressing SHF key and then pressing the one key PART 7 SETUP AND CONFIG 48 AO 73290 SETUP AND CONFIGURATION SETUP amp CONFIG 4 2 52 SD70 KNIFE DIA in mm This parameter is for the special swivel knife compensation routine which modifies the cut path to produce sharp corners rather than the radius corners caused by the knife offset If this option is installed in the control this parameter should be set to twice the offset distance from the center of rotation to the knife point This is the same as the diameter of the circle which would result if the knife was rotated 360 degrees SETUP amp CONFIG 4 2 53 SD71 KNIFE BP ANGLE degrees This parameter is also used with the special knife compensation option It sets the minimum change in direction which causes the special knife processing to take effect Thus for small changes in direction the path is unaffected However if a sharp corner greater than this parameter value is found the path is modified so that a sharp corner is actually cut SETUP amp CONFIG 4 2 54 SD80 SD95 PROGRAMMABLE OFFSETS in mm Programmable Offsets can be used with multiple PLASMA and or OXY FUEL torches that may or may not have multiple markers mounted on the same station These additional offsets allow the marker on one torch to be used with another torch simply by prog
63. NUMBER OF MOTOR REVS Multiply by 1 4 if jumpers on processor or 1 0 card NOTE are moved to the X1 position THIS ONLY OCCURS ON THE OLD STYLE SYSTEMS instead of the normal X4 NEW BURNY 2 5 amp BURNY 3 DO NOT HAVE JUMPERS NUMBER MOTOR PULLEY 1 NUMBER OF OF i a GEARBOX OUTPUT MOTOR REVS GEARBOX PULLEY GEARBOX RATIO REVOLUTIONS GEARBOX OUTPUT CIRCUMFERENCE NUMBER OF PINION GEAR 5020 5021 ENC DIST REV REVOLUTIONS FOR DIAMETRAL PITCH GEARS FOR CIRCULAR PITCH GEARS CIRCUMFERENCE P D x 3 1415962 CIRCUMFERENCE TOOTH SIZE x NUMBER OF TEETH ON For 25 circular pitch PINION Pitch Diameter Pi teeth are 2500 inches EXAMPLE A MO 08935 0 REFER TO TABLE FOR SPECIFICATIONS B A08 16223 BURNY STANDARD PINION 16DP 20 DEGREE PA 1 5 PITCH DIA 24 TEETH STEP 1 5200 40 2 40 ay x3 786627 NUMBER OF MOTOR REVS NUMBER OF GEARBOX OUTPUT REVOLUTIONS STEP 3 786627 1 5 3 1415926 3 70689 5020 SD21 ENC DIST REV This print is the property of Cleveland Motion Controls Inc and is furnished as confidential information only It must not be copied traced or reproduced in any manner nor submitted to any outside parties for any purpose without our written permission Any use of this print without written permission of Cleveland Motion Controls Inc is a violation of our exclusive rights PARAMETERS 200 COUNT MODULAR ENCODER CAD DWG NO B0 9371CO2 WG DWG
64. OUTPUT ADAPTER Figure 118 PART 5 SERIAL 6 AO 73290 SERIAL COMMUNICATIONS SERIAL Then the gasket is pulled back to reveal the 232 422 selection switches There are 3 switches See the drawing below All three switches must be thrown in the same direction Set the switch to the desired setting and reassemble the unit INTERNAL VIEW OF MO 06354 AFTER GASKET IS REMOVED RS232 Se SET ALL THREE SWITCHES TO SAME DIRECTION SERIAL 2 CONNECTING TO RS 232 DEVICES RS 232C is an abbreviation for Recommended Standard 232 Revision C This standard comes from the engineering department of the Electronic Industries Association EIA RS 232C defines the wiring between two serial devices It also defines the supposed purpose of 25 different wires which pins they should terminate on and even what voltage levels current drains and loads are allowed Of the 25 pins wires defined by the standard only 11 are used for asynchronous communications The others are used for synchronous communication or reserved for future use Although there are 11 used for asynchronous communication the 2 5RS can communicate with as few as 3 TRANSMIT RECEIVE AND GROUND using SOFTWARE HANDSHAKING or as many as 5 TRANSMIT RECEIVE Request To Send Clear To Send and Signal Common using HARDWARE HANDSHAKING This means that either a 3 wire or 5 wire cable could connect the 2 5RS and a host storage device NOTE The host storage device could be a computer tape
65. Once the correct one is displayed press the ENTER key This causes the current value for that variable to be displayed SETUP amp CONFIG 4 4 1 V01 X DRIVE Displays the X drive output from the position loop as a percentage from 0 to 100 When the operator is controlling the machine speed with the speed dial a 100 READING indicates that the position loop is COMMANDING 100 of the speed dial setting If a traverse move is being performed the 10096 value indicates 10096 of the maximum speed of the machine as entered for SD04 This display is useful when the machine is not running at the correct speed If the Feedrate shown for SERV03 FEEDRATE is correct and this display shows that the position loop is commanding 100 of the current feedrate it indicates the machine should be running at the feedrate speed If it is running slower it indicates a mechanical or electrical problem usually outside of the 2 5RS SETUP amp CONFIG 4 4 2 V02 XDAOUT This display shows the actual bit value being sent to the X axis D A converter Since a 10 bit converter is used in the 2 5RS a displayed value of 03FF indicates the full 100 bit value is being sent to the converter A negative output has an 8 in the first digit 53FF The D A bit value is determined by multiplying the X drive value V01 by the SPEED CALIBRATION FACTOR for the X axis SETUP amp CONFIG 4 4 3 V03 X ABS in mm Shows the same data as SER V01 the curre
66. PART 4 ESSI 19 2 5RS OPERATION AND MAINTENANCE MANUAL BLOCKS WITH 2 SIGNS EITHER OR ARE LINE FUNCTIONS The first signed value is the X incremental distance and the second signed value is the Y incremental distance If one of the dimensions is 0 only a sign need appear in the block Examples Line of 1 inch in the X axis and 5 inches Line of 2 5 inches in the Y axis with no in the Y axis would appear movement in the X axis would appear 1100 50 40 250 BLOCKS WITH 5 SIGNS ARE ARC FUNCTIONS The FIRST signed dimension is the incremental gt X Y XC YC distance from the Start Point to the End Point ofthe ARC along the X axis The SECOND signed dimension is the incremental distance from Start Point to the End Point ofthe ARC along the Y axis The THIRD signed dimension is the incremental distance from the Start Point to the Center ofthe ARC along the X axis The FOURTH signed dimension is the incremental distance from the Start Point to the Center ofthe ARC along the Y axis The FIFTH sign in the data block determines the Direction ofthe Indicates aCCW arc Indicates a CW arc SEE THE ESSI SAMPLE PART FOR EXAMPLES OF ARC PROGRAMMING PART 4 ESSI 20 AO 73290 PART PROGRAMMING ESSI The following maximum values that can be used for X Y XC and values 99999 99 inchesESSI value 9999999 99999 9 mmESSI value 9999999 IMPORTANT Values
67. PLA TE SIDE value After moving away from the corner a cut is made back towards the corner as shown under REPEAT PATTERNS PART 2 SHAPES 12 AO 73290 SYSTEM OPERATION SHAPES SHAPES3 8 SHAPE 8 FLANGE REPEAT PATTERNS PLATE SIDE LEFT RIGHT 1 INNER DIAMETER SIZE I INCHES OR MILLIMETERS 2 OUTER DIAMETER SIZE INCHES OR MILLIMETERS 3 BOLT CENTER DIAMETER INCHES OR MILLIMETERS 4 BOLT HOLE DIAMETER INCHES OR MILLIMETERS 5 NUMBER OF BOLTS COUNT 0 to 99 6 KERF DIMENSION I WIDTH OF CUTTING TOOL PATH 7 SCRAP DIMENSION 2 DISTANCE BETWEEN PARTS 8 LEADIN DIMENSION INCHES OR MILLIMETERS 9 LEAD OUT DIMENSION INCHES OR MILLIMETERS 10 VERIFY YES NO YES OR NO NOTES If an INNER DIAMETER of 0 is defined no center hole is cut If the NUMBER OF BOLTS is defined as 0 no bolt holes are cut Only the INNER DIAMETER and the OUTER DIAMETER cuts use the LEAD IN DIMENSION as the diameter of the circular lead in The lead in distance for the bolt holes is automatically set to of the BOLT HOLE DIAMETER value AO 73290 PARTS 2 SHAPES 13 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 9 acd INNER DIAMETER SIZE OUTER DIAMETER SIZE SPLIT DEGREES LEADIN DIMENSION LEAD OUT DIMENSION KERF DIMENSION SCRAP DIMENSION VERIFY YES NO Q gt SHAPE 9 SPLIT RING REPEAT PATTERNS PLATE
68. S DR INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS WIDTH OF CUTTING TOOL PATH DISTANCE BETWEEN PARTS IN MM INCHES OR MILLIMETERS INCHES OR MILLIMETERS YES OR NO NOTES If a HOLE DIAMETER of 0 is defined no center hole is cut AO 73290 PARTS 2 SHAPES 19 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 15 1 WIDTH DIMENSION 2 HEIGHT DIMENSION 3 BEVEL LENGTH 4 KERF DIMENSION 5 SCRAP DIMENSION 6 VERIFY YES NO SHAPE 15 WEDGE PAIR REPEAT PATTERNS PLATE SIDE LEFT RIGHT INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS WIDTH OF CUTTING TOOL PATH DISTANCE BETWEEN PARTS IN MM YES OR NO NOTES If a BEVEL LENGTH of 0 is defined no bevel is cut at the corners Only sharp 90degree corners are cut This shape creates a special 4 part repeat sequence to minimize the amount of scrap However any number of parts may be cut since each of the 4 is counted as a separate part PART 2 SHAPES 20 AO 73290 SYSTEM OPERATION SHAPES SHAPES3 16 SHAPE 16 STRAIGHT PIPE SUPPORT REPEAT PATTERNS 7 Z PLATE SIDE LEFT RIGHT 8 Z 2 Y IN 4 1 WIDTH DIMENSION INCHES OR MILLIMETERS 2 HEIGHT DIMENSION INCHES OR MILLIMETERS 3 RADIUS DIMENSION INCHES OR MILL
69. SET SCREWS ACCESS CHANNEL GAP GAUGE MYLAR SHIM FIGURE 2 STEP 4 ELECTRICAL CONNECTIONS WIRE COLOR OUTPUT FUNCTION A OUTPUT A COMP M COMP COMMON RED tVS ORANGE B OUTPUT WHITE BLK B COMP WHITE M OUTPUT VIOLET SHIELD GREEN RED BLK BLUE BLACK TOLERANCES DECIMAL 030 X XX 015 005 ERE 5 1 SHOULD IT BE NECESSARY TO REMOVE AN ENCODER FOR ANY REASON IT CAN BE ACCOMPLISHED QUITE SIMPLY WITHOUT CAUSING DAMAGE BY REVERSING THE INSTALLATION PROCEDURE BE SURE TO RE INSERT THE 6AP GAUGE MYLAR SHIM TO PREVENT DAMAGE TO THE ENCODER DISK 2 THE OUTPUT SIGNALS PHASE RELATIONSHIP AND DUTY SIGNAL ARE FACTORY PREALIGNED AND SHOULD NOT REQUIRE ANY ADJUSTMENT SEE FIGURE 3 IF THE OUTPUT SIGNALS DO NOT MEET PUBLISHED FACTORY SPECIFICATIONS IT COULD BE DUE TO AN IMPROPERLY SET AIR GAP IF THE UNIT IS FOUND TO BE OUT OF PUBLISHED SPECIFICATIONS THE AIR GAP SHOULD BE CHECKED TO INSURE THAT IT WAS SET PROPERLY DURING THE INSTALLATION PROCEDURE Voh Vol 0 Voh Vol 0 Voh Vol FIGURE 3 ASSY M21 ENCODER TO MT2630 SERVOMOTOR CO 11466 BLANK 521755 STEP 2 UNPLUG WIRING HARNESS TO BEEPER REMOVE EXISTING BEEPER AND ALL MOUNTING HARDWARE MO 06354 ADAPTER USE TWO 0 32 x 3 8 STANDOFFS SUPPLIED IN POLY BAG AS NUTS TO FASTEN ADAPTER TO ENCLOSURE DZ CONNECT GREEN WIRE TO
70. SIDE LEFT RIGHT m EI INCHES OR MILLIMETERS INCHES OR MILLIMETERS DEGREES INCHES INCHES OR MILLIMETERS WIDTH OF CUTTING TOOL PATH DISTANCE BETWEEN PARTS IN MM YESOR NO NOTES The starting position is always at the 45 degree position as shown The ending position is determined by the SPLIT DEGREES value The actual spacing between parts is based on the assumption that SPLIT DEGREES is less than 135 degrees If not the scrap between parts may be excessive Therefore smaller arc segments should be cut using shape 10 RING DEGREES PART 2 SHAPES 14 AO 73290 SYSTEM OPERATION SHAPES SHAPES3 10 SHAPE 10 RING DEGREES INSIDE RADIUS SIZE OUTSIDE RADIUS SIZE STARTING DEGREES ENDING DEGREES CROSS REPEAT DISTANCE RAIL REPEAT DISTANCE LEAD IN DIMENSION LEAD OUT DIMENSION 9 KERF DIMENSION 10 VERIFY YES NO REPEAT PATTERNS MANUAL REPEAT ALL DIRECTIONS ALLOWED INCHES OR MILLIMETERS INCHES OR MILLIMETERS DEGREES DEGREES Y DISTANCE TO NEXT PART X DISTANCE TO NEXT PART INCHES OR MILLIMETERS INCHES OR MILLIMETERS WIDTH OF CUTTING TOOL PATH YES OR NO NOTES The STARTING DEGREES and ENDING DEGREES values represent angular position with respect to the Y axis 0 degrees is parallel to the Y axis and 90 degrees is parallel to the X axis The REPEAT DISTANCE parameters define the distance from the start of one part to the next T
71. SOFTWARE HANDSHAKING which uses special characters to control the flow of data between two serial devices They are lt XON gt for TRANSMITTER ON and lt XOFF gt for TRANSMITTER OFF SERIAL 8 1 RTS CTS HARDWARE PROTOCOL NOTE RTS CTS hardware protocol is not supported when the port is configured as a RS 422 port The RTS CTS protocol uses electrical control signals defined by the RS 232 standard to regulate the transmission The 2 5RS has 1 input status line and 1 output control line to perform this handshaking The status input to the 2 5RS should be connected to a suitable status output signal from the external device Similarly the 2 5RS control output should be connected to a status input line on the remote device Traditionally these two signals have been called REQUEST TO SEND RTS CONTROL OUTPUT and CLEAR TO SEND CTS STATUS INPUT However the exact definition may vary thus they are referred to as only the status input and control output lines In this way it implies that they should be connected to give the correct function not necessarily to the pin bearing the same name By using this type of handshaking either the 2 5RS or the external device can control the data transmission This compensates for the fact that the data may be transmitted faster than a particular device can process it If no handshaking is used data can be lost due to this processing time With the handshaking either device can stop the transmissi
72. T3 Selects overlay table 3 G46 T4 Selects overlay table 4 G46 TO Selects standard SERV 10 table NOTE The G46 can be swapped to any other M or G code desired by use of the custom code conversion feature available through WADDR3 The number following the word must be an integer 0 4 or it defaults to the standard 0 table The part program can contain any number of table select functions This would allow customizing one table for high speed cutting on large data blocks and another for intricate portions of the program Also the inclusion of the RUN SPEED LIMIT parameter allows the maximum cutting speed of the part to be limited so that it does not exceed the capacity of the tool this would help prevent router bit breaks by limiting the feedrate to a safe range The TRAVERSE SPEED LIMIT is not table selectable since there is no cutting process running during traverse moves PART 7 SETUP AND CONFIG 52 AO 73290 SETUP AND CONFIGURATION The setup procedure for the tables is similar to the standard SERV 10 procedure IMPORTANT These tables will return to the previously saved values ifthe RECYCLE key is pressed the system is turned off or power is lost unless the SERV97 VARSTOR function is used Read the section of this manual entitled SERV97 VAR STOR SERV 10 Sets up the non overlayed parameters and also the 0 table entries of the overlayed ones This function operates the same as in previous so
73. TEACH MEMORY ERRORS During the TEMPLATE TEACHING process the data storing operation is constantly being checked for errors If an error is detected the teaching process stops and an error message is displayed The various explanations for these errors are found in section TEMPLATE TEACH TRACE ERROR 4 ERRORS DURING SERIAL I O OPERATIONS Several conditions can occur during the SERIAL I O operations which cause error messages to be displayed ERROR 4 1 READ TIMEOUT This error indicates that the data being received by the 2 5RS has stopped for longer than the nominal timeout value 60 SEC The operation has been aborted PART 8 ERROR 4 AO 73290 ERROR MESSAGES ERROR 4 2 WRITE TIMEOUT This error indicates that data transmission has been delayed due to an in operative device being connected to the RS 232 port for longer than a the nominal timeout value 60 SEC ERROR 4 3 PARITY ERROR This error indicates that during a serial operation aPARITY ERROR was detected and caused the operation to abort ERROR 4 4 OVERRUN ERROR During data reception if the data is transmitted too fast or is sent at the wrong baud rate an overrun error occurs and terminates the operation ERROR 4 5 FRAMING ERROR During data reception a received character with the wrong number of bits causes this error to be displayed and terminates the operation This can occur if noise is present on the transmission line or if the wrong baud rate is used
74. TO FLOPPY The STORE TO FLOPPY selection is used to save a part program to a floppy disk Ifthe control has an internally mounted disk drive the program is stored there If the control does not have an internal disk drive and an external portable floppy drive is connected to the serial port the selected program is saved to the external floppy drive See FLOPPY DRIVE in utilities section for additional information on operation FUNCMENU 11 LOAD FROM FLOPPY The LOAD FROM FLOPPY selection is used to load part programs from a floppy disk If the control has an internally mounted disk drive the program is loaded from there If control does not have an internal disk drive and an external portable floppy drive is connected to the serial port the selected program is loaded from the external floppy drive See FLOPPY DRIVE in utilities section for additional operation FUNCMENU 12 LOAD RUN RS 232 Use LOAD RUN RS 232 to load a part program from the serial port and immediately run that program The 2 5RS can also automatically delete the program after cutting and load the next program See LOAD FROM RS 232 above FUNCMENU 13 LOAD RUN FROM FLOPPY Use LOAD RUN FLOPPY to load a part program from a floppy and immediately run that program The 2 5RS can also automatically delete the program after cutting and load the next program See LOAD FROM FLOPPY above AO 73290 PART 2 FUNCTION MENU 5 2 5RS OPERATION AND MAIN
75. act as the end of a Word Address or ESSI Program This feature aids in reading tapes from other controls which do not provide a normal auxiliary function M G or ESSI code at the end of a program For example some controls use sign as the end of program Ifthe is the end of program code the ASCII value of the is 25 The EOP value would be equal to EOP 25000000 Ifthe end of program code was END then EOP 454E4400 because in ASCH 45 N D 44 PART 7 SETUP AND CONFIG 34 AO 73290 SETUP AND CONFIGURATION ASCII CODES CHAR HEX CHAR HEX CHAR HEX NULL 00 2B V 56 SOH 01 4 2 W 57 STX 02 2D X 58 ETX 03 2E 59 04 2F 7 5A ENQ 05 0 30 5B ACK 06 1 31 5 BEL 07 2 32 5D BS 08 3 33 A 5E HT 09 4 34 5 LF 0A 5 35 60 0B 6 36 a 61 FF 0 7 37 b 62 CR 0D 8 38 63 SO 0E 9 39 d 64 SI 0 3A e 65 DLE 10 3B f 66 DCI 11 XON lt 3C g 67 DC2 12 RON 3D h 68 DC3 13 XOFF gt 3E 1 69 DC4 14 ROFF 2 3F j 6A NAK 15 40 k 6B SYN 16 A 41 1 6 17 B 42 m 6D CAN 18 43 6E EM 19 D 44 o 6F SUB 45 p 70 ESC 1B F 46 q 71 FS 47 r 72 GS 1D H 48 5 73 RS 1 I 49 t 74 US 1F J 4A u 75 SP 20 K 4B 76 21 L 4C w 77 22 M 4D x 78 23 N 4E 79 24 4F 7 7 25 50 7 amp 2
76. contact output a timer function is provided which delays motion by a specific time after this input receives the ON signal This plasma on delay time is set with the SDO1 ARC DELAY parameter described in the Installation section of this manual A second timer set by SD17 ARC OFF DLY causes a delay after the arc goes out This allows the machine to continue moving after a part falls out and causes the arc to extinguish PART 7 INTERFACE 6 AO 73290 SETUP AND CONFIGURATION INTERFACE 2 10 PLASMA ENABLE CONTACT PINS 5 AND 6 OF 6PL 6PL 5 This contact is typically connected in series with the plasma stop circuit so that opening it will stop the cut but closure does not initiate the cut The enable contact will not close until the arc on input is sensed as being OFF Once it has closed to enable a plasma cut it will remain closed for the entire part and then open when it is finished It will also open if either the CYCLE STOP or BACKUP button is pressed If the 2 5RS is set to OVERRIDE this contact will be maintained in a closed position to allow for normal manual control of the plasma circuit AO 73290 PART 7 INTERFACE 7 2 5RS OPERATION AND MAINTENANCE MANUAL MACH 2 11 PLASMA START CONTACT PINS 3 AND 4 OF 6PL 6PL 3 E ora This contact should be connected to the plasma control circuitry so that it can close to initiate the plasma cut but
77. defined through SYSTEM SETUP DATA If excessive scrap can be eliminated by creating part pairs use shape 47 L BRACKET 1 AO 73290 PARTS 2 SHAPES 53 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 49 CENTER DISTANCE OUTER DIAMETER INNER DIAMETER THICKNESS DIMENSION RADIUS DIMENSION KERF DIMENSION SCRAP DIMENSION LEAD IN DIMENSION 9 LEAD OUT DIMENSION 10 LEAD IN POINT 1 P1 11 LEAD IN POINT 2 P2 12VERIFY YES NO tn gt SHAPE 49 BIDAMPER REPEAT PATTERNS PLATE SIDE LEFT RIGHT INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS WIDTH OF CUTTING TOOL PATH DISTANCE BETWEEN PARTS IN MM INCHES OR MILLIMETERS INCHES OR MILLIMETERS YES OR NO YES OR NO YES OR NO NOTES If an INNER DIAMETER of 0 is defined no hole is cut If LEAD IN POINT 1 is selected the prompt for LEAD IN POINT 2 is not displayed If NO is selected for both optional LEAD IN POINTS then the default LEAD IN POINT 0 position is used PART 2 SHAPES 54 AO 73290 SYSTEM OPERATION SHAPES SHAPES3 50 SHAPE 50 DAMPER REPEAT PATTERNS 1 sd PLATE SIDE LEFT RIGHT PO 8 9 P QUE V p A 4 4 2 1 HANDLE CENTER DIST INCHES OR MILLIMETERS 2 OUTER DIAMETER INCHES OR MILLIMETERS 3 INNER DIAMETER INCHES OR MILLIMETERS 4 THICKNES
78. description for PGMEND 22 DO NOT USE FOR EDITING This code is used to setup the optional Code Conversion tables only and has no other function Since the same function list is used for the Editing and the Code Convert it appears in this list DO NOT USE FOR EDITING See comments for Spkon 24 MARKER 2 ON Not used in 2 5RS MARKER 2 OFF Not used in 2 5RS MARKER 2 OFFSET ON Not used in 2 5RS MARKER 2 OFFSET OFF Not used in 2 5RS FUNCTION 30 38 NOT USED FOR NORMAL EDITING AO 73290 PART 3 EDIT 11 2 5RS OPERATION AND MAINTENANCE MANUAL TB SEL VAL GOHOME VAL 1 TOOL41 VAL 1 KRFDIM VAL 1 FEEDRT VAL 1 HTDIS HTENA LDAUTO VAL 1 COUNT PART 2 RUN 12 39 40 42 43 44 45 46 50 INTERNAL FUNCTION NAMES CODES CONT PARAMETER TABLE OVERLAY VAL 1 Indicates which parameter overlay table is being used Possible Values are 0 1 2 3 4 CAUTION When a value of 1 2 3 4 is entered the corresponding overlay table accessed by SERV41 SERV42 SERV43 and SERV44 must be set up before the program is run GO HOME Indicates which cutting table home the machine should move to VAL1 prompts for cutting table home 1 2 3 4 Special for multiple cutting tool operations VAL 1 selects the the tool code PROGRAMMABLE KERF A kerf value may be inserted with this function VAL 1 equals programmed kerf dimensions in the same units as system para
79. encoders cables first decide where the encoders will be mounted Then measure the length from each encoder X and Y to the lower back panel of 2 5RS The two lengths normally will be different Generally the cross axis encoder cable will be longer then the rail axis encoder cable Because the 2 5RS and the rail axis encoder are both stationary the distance from the 2 5RS to the rail axis encoder is fixed The cross axis encoder cable length is determined by measuring from the 2 5RS to the tracing eye or the cross axis drive where the encoder is mounted This cable should be long enough to reach both limits of the axis Generally the 2 5RS is mounted to the operators station which contains all the signals needed to control the cut solenoids However if this 1s not the case a power oxy cable length may be needed for some 2 5RS application This length is determined by measuring between the cutting machines existing operators panel where the gas function controls are located and the back panel of the 2 5RS Generally the 2 5RS is mounted to the operators station which contains all the signals needed to control the drives However if a drive cable length may be needed on some 2 5RS applications This length is determined by measuring between the cutting machines operating station where tracing and stripping controls are located to the back panel of the 2 5RS When measuring for cables DO NOT measure in a straight line from point to point
80. external circuitry directs these 3 relays to the appropriate process With the setup parameters set to allow both processes a prompt appears for the operator to select which process is to be used for the MANUAL CONTROL Use the key to toggle between the PLASMA and OXY FUEL selections and press ENTER when the correct choice is shown NOTE If the machine has Plasma and Oxy Fuel the choice should be made now Once the Plasma or Oxy Fuel choice is made only the Manual Control functions for that selection are available To switch to the other process the operator must press the RECYCLE key to cancel the current operation and re select the manual control function again this time choosing the other cutting process If only one cutting process is used on the machine the setup parameters should have been set so that the selection of PLASMA or OXY FUEL is made automatically In this case the prompt for OXY FUEL or PLASMA does not appear Once the OXY FUEL or PLASMA choice has been made the display shows MANUAL CONTROL then SELECT Then the menu of available MANUAL CONTROL functions for the selected cutting process is displayed Use the SCROLL keys to move through the list and press ENTER when the correct function is displayed PART 3 SPECIAL FUNCTIONS 2 AO 73290 SYSTEM UTILITIES SPECIAL FUNCTIONS SPECFUNC 2 1 OXY FUEL MANUAL CONTROL FUNCTIONS For OXY FUEL cutting the following manual cont
81. function with the torch firing a second cutting mode has been added which provides a better interlock between the torch and JOG controls See PLASMA CUT JOG To turn the plasma torch OFF press the CYCLE STOP key To return to the MANUAL CONTROL menu press either the SCROLL UP or SCROLL DOWN arrow key SPECFUNC 2 2 2 PLASMA CUT JOG This mode also provides a way to turn on the plasma torch for cutting up scrap material or stripping the plate However the first selection PLASMA CUT has the plasma controls and JOG controls operating independently While this may work for some thicker plate applications thin plate requires that the machine begin moving as soon as the arc fires otherwise the torch goes out The PLASMA CUT JOG function interlocks the JOG controls with the plasma firing as follows Once PLASMA CUT JOG is selected the control prompts to press the CYCLE START key to ENABLE the plasma torch This does not fire the torch it only sets the electronics in a condition where they can be started from a separate start input On some machines the ENABLE causes the torch to be lowered to the plate Once enabled the display changes to HOLD JOG KEY TO FIRE PLASMA AO 73290 PART 3 SPECIAL FUNCTIONS 5 2 5RS OPERATION AND MAINTENANCE MANUAL For old front panel styles the operator must press the II key at this point to activate the jog mode One of the numbered keys 1 9 for is pressed and held to indic
82. ime d 0 79 3 ua e 27 AX 0 600 amp LN ON 1 500 A 1 05 1 15 SEE DETAIL B SEE DETAIL E AN 1 PLACE 1 75 1 PLACE 2 HOLES D 2 37 0 163 0 003 0 000 DIA THRU INSTALL PEM P N FHS 832 10 1 PLACE C 0 80 3 45 This print is the property of Cleveland Motion Controls Inc and is furnished as confidential information only It must not be copied traced or reproduced any manner nor submitted to any outside parties for any purpose without our written permission Any use of this print without written permission of Motion Inc is a violation of our exclusive rights ADD NOTES ONLY CLF1867 03 0 UNPAINTED BLIND GND HOLES 6100 BRL 04 88 ToLerances DETALS C 1 amp E CLE1598 KAP O7 O0 EA CORRECT O4 DM 5581 BRL 12 86 cer as noreo ADD SPARE HOLE FOR ENCODER CLE1491 ROM os oc pA App RECP HOLE 5511 BRL 08 86 erus ADD PEW MOVE HOLES CE REQURED 12695 KAP 04 98 ADD BLIND PEM NUTS 5258 BRL 11 85 DETAIL HOLES WERE 0 1495 10974 GMC 108 95 WINDEN CONDUCTIVE PLATING CONDUCTIVE PLATING 5244 BRL 11 85 85 ADD POWER SUPPLY HOLES REVISION CABINET BURNY 2 5 SYSTEM 70 X XX 015 2 Company 005 CAD DWG D03 12697MA DWG DRAWING NUMBER ANGULAR 7550 HUB PARKWAY CLEVELAND OHIO 005 12697 MA 7231 BRL 09 90 REDRAW DELETE BLUE POLANE DELETE BLUE POLAN
83. in incremental programming format Only used in absolute programming mode When included in a data block containing only X Y dimensions it causes the internal absolute registers to be set to the X Y dimensions from the data block No machine motion occurs This code is useful for re setting the absolute zero position at various points in a part program to make the X Y dimensioning of the subsequent data blocks easier G97 SET PROGRAM REPEAT POINTER G98 JUMP TO G97 POINTER These two commands are used as a pair within a part program to perform an overall program repeat function and also to allow LOOP PROGRAMMING within a part program PART 4 WADR 10 AO 73290 PART PROGRAMMING WORD ADDRESS WADR 1 13 1 OVERALL PROGRAM REPEAT The overall program repeat function is implemented by programming the G97 to set the repeat pointer location This is normally very close to the start ofthe program Any commands before the G97 will only be performed the first time through the part but will be skipped on each repeat pass This is sometimes used to allow the program to start at the corner of the plate and move to the first pierce point Then the G97 is programmed so that the move from the corner isn t repeated on each repeat ofthe part When the program repeats it will only execute the commands after the G97 To set the overall repeat pointer aG97 must be located in a data block by itself No other information should be included in this data block
84. is used all subsequent arcs are in the same direction until the opposite code is used G04 This code causes a SYSTEM DWELL to be performed During this time the machine is held in position and all control outputs remain in their current condition The DEFAULT DWELL time is established during the setup and installation procedure This time is used for all G04 blocks until an F variable is included in the same block as the 604 In this case the value contained by the F variable is used as the dwell time for this and all subsequent G04 blocks until changed by a new G04 block containing a different F time G40 These 3 commands are used by the DIAL IN G4 Routine to compensate the cutting path for the G42 Amount of material removed by the cutting process The kerf directions LEFT G41 or RIGHT G42 are based on which way the centerline of the torch needs to be offset as it travels along the cutting path G40 is provided to cancel the kerf however it is not needed in the program since the kerf is automatically turned off when not cutting NOTE When a Part Program contains either Kerf Left or Kerf Right auxiliary codes the software assumes that the DIAL IN KERF option is used to run the part When the kerf is added to the part program it requires approximately 25 more memory to store the kerf data along with the part dimensions Therefore when the incoming program is stored this extra 25 of me
85. key first shows OPTIONS ON OFF and then switches to a list of all the available options for the system along with an ON OFF indication next to the name showing whether the option is enabled turned ON or not OFF Use the ENTER or the Scroll keys to sequence through the list IMPORTANT Before calling regarding a service or operation problem use DSPY 80 and write down the SOFTWARE SERIAL NUMBER and SOFTWARE VERSION NUMBER displayed on the readout This will aid the service personnel in determining the type of system and the software installed NOTE The serial number must be the one displayed on the readout not the one found on a label somewhere on the enclosure AO 73290 PART 6 SERVICE 11 2 5RS OPERATION AND MAINTENANCE MANUAL BLANK PART 6 SERVICE 12 AO 73290 PART 7 SYSTEM SETUP AND CONFIGURATION Insert Tab Part 7 SETUP AND CONFIGURATION SYSTEM SETUP AND CONFIGURATION This section describes the various SERVICE displays and adjustment procedures for the 2 5RS The displays show various machine conditions and can be helpful in diagnosing a problem In addition the SERVICE MODE permits adjustment of the operating characteristics of the control in order to tailor it to a specific machine Once the operation has been adjusted for optimum performance the parameters are stored in a non volatile memory This insures that the operation of the control remains consistent and is not aff
86. key is pressed any additional communication parameter prompts are displayed as set by SD50 Once the parameters are entered the 2 5RS turns on it s control line then waits for the remote device to signal it s ready to receive data by sensing the status input line At this point if the COMMUNICATION ENHANCEMENT OPTION is enabled the 2 5RS sends 10 null characters delays for 1 second and then send the following message DOWNLOAD PROGRAM 12345678 lt CR gt lt EOB gt PART 5 SERIAL 16 AO 73290 SERIAL COMMUNICATIONS SERIAL The remote device begins transmission of the program If the 2 5RS needs to halt the transmission it turns off it s control output line which should cause the remote device to stop sending data The 2 5RS turns the control output line back ON when data transmission can resume If the COMMUNICATION ENHANCEMENT OPTION is not enabled in the system when the END OF PROGRAM CODE is received the 2 5RS simply turns off its control output line while the program load is finishing If the program ends with the PROGRAM END REWIND CODE the download software terminates and displays PROGRAM LOADED However if the program just loaded ended with the PROGRAM END only no rewind code the download software finishes loading the first program and after a slight pause turns the control output line back ON and displays WAITING FOR NEXT on the readout This allows multiple programs to be loaded by ending the
87. mann En 6 EDITOR 1 4 INSERTING A DATA 6 EDITOR 1 5 TERMINATING THE EDITOR 2 7 EDITOR 1 6 INTERNAL FUNCTION NAMES CODES L 8 EDITOR 2 CREATING A SAMPLE 13 TEMPLATE FEACH TRACE kaka wakaqa decer RE reb nnne SA Sa MURRA 1 1 TEACHING VALUES 2 a arena 1 DIGITIZING FACTOR 2 EE 2 MAXIMUM RADIUSZ Suyu er ern been ee Heer usa ia awisa enn 2 MINIMUM RADIU S 2 RADIUS ERROR ertet tbid 2 LINE REDUCTION u 2 KERF DIREGTION 20 tan an reset 2 TEACH 2 THE TEACHING PROCESS re dea RR SRI TA eee e AAE aaa ne 3 TEACH 3 TEACHING A PROGRAM WHERE EACH PART IS 5 TEACH 4 TEACHING A CHAIN CUT 6 DISPLAY 5 1 DISPLAY 1 DPSYOO EXIT MODE een nein ein ri 1 DISPLAY 2 DSPYO1 X Y DISPLAY 1 DISPEAY 2 1 IDSPYO2 PARTS OUT rt tum teret ie 2 DISPLAY 2 2 DSPYO3 FEEDRATE esent a Q attesa tasa ains aste dann 2 DISPLAY 3 DSPYOb STAT US tnr ertet ana tiet Fe ere ee ee 2 DISPLAY 4 DSPY10 DSPY44 SERVICE
88. maximum 2 230V AC maximum or 2 A 30VDC maximum 2 230V AC maximum or 2 A 30VDC maximum See pin 32 Interface card MO 03541 0 115VAC 15 Ma maximum See operator manual MACHINE INTERFACE SENSING INPUT Interface card MO 03541 1 230VAC 15 Ma maximum See operator manual MACHINE INTERFACE SENSING INPUT Chassis Ground PART 10 SPECIFICATIONS 13 2 5RS OPERATION AND MAINTENANCE MANUAL Input pin for powering the 2 5RS from a 115VAC machine power source Input pin for powering the 2 5RS from a 230V AC machine power source DIR 2 5RS with MNJ 10380 for ETEK NS3003 2001 USING MO 03650 INTERFACE CARD MO 03561 CABLE 2 5RS BACK PANEL 37 PIN EXT DRIVE CONNECTOR DESCRIPTION RATINGS Signal Ground Positive supply power output 24VDC 40 mA Output 4 Input to supply power to 12VDC powered See installation section of 2 5RS manual for encoders encoder setup 6 Anl Grund Nominal 0 to 5V peak or 0 to 5V peak Speed reference input Limits 2 4 to 7 7V peak or 42 4 to 7 7V peak 0 1 mA Maximums 30VDC 2 A or 60VDC 05 A 7 2VDC 15 mA if Burny reference is BURNY speed reference output used If customer signal is selected see pin 10 for specifications Sinks 500 mA 50V High impedance to negative voltages 50V maximum These pins are isolated from each other with common cathode diodes NC Run output low true If Burny signal s
89. new point the cut switch must be turned off and back on to restart the cut For Oxy Fuel cutting the operator must manually start the cutting oxygen using the machine s cutting oxygen switch or controls The 2 5RS automatically turns the cut off at the end or the operator can stop the cut by turning off the machine s cutting oxygen switch AO 73290 PART 2 RUN 11 2 5RS OPERATION AND MAINYENANCE MANUAL For Plasma cutting the operator must manually start the plasma cut This can be done in one of two ways If the machine is equipped with a separate plasma control station the cut can be started by pressing the Start button on the plasma operators console The plasma cut can also be started manually by pressing the CYCLE START key on the 2 5RS This allows manual cutting to be done on machines which do not have a separate manual control station If AUTO CUT was selected the program advances to a new pierce point and then automatically turns on the cutting process If Oxy Fuel cutting is being done the high preheat turns on for the specified time and then the cutting oxygen To extend or shorten the high preheat time press the START CYCLE key and hold for the desired preheat time To shorten the time just press and release the START CYCLE key when the cut is to start NOTE The Auto Cut cycle will not start if the manual cutting switch is in the ON position If TEST RUN is selected the program begins running but with all cu
90. one part to the next The PROGRAMMABLE FEEDRATE option allows the feedrate to be controlled from the part program The feedrate option must be enabled and the correct bit set in SD62 SYS CONFG2 See the section SETUP AND CONFIGURATION for programmable feedrate information Once a program contains a programmed feedrate code the control is automatically switched to the digital feedrate mode where the normal speed pot is now a 0 100 override control on the programmed feedrate Pressing the feedrate button or selecting DSPYO3 displays the current digital feedrate scaled by the 0 100 override pot and allows the programmed value to be altered by either scrolling or entering the new feedrate on the keypad NOTE On older controls the feedrate key is the white dot that is located between the SHF key and the down SCROLL arrow OPSUMMARY 5 JOG CONTROLS In order to help in positioning the machine the 2 5RS provides a front panel jog function The instructions below explain jog for the older style front panel as well as for the new style front panel The figure on the following pages is for the new front panel PART 1 OPSUMMARY 4 AO 73290 SYSTEM OVERVIEW GENERAL OPERATION SUMMARY 5 1 JOG CONTROLS OLD STYLE FRONT PANEL The jog operation is initiated by pressing the key on the left side of the panel When this key is pressed the readout temporarily changes to the SELECT JOG prompt and then retur
91. plate and cause an abrupt turn off of the torch This will cause attempts to restart the plasma and thus excessive wear on torch parts PART 2 SHAPES 4 AO 73290 SYSTEM OPERATION SHAPES ss ees 14 25 Bee OR Fil 15 t 17 non 19 200 n ann 22 23 24 25 26 27 28 oO o WCQ Ite 31 32 330 134 3 UC 37 en el 42 d N 43 44 45 46 47 48 E gt m DOOR 22 9900 2000 U 5 SEE pe L LZ 4 ae ERS i dE BE amps e 5 PUS e uf Fee N PA SIT Z SHAPES 3 53 STANDARD SHAPES Selectable start position cw ccw cutting and selectable repeat mode and direction Shapes 51 52 and 53 are enhanced versions of shapes 1 2 and 3 Allows selection of any number of holes Dashed holes are optional Corner radius values may be set to 0 for sharp corners AO 73290 PARTS 2 SHAPES 5 2 5RS OPERATION AND MAINTENANCE MANUAL S
92. punch another 2 5RS or any other type of serial device AO 73290 PART 5 SERIAL 7 2 5RS OPERATION AND MAINTENANCE MANUAL SERIAL 3 RS 232 PIN CONFIGURATION The MO 06354 SERIAL OUTPUT ADAPTER uses an industrial type round 9 pin AMP connector for it s serial output rather than the normal and somewhat fragile D connector found on most computers and RS 232 devices The following is a description of each of the 9 pins of the port SIGNAL PORTA NAME PIN DESCRIPTION SHIELD PIN PROTECTIVE SHIELD DO NOT TIE TO PIN 7 RIN PIN XOUT PIN 1 2 RECEIVED DATA INPUT TO 2 5RS 3 TRANSMITTED DATA OUTPUT FROM 2 5RS 4 5 VDC 25ma PIN 5 12 VDC 25mA May be used for pullup 6 12 VDC 25mA 7 SIGNAL GND 8 CONTROL STATUS LINE OUTPUT FROM 2 5RS 9 INPUT STATUS LINE INPUT TO 2 5RS NOTE The CTRL OUT and STAT IN terminologies used rather than the more conventional REQUEST TO SEND or CLEAR SEND since these imply specific data set and data terminal definitions and do not function identically on all serial devices By choosing more general names the correct connection to the remote equipment must be made based on signal function rather than assuming the same named pins are automatically connected GND PIN CTRL OUT PIN STAT IN PIN The signal levels from the 2 5RS are RS232 compatible and could be connected directly to a remote computer up to 50 feet away using any type of standard cable or up to up
93. reached releasing the key cause the program to continue forward from that point AO 73290 PART 1 OPSUMMARY 9 2 5RS OPERATION AND MAINTENANCE MANUAL BLANK PART 1 OPSUMMARY 10 AO 73290 PART 2 SYSTEM OPERATIONS Tab Page Part 2 SYSTEM OPERATION SHAPES MAIN FUNCTION SELECTION MENU The FUNCTION SELECTION MENU is the starting point for all machine operations At any time during any operation pressing the RECYCLE key aborts the current operation and returns to this top level of prompting When the RECYCLE key is pressed the display sequences through SELECT FUNCTION RUN PROGRAM or last function selected USE SCROLL SELECT The RUN PROGRAM function is the default when power is applied to the 2 5RS The default function then becomes the last function used The other functions are selected with UP and DOWN scroll arrows or by pressing the appropriate number associated with that function The selections are as follow KEY 1 N t gt W 3 SHF TWO KEY SEQUENCE SHF TWO KEY SEQUENCE AO 73290 FUNCTION RUN PROGRAM LOAD STD SHAPE LOAD FROM RS 232 STORE TO RS 232 TEACH PROGRAM DELETE PROGRAM EDIT NEW PROGRAM STORE TO FLOPPY LOAD FROM FLOPPY LOAD RUN RS 232 LOAD FROM FLOPPY DESCRIPTION Run the current program Load from STANDARD SHAPE LIBRARY Option must be enabled Load from a RS 232 device Store to aRS 232 device Teach
94. return to the 0 0 position on the machine This position is the point from which all other table home positions are measured GO TO TABLE HOME 2 Causes the machine to move to TABLE 2 0 0 which is defined as an offset from TABLE 1 0 0 position by parameter SD74 and SD75 GO TO TABLE HOME 3 Causes the machine to move to TABLE 3 0 0 which is defined as an offset from TABLE 1 0 0 position by parameter SD76 and SD77 GO TO TABLE HOME 4 Causes the machine to move to TABLE 4 0 0 which is defined as an offset from TABLE 1 0 0 position by parameter SD78 and SD79 Either use the SCROLL ARROWS or enter the digit directly to select GO HOME 1 2 3 4 Once the correct number is displayed press ENTER The display changes to PUSH CYCLE START The machine does not actually move until the CYCLE START key is pressed When it is the machine begins moving to the selected home position and the readout shows the X Y distance to the final location When it is reached the readout shows 0 0 PART 3 SPECIAL FUNCTIONS 8 AO 73290 SYSTEM UTILITIES SPECIAL FUNCTIONS SPECFUNC2 2 GO TO TABLE HOME FROM PART PROGRAMS There are several commands and functions in the 2 5RS that allow the table homes to be accessed automatically through the part program The following codes in Word address and ESSI allow the part program to command the machine to go to a particular home position WADRI WADR2 ESSI Go to Table 1 ho
95. run a different one PART 8 ERROR 2 AO 73290 ERROR MESSAGES ERROR 1 9 RECYCLE ERRORS Each time the RECYCLE key is pressed the main system memory used for storing part programs is checked for any data or format errors If all tests are OK the main SELECT FUNCTION prompt returns However if an error is detected a PGM MEMORY ERR appears instead Press RECYCLE again to try to clear the error If the memory can be reset the error message is removed and the usual SELECT FUNCTION prompt is redisplayed ERROR 1 10 DATA ERROR RESET MEMORY Ifa DATA ERROR message followed by YES RESET MEM NO appears it indicates that the program data is invalid and is unusable To abort the reset operation press the key to make the word NO in the readout flash and then press ENTER This does not correct the problem however and program memory is not reset To reset memory and return to normal operation press the key to make the word YES in the readout flash then press ENTER When the reset operation is selected a further prompt is issued to make sure that the operator realizes that this operation erases all programs in memory To continue with the reset press the key to make the word YES in the readout flash then press ENTER ERROR 1 11 RESET MODE ONLY Some operations cannot be used while others are running If they are attempted at the wrong time a R
96. starts the calibration procedure The Automatic Calibration routine Patented runs a square shape and monitors the speed on each of the sides of the square Each time the square is complete the calibration factor for each side is adjusted to try to balance the speeds Another square is run to check the results of the new calibration values This process continues until the 4 directions are balanced or for a maximum of 10 times around the square While the Calibration is being done the display shows the X and Y speeds Once all 4 directions are balanced the machine stops and the operator is again prompted to SET SPEED DIAL THEN CYCLE START SET SPD XXX NNNNNN The operator should set the speed dial to the new speed indicated by the XXX digits in the readout and press CYCLE START This process is repeated 4 times each time with a new setting of the speed dial When the procedure is complete the display shows CALIBRATION DONE PART 7 SETUP AND CONFIG 64 AO 73290 SETUP AND CONFIGURATION IMPORTANT The calibration value will return to the previously saved value ifthe RECYCLE key is pressed the system is turned off or power is lost unless the SERV97 VARSTOR function is used Read the section of this manual entitled SERV97 VAR STOR At this point the calibration values are stored in the operating memory of the system However they have not been transferred to the non volatile parameter storage memo
97. that exceed these limits produce a SYNTAX ERR SPECIAL NOTE ON PROGRAMMING ARCS The 2 5RS attempts to cut exactly what it is programmed to cut When programming arc blocks the distance from the start point of the arc to the center should equal the distance from the end point to the center If the values are not equal the 2 5RS control uses the end point to center distance when cutting the part The difference is a PATH ERROR As this PATH ERROR increases an undesirable cut path and machine motion occurs The machine motion being a factor of setup parameters and machine speed If BACKUP is used to go in reverse through a cut path with improperly programmed arc blocks machine motion is affected The machine motion being a factor of setup parameters and backup speed IMPORTANT To prevent the possibility of a program containing a improperly programmed arc block from making unwanted cuts use the TEST RUN mode of operation first before cutting the part AO 73290 PART 4 ESSI 21 2 5RS OPERATION AND MAINTENANCE MANUAL ESSI 2 2 ESSI AUXILIARY FUNCTIONS The third type of ESSI DATA BLOCK is used for the various AUXILIARY FUNCTIONS for the part program The following is a list of the supported ESSI FUNCTION CODES 00 PROGRAM STOP 64 PROGRAM END REWIND 03 PROGRAM IGNORING ON 65 MULTIPLE PARAMETER TABLE SELECT 04 PROGRAM IGNORING OFF 66 TOOL SELECT 07 CUT ON 67 PLASMA HEIGHT SENSOR ENABLE 08 CUT OFF 68 PL
98. the arc either CW or CCW The second display shows which dimensions are present in the data block and their direction Again to avoid extra displays the individual dimensions are not shown at this point As with the line the block must be selected for editing to see the actual X Y I J dimensions PART 2 RUN 2 AO 73290 SYSTEM UTILITIES PROGRAM TEXT EDITOR For FUNCTION data blocks there are several possible displays B0005 NAME F In this display the NAME and F are one of the functions listed at the end of this section For example if block 5 performed the CUT ON function the display would show B0005 CUT ON F06 0005 INTERNAL Internal functions have been created by the 2 5RS Although they are displayed they cannot be edited or deleted since they are essential to the programs execution Normally they should be ignored EDITOR 1 2 EDITING COMMANDS After the desired block is displayed the data may be displayed and changed if necessary To edit the block being displayed press the DECIMAL POINT key and then ENTER This two key combination is used to prevent accidental editing of a data block If the block is a line or arc continue at section LINE ARC BLOCK EDITING If the block is a function continue at section FUNCTION BLOCK EDITING To abort the edit process without altering the block data press the RECYCLE key This returns to the MAIN BLOCK DISPLAY without altering
99. the cut can still be stopped either by the PLASMA ENABLE CONTACT opening or by the operator pressing the plasma stop button This contact only operates when AUTO plasma cutting is selected and will remain closed during the entire plasma cut If MANUAL cutting is selected this contact will remain open If the 2 5RS is in OVERRIDE this contact stays open MACH 2 12 PLASMA HEIGHT DISABLE CONTACT PINS 1 AND 2 OF 6PL 6PL 1 6PL 2 This contact is connected to the plasma height sensing system such that when activated the height sensor is disabled and the torch is FROZEN at the existing height When the contact is released the height sensor regains control of the torch height The normal non activate state of this contact is selectable by SD28 HEIGHT RELAY parameter for either NORMALLY OPEN or CLOSED operation Thus it can be set to accommodate the various height sensing systems The contact will maintain the NORMAL condition as long as the machine is running at the speed set by the operators speed dial However when the machine is slowed for a corner this contact will switch and maintain the activated condition until the machine has accelerated back to the normal cutting speed This prevents the height sensor from lowering the torch due to the reduced cutting speed in the corner If the 2 5RS is in OVERRIDE this contact will be maintained in the NORMAL condition as set by the SD28 PARAMETER
100. the data AO 73290 PART 3 EDIT 3 2 5RS OPERATION AND MAINTENANCE MANUAL EDITOR 1 2 1 LINE ARC BLOCK EDITING If the selected data block is a line or arc the following sequence of prompts appears X DIM HHH Displays current X dimension enter new value if desired DIM 999898 Displays current dimension enter new value if desired I DIM Displays current I dimension The I dimension is distance from start point to center of an arc along the X axis This value must be 0 00 for line blocks since including an I or J dimension in a data block causes an arc Although the input block may have been a line the prompts for the I and J dimensions appears Enter the new value if desired J DIM 999 DISPLAYS CURRENT J DIMENSION The J dimension is the distance from the start point to the center of an arc along the Y axis SEE COMMENTS FOR I DIMENSION ABOVE EDITOR 1 2 2 ARC DIRECTION CW CCW ARC DIRECTION CW CCW This prompt only appears if either the I or J dimension is not 0 00 which indicates an arc data block If both are 0 the block is a line and thus has no direction To toggle between and CCW press the key to display the desired direction Then press ENTER PART 2 RUN 4 AO 73290 SYSTEM UTILITIES PROGRAM TEXT EDITOR VERIFY YES NO VERIFY YES NO After all the previous prompts have occurred the verify prompt is displa
101. the desired protocol from the following menu PROTCL I RTS CTS Standard HARDWARE PROTOCOL using Request to Send and Clear to Send RTS CTS PROTCL 2 XON XOFF Standard SOFTWARE PROTOCOL using XON and XOFF control characters PROTCL 3 BURNY4 Special protocol used to communicate with BURNY 4 controls PROTCL 4 CASS 1 Not used PROTCL 5 PTAPE Not used PROTCL 6 CLINK 1 Special protocol for communication with remote CAD programming center A detailed description of each of these protocols is provided in this section PART 5 SERIAL 2 AO 73290 SERIAL COMMUNICATIONS SERIAL If the program type parameter is set to 0 the operator must select the type of program to be LOADED or STORED from the following menu PGM TYPE I WADR Standard 2 5RS WORD ADDRESS PROGRAM PGM TYPE 2 ESSI Standard 2 5RS ESSIPROGRAM PGM TYPE 3 INTL TEST FORMAT NOT FOR NORMAL USE PGM TYPE 4 WADRI Special WORD ADDRESS PROGRAM TYPE 1 PGM TYPE 5 WADR2 Special WORD ADDRESS PROGRAM TYPE 2 PGM TYPE 6 WADR3 Special WORD ADDRESS PROGRAM TYPE 3 PGM TYPE 7 ESSI Special ESSITYPE PROGRAM 1 Specifications for the various program types are found in the PART PROGRAMMING SECTION of this manual If the character format parameter is set to 0 the operator must select the desired character format from the following menu CHAR TYPE 1 NP7D ASCII NO PARITY 7 DATA BITS CHAR TYPE 2 NP8D ASCII NO PARITY 8 DATA BITS CHAR TYPE 3 EP7D ASCII EVEN PARITY 7 DATA
102. the housing of the encoder See customer instruction drawing for the rack mounted encoder ground clamp Motor cables are handled in a like manner as shown on the drawing for motor cable ground clamp installation If motor mounted encoders are used the Burny supplied kit must be installed over the junction of the plastic connectors between the encoder cable and the short lead coming from the encoder This kit and instructions are shipped with cables for encoders and motor mounted encoders The connector shield is also shown on the customer instruction drawing for the encoder connector shield A connection between two cables for example a cable connected to an extension cable should be treated in the same way Tracer unit cables are handled in a like manner as shown on the customer instruction drawing for the tracer connector shield PART 6 SERVICE 2 AO 73290 SERVICE Compliance with the AC line Conducted Emission portion of the EMC Directive of the EC is only possible if the 2 5RS is equipped with the Burny supplied line transformer power supply If the 2 5RS is powered with the DC supply of the cutting machine drive or tracing system compliance with the Line Conducted Emission portion of the EC directive is then the responsibility of the drive or tracing system manufacturer SERVICE 1 3 CHECKING THE INSTALLATION A check of the installation is recommended to ensure that safety performance and time are not lost In CE installations
103. the marking path If the SD42 Marking Speed parameter is set to 0 00 the operator can control the speed of the marker using the normal feedrate controls on the machine If the SD43 parameter is set to a speed other than 0 00 the marker moves at that speed automatically provided that the machine s feedrate control is set higher than the SD43 marking speed If the feedrate control is set to a lower speed it overrides the SD43 speed and runs at the lower value Parameters SD80 SD95 are offsets that may be used on machines that have multiple PLASMA and OXY FUEL torches on the same station These additional offsets allow the marker on one torch to be used with another torch simply by programming the appropriate T field value NOTE For a more detailed description see 5080 PROGRAMMABLE OFFSETS SETUP amp CONFIG 4 2 33 SD41 Y MARKER OFFSET 71 in mm Marker offset dimension in the Y axis See SD40 for description PART 7 SETUP AND CONFIG 22 AO 73290 SETUP AND CONFIGURATION SETUP amp CONFIG 4 2 34 SD42 MARKING SPEED Not used in this control ipm MPM Sets the speed to be used for both the plate marking device when the marker is turned ON If this parameter is set to 0 00 the operator is able to set the marking speed manually using the normal feedrate controls on the machine SETUP amp CONFIG 4 2 35 SD43 MARKER DELAY Not used in this control seconds This timer is used to delay the start of motion when the plate ma
104. time a part is running regardless of whether the machine is moving or stopped IMPORTANT If PARAMETERS are adjusted but the new values are not stored using the SERV97 procedure before the RECYCLE key is pressed the new values are replaced by the previously stored data which is recalled from the Non Volatile memory Similarly if the parameters are adjusted in the Recycle state and then a part is selected for running without storing the values first they are also returned to their previous values SETUP amp CONFIG 4 4 SYSTEM VARIABLE DISPLAY This function is an important tool in checking the controls and various operating and diagnostic displays It displays many of the values used in the position loop calculations It also shows various hardware locations which reduces the need for external test equipment when looking for a problem The SYSTEM VARIABLE DISPLAY FUNCTION allows many internal data values to be displayed for troubleshooting and diagnostic purposes When SERV 11 or DSPY11 is selected a second menu is presented Select the desired display from the following menu either by scrolling or entering the specific display number PART 7 SETUP AND CONFIG 54 AO 73290 SETUP AND CONFIGURATION Once the mode is selected the display changes to 01 DRIVE which is the first variable in the list Select the desired variable by scrolling or by directly entering the 2 digit number of the particular variable
105. to Marker 1 When this function is turned on Offset 1 would be set to the Oxy Fuel to Marker 1 offset dimension and Offset 3 would be set to the Plasma to Marker 1 offset dimension Then the part program would only specify to use Offset 1 Ifthe machine was cutting with Oxy Fuel the actual Offset 1 dimensions would be used to move the machine from the Oxy Fuel torch to the Marker 1 location But if the machine is cutting with Plasma the offset dimension would be swapped so that the part program which still specifies to use Offset 1 would actually use Offset 3 and would correctly move from the Plasma torch to the Marker 1 location Offsets 2 and 4 work the same and would be used for a second marking device p1 p2 ps DS nc D7 ps mens IG SWAP OFFSETS 1 2 WITH 3 4 IF X X PLASMA SELECTED NO DECEL ON BACK UP BUTTON PRESS OR RELEASE AO 73290 PART 7 SETUP AND CONFIG 41 2 5RS OPERATION AND MAINTENANCE MANUAL PROGRAM FORMAT SD62 D6 is used to re configure the jog directions to match the machine axis and disable the latched jog function and also to disable latched jogs bi oa os n os ws o vs gt Jol lzlslelsisllslslalslelolelr x x s x were xix six X and Y X X XIX JOG DIRECTIONS EXCHANGED isanrerarenenwoes TT TT If D6 IS EQUAL TO 0 1 2 4 5 6 Ti 8 9 B C D
106. u 15 SERIAL 8 2 XON XOFF SOFTWARE PROTOCOOL SPECIAL HANDSHAKING PROTOCOL 16 SERIAL 8 3 COMMUNICATION ENHANCEMENT 16 SERIAL 8 4 RS232 USING RTS CTS HARDWARE 16 SERIAL 8 5 TYPICAL LOAD FROM RS232 USING XON XOFF SOFTWARE HANDSHAKING 18 SERIAL 8 6 CAD LINK CLINK PROTOCOL L Q 19 SERIAL 8 7 FILE DATA lt ESC gt FD 19 SERIAL 8 8 FILE GET lt sei dac iari de 20 SERIALE 8 9 FIEEEQUEUE euidenter cte te unta su telnet 21 SERIAL 8 10 FILE QUIT ESQC IQQ ea ean upah asal 22 SERIAL 8 11 THREE DIGIT STATUS 5 23 PART 6 SERVICE a u Au NIA MANC e Iuda 7 SERVICE ELEM 1 SERVICE 1 INSTALLATION OF THE BURNY 2 5 5 4 2 2 0 0 1 n nn sansa 1 SERVICE 1 1 PHYSICAL INSTALLATION OF THE BURNY 2 5RS nennen 1 SERVICE 1 2 ELECTRICAL INSTALLATION OF THE BURNY 2 5RS nennen 2 SERVICE 1 3 CHECKING THE 3 SERVICE 1 4 FUNCTIONAL TESTING OF THE SYSTEM AFTER INSTALLATION 4 INSTALLATION 2 LIST OF DIAGNOSTICS AND TESTS OF THE 2 5RS 5 INSTALLATION 3 REPAIR OF THE BURNY 2 5 5 6 SERV
107. used to look through the list for the desired value AO 73290 PART 3 EDIT 5 2 5RS OPERATION AND MAINTENANCE MANUAL Instead of scrolling to the desired function the function number can be entered directly on the keypad As soon as the number entry starts the display changes to FUNCTION With the numbers being entered in the digits Once the desired value is displayed press ENTER The display returns to the FNC NAME display described in FUNCTION BLOCK EDITING After the desired function is displayed either by scrolling through the list or by entering the desired function number directly press the ENTER key In most cases this finishes the editing process for the function and replaces the original data block with the new function code Once this is done the display returns to the MAIN DATA BLOCK DISPLAY and the new function code is shown EDITOR 1 3 DELETING A BLOCK If it is necessary to delete a block from the program the desired block should first be displayed as described in DATA BLOCK DISPLAY When it is displayed press the CE or CLR key The display changes to 0000 TO DELETE Press ENTER The display now prompts again to insure that the block is not deleted by accident again block 5 is used for example DELETE B0005 NO Pressing ENTER at this point ABORTS the DELETE and does not alter the program in any way To go through with the delet
108. with the time being shown in seconds When the block is edited the same value prompt appears which allows the dwell time to be edited as desired LEADIN 20 PROGRAMMED LEAD IN This code operates with the DIAL IN KERF option It indicates that the following Line or Arc block is a Lead In to a part and should not be kerf compensated This causes the pierce point to remain fixed rather than being offset by the kerf dimension PGMSTP 21 PROGRAM STOP Causes the machine to Stop and all cutting functions to be turned Off The operator must press the START CYCLE key resume operation PART 2 RUN 10 AO 73290 SYSTEM UTILITIES PROGRAM TEXT EDITOR INTERNAL FUNCTION NAMES CODES CONT PRGMEND 22 PROGRAM END This code and the 23 code both indicate the end ofthe part program The only difference between these two occurs if the program is STORED via the RS232 port The 22 PGMEND code is output as a Program End No Rewind function while the 23 PGMRWD code is output as a Program End Rewind If multiple programs are downloaded all but the last one must end with the PGMEND No Rewind code This allows multiple download operation The last program in the group normally contains the PGMRWD rewind code which causes the rewind process to operate IMPORTANT DO NOT DELETE THE PROGRAM END CODE PGMRWD 23 SPKON 24 SPKOFF 25 MRK2ON 26 MRK2OF 27 OFS2ON 28 OFS2OFF 29 PROGRAM END WITH REWIND See
109. 0 30 ipm SETUP amp CONFIG 4 2 29 SD31 PLASMA 1 SD31 prompts PLASMA TBI and is answered by a YES or NO response If the NO response is entered the control uses the standard SD10 setup parameters for both OXY FUEL and PLASMA cuts However if SD31 is set to YES and the control is set for PLASMA CUTTING the parameters in Overlay Table 1 are used to control the machine This allows the SD10 Table 0 parameters to be set for the best OXY FUEL cutting and the overlay SERV41 Table 1 parameters to be set for the best PLASMA cutting This allows the overlay table to be used even though the part program does not contain any specific codes PART 7 SETUP AND CONFIG 20 AO 73290 SETUP AND CONFIGURATION SETUP amp CONFIG 4 2 30 SD32 MIN SLW ANG degrees multiple parameter This parameter along with SD33 MAX SLW ANG define the angle range for the slowdown routine When a part is run the change in direction which occurs between data blocks is checked If the direction of the programmed path changes by more than the SD33 SLW ANG Maximum slowdown angle parameter the machine performs a full corner slowdown at the intersection of the two blocks Similarly if the change in direction between two data blocks is less than the number of degrees specified by SD32 MIN SLW ANG Minimum Slowdown Angle the machine runs through the intersection with no slowdown at all Changes in direction which are between the MIN and MAX values are scaled acc
110. 2 7 kOhm input impedance 500 mV input sensitivity over range of Chassis ground input from encoder 15V 2 7 kOhm input impedance 500 mV input sensitivity over range of 15V 2 7 kOhm input impedance PART 10 SPECIFICATIONS 25 2 5RS OPERATION AND MAINTENANCE MANUAL BLANK PART 10 SPECIFICATIONS 26 AO 73290 PART 11 DRAWINGS amp SCHEMATICS Tab Page Part 11 DRAWINGS AO 72106 Customer Instruction Motor cable ground installation Customer Instruction Encoder connector Shield installation AO 72108 Customer Instruction Tracer connector Shield installation BO 11464 Assembly amp Schematic Encoder amp cable wiring CO 11466 73153 D03 12697 Assembly M21 Encoder to MT2630 Servomotor Assembly B2 5 RS232 422 adapter Cabinet Burny 2 5 System 70 BO 9371 Parameters 200 count Modular Encoder AO 73290 PART 11 DRAWINGS 1 2 5RS OPERATION AND MAINTENANCE MANUAL BLANK PART 11 DRAWINGS 2 AO 73290 BLANK BLANK USE 360 METAL CLAMP GROUND EXTERNAL BRAID CABINET GROUNDING SCREWS PROVIDED ON THE BACK UF ALL BURNY PRODUCTS ALL CABLES MUST BE GROUNDED IN THIS FASHION METAL CLAMPS PROVIDED WITH ALL BURNY CABLE ASSEMBLIES This print is the property of Cleveland Motion Controls inc and is furnished as confidential information Mech It must not be copied traced or reproduced in any manner nor submitted to any outside parties for any purpose without o
111. 21 X ENC DIST REV is the length of travel in mm along the Y axis per one revolution of the Y axis encoder AO 73290 PART 7 SETUP AND CONFIG 17 2 5RS OPERATION AND MAINTENANCE MANUAL Parameter SD22 ENC COUNTS REV affects both the X and Y axis The value entered is the number of quadrature encoder counts lines per one revolution of the encoder The 2 5RS uses the distance per revolution and the counts per revolution parameters while the machine is moving to convert the encoder counts to total inches or millimeters of travel See SETUP amp CONFIGURATION amp SETUP ENCODERS for further information SETUP amp CONFIG 4 2 21 SD23 X ENCODER DIR The quadrature encoders used for position feedback provide both direction and position information Depending on the mounting of the X axis encoder the direction information may or may not be correct This can be checked by using the SERVOI X Y DISPLAY function If the direction needs to be reversed press the key which toggles the NORM REV data to the opposite condition This causes the X axis encoder to count in the correct direction SETUP amp CONFIG 4 2 22 SD24 Y ENCODER DIR Y AXIS ENCODER REVERSING See X axis descriptions SD23 SETUP amp CONFIG 4 2 23 SD25 X DRIVE DIR This parameter is used to reverse the polarity of the X axis drive output signal Depending on the machine s drive electronics and the interface card in the 2 5RS the drive output signal for the X axis
112. 3 Y BACKLASH Use DSPY11 to display V72 XBKLSH and V73 YBKLSH to show the backlash compensation value being applied and removed as the machine is changing directions while moving along the part profile Note that backlash compensation is only used for cutting and not for jogging SETUP amp CONFIG 4 5 MEMORY DISPLAY UTILITIES The 2 5RS has 5 display utilities which can be used to display any memory or CRU location in the system in a variety of display formats The CRU address space is a single bit processing utility which provides 32k bit locations in addition to the normal 64k address space of the microprocessor The five display utilities are SERV30 DSPY30 SINGLE WORD MEMORY DISPLAY SERV31 DSPY31 DOUBLE WORD MEMORY DISPLAY SERV32 DSPY32 16 BIT CRU DISPLAY SERV33 DSPY33 SINGLE BYTE MEMORY DISPLAY SERV34 DSPY34 8 BIT CRU DISPLAY For any of these displays once the selection is made the display changes to the DISPLAY FORMAT selected See the individual descriptions of the display formats Regardless of which is selected the address of the data is displayed on the left of the readout as a 4 digit hexadecimal number while the data is displayed on the right of the display The memory address is flashing which indicates that the address value can be changed by entering the desired value Once the correct address is entered the data at that address is Automatically displayed To alter the data at that address press the ENTER ke
113. 30VDC maximum 2 A 220V AC maximum or 2 30VDC maximum X drive reference output X drive reference input Start Cut contacts These are dry contacts Enable Cut contacts These are dry contacts PART 10 SPECIFICATIONS 22 AO 73290 PRODUCT SPECIFICATIONS 230VAC 15 mA See the operator 31 Sense return for pin 32 manual section MACHINE INTERFACE SENSING INPUT 32 Cut Sense input Signals 2 5RS that the cutting oxygen is operating 2 5RS with MNJ 10380 using MO 05572 INTERFACE CARD MO 05376 TWO ENDED CABLE MO 08709 RETROFIT HARNESS DESCRIPTION RATINGS 23 Maximums 30VDC 2 A or Speed reference input 60VDC 0 5 A 120 VAC 2 A 23 7 2 VDC 15 mA if Burny B 11 BURNY speed reference output reference is used If customer signal is selected see pin 10 for specifications 4 I _ If Burny signal selected output is 1 19 ma 15V If signal selected is A I customer signal from pin 15 then maximums are the same as for pin 15 d 15 Y drive reference input SUD Q ZADI B pue 60VDC 0 5 A 120VAC 2 Logic HI is 4 90V minimum 24V 7 ZW maximum AandB 16 Input X and Y Enable Drive input VoneLoisl35Vimadmun OV minimum 1 mA maximum If Burny signal selected output is 1 6 ma 15V If signal selected is A E customer signal from pin 18 then maximums are the same as for pin 15 B 60VDC 0 5
114. 36 115VAC 0 25 A 37 230VAC 0 110 A 2 5RS with MNJ 10380 using MO 03502 0 INTERFACE CARD MO 06669 005 J17 PLUG IN CABLE SEE RATINGS OF PINS 31 32 AND 33 BELOW FOR THE DIFFERENT SUFFIXES 0 1 2 OF THE MO 03502 X INTERFACE CARD MO 06669 005 CABLE EXT DRIVE DESCRIPTION NOMINAL RATINGS Signal Ground Speed reference input from customer Nominal 0 to 8 1V peak i Maximum 5 4 to 10 8V peak E I 0 025 mA Maximums 30VDC 2 A or 60VDC 0 5 A 120VAC 2 7 2VDC 15 mA maximum if Burny signal is used If customer signal is selected see pin 10 for specifications Speed reference input Speed reference output AO 73290 PART 10 SPECIFICATIONS 19 2 5RS OPERATION AND MAINTENANCE MANUAL Pin 12 can sink 500 mA maximum co 12 Denkens o ee Hi true output signals that Burny 2 5 13 reference signal is being used not the 23 4VDC 1 customer reference signal If Burny signal selected output is 1 3 14 Y drive reference output I Ht signa aun customer signal from pin 15 then maximums are the same as for pin 15 Maximums 30VDC 2 A or Ex 7 Y drive reference input 60VDC 0 5 A 120VAC 2 A If Burny signal selected output is 4 17 X drive reference output mane 15 ASTE enal customer signal from pin 18 then maximums are the same as for pin 15 5 These normally open dry contacts 2 30VDC maximum c
115. 4 SERVICE AND DISPLAY MODES The SERVICE key may be pressed at any time during any operation to access the service FUNCTION MENU When it is pressed the readout displays SER V00 EXIT MODE The operator should select the desired service function from the following list by either scrolling to the number or by entering the service function number directly Once the correct value is displayed press the ENTER key to access the function NOTE Since the DISPLAY mode accesses many of the same functions as the Service mode the following menu also displays the various DISPLAY functions These are accessed by pressing the DSPY key at any time and then selecting the desired display function PART 7 SETUP AND CONFIG 4 AO 73290 SETUP AND CONFIGURATION SETUP amp CONFIG 4 1 SERVICE AND DISPLAY MODE MENUS SERVICE MODES IN THE 2 5RS 00 EXIT MODE SERV50 AXIS SPEEDS SERVO0I X Y DISPLAY SERV51 SPEED CALIBRATION SERV02 PARTS CUT SERV52 MEMORY RESET SERV03 FEEDRATE SERV54 REFERENCE ADJUST SERV05 SYSTEM STATUS SERVIO SYSTEM DATA SETUP SERV11 DISPLAY VARIABLES SERV70 CUSTOM AUX CODES SERV30 SHOW WORD SERV78 LOOP BACK TEST SERV31 SHOW DOUBLE WORD SERV32 SHOW CRU WORD SERV80 CONFIGURE SERV33 SHOW BYTE SERV34 SHOW CRU BYTE SERV40 CURRENT TABLE SERV41 TABLE DATA SERV97 VARIABLE STORE SERV42 TABLE 2 DATA SERV98 SYSTEM RESET SERV43 TABLE 3 DATA SERV44 TABLE 4 DATA SETUP amp CONFI
116. 40 24 30 24 8 BLANK MODULAR ENCODER INSTALLATION TO SERVOMOTOR MOUNTING CONFIGURATION PLEASE REFER TO FIGURE 1 FOR PROPER MOUNTING SURFACE CONFIGURA TION YOU WILL NOTE THAT TWO 4 40 X 18 DEEP TAPPED HOLES ARE REQUIRED THE TWO TAPPED HOLES ARE USED TO MOUNT THE MODULAR ENCODER TO THE MOTOR SURFACE WITH THE 4 40 X 38 SOCKET HEAD SCREWS PROVIDED THE ENCODER COVER IS HELD IN PLACE USING TWO 2 X 3 8 P H SELF TAPPING SCREWS THESE SCREWS THREAD INTO THE MAIN ASSEMBLY AS SHOWN IN FIGURE 1 SERVOMOTOR LE MOUNTING SURFACE Neon X 3 8 SOCKET HEAD SCREWS FIGURE 1 INSTALLATION PROCEDURE STEP 4 REMOVE COVER BACK OUT THE TWO NO 2 P H ENCODER COVER SCREWS WHICH SECURE THE COVER TO THE MAIN ASSEMBLY REMOVE THE COVER BEING CAREFUL NOT TO DISLODGE THE GAP GAUGE MYLAR SHIM FROM THE ASSEMBLY STEP 2 MOUNT MAIN ASSEMBLY SLIDE THE MAIN ASSEMBLY ONTO THE MOTOR SHAFT CARE SHOULD BE TAKEN TO AVOID ANY EXCESSIVE FORCE IN MOUNTING AS THE CAPTURED ENCODER DISK COULD BE DAMAGED IF THE ASSEMBLY DOES NOT SLIDE ON FREELY DO NOT PROCEED UNTIL THE CAUSE OF THE INTERFERENCE HAS BEEN DETER MINED A SLIP FIT IS DESIRED A DISK HUB ASSEMBLY WHICH IS EXCESS ARIES WILL RESULT IN UNACCEPTABLE SIGNAL ERROR CAUSED BY GAP ARIATION LOCATE AND ALIGN THE MOUNTING HOLE LOCATIONS OF THE ENCODER WITH THOSE OF THE MOTOR MOUNTING SURFACE SECURE THE MAIN ASSEMBLY TO THE MOUNTING SURFACE USING THE MOUNTING HARDWARE PROVIDED AFTER SECURING
117. 6 51 7C 27 R 52 7D 28 5 53 7E 29 T 54 DEL 7F 2 U 55 AO 73290 PART 7 SETUP AND CONFIG 35 2 5RS OPERATION AND MAINTENANCE MANUAL SETUP amp CONFIG 4 2 44 SD53 FILE EXTEN This variable gives the 2 5RS control the ability to add a fixed file extension of any type to part programs Files that are tagged with a CNC TXT or any other valid file extension can be loaded from the 2 5RS DISK DRIVE or serial port Programs that are stored to the 2 5RS DISK DRIVE or out the serial port have this file extension added to the program number SD53 FILE EXTEN allows up to 4 characters to be entered in ASCII as 8 digits which can act as the file extension NOTE Although 4 characters may be entered the MS DOS operating system only allows a 3 character extension Other operating systems allow more than 3 characters For example If the desired file extension of all files that are to be loaded from the floppy and stored to the floppy is Then SD53 FILE EXTEN 434E4300 C 43 N C 43 The 2 5RS control adds the automatically If the desired file extension of all files that are to be loaded from the floppy and stored to the floppy is TXT Then SD53 FILE EXTEN 54585400 T 54 X 58 T 54 The 2 5RS control adds the automatically SEE ASCII CODE TABLE ABOVE IN THIS SECTION ON SD52 FOR A LIST OF CHARACTERS AND THEIR ASCII VALU
118. 60 If an INCH system is selected the units are INCHES and INCHES PER MINUTE ipm If a METRIC system is selected the units are MILLIMETERS and MILLIMETERS PER MINUTE MPM For this reason if a new system is being setup 5060 and SD68 SPEED RANGE should be set first so that the other values which are affected by the INCH METRIC switch and speed are correct AO 73290 PART 7 SETUP AND CONFIG 9 2 5RS OPERATION AND MAINTENANCE MANUAL SETUP amp CONFIG 4 2 1 SD01 ARC ON DELAY seconds This time value is only used when the PLASMA CUTTING operation is selected It delays the start of motion on a plasma cut after the ARC ON input has been received For Plasma Systems with Current Sensing Relay outputs this value is normally set to 0 00 causing the machine to begin moving as soon as the arc transfers to the plate For Plasma Systems without the CSR output this timer can be used to delay machine motion for approximately the same time as the purge cycle at the beginning of a plasma cut Thus the machine holds position until the timer reaches 0 and then begins along the cut path If a machine uses OXY FUEL cutting only this parameter should be set to 0 SETUP amp CONFIG 4 2 2 SD02 BLEEDOFF TIME seconds This time value is used with OXY FUEL CUTTING When the cutting oxygen is turned off at the end of a cut the machine holds position for the specified time to allow the oxygen to BLEED OFF be
119. 650 14 33 9 24 28 2098 39 55000 0 119150 3 026 3 9717 4 7660 5 1632 5297 8000 SP 150 W ENCODER FOLDED MO 11783 32F MO 11344 32F MO 08935 1 300 7 6 MT 2630 141AF 19 1 20 50 1824 28 65000 0 164481 4178 4 1120 4 9344 5 3456 5 4828 6000 _ SP 150 W ENCODER FOLDED MO 11783 42F NONE 0 09502 0 450 11 4 MT 2630 141AF 33 9 30 20 2158 22 6000 0 208513 5 296 41703 5 0043 5 4213 5 5605 4800 SP 150 W ENCODER FOLDED MO 11783 52F MO 11344 52F 08795 1 500 12 7 MT 2630 141AF 19 1 24 28 2564 22 28333 0 211476 5 371 42295 50754 5 4984 5 6395 SP 150 W ENCODER FOLDED MO 11783 82F MO 11344 82F 10638 800 20 3 MT 2630 141AF 19 1 30 20 2162 12 73333 0 370083 9 400 4 6260 5 5512 6 0129 6 1682 wF Vn SP 150 W ENCODER INLINE NONE NONE MO 10335 70 18 MI 2630 141AF 33 9 15 44 1477 99 44000 10 047389 1 204 3 9491 4 7389 54338 5 2655 SP 150 W ENCODER INLINE 0 11785 121 MO 11344 121 MO 08934 0 150 3 8 MT 2630 141AF 33 9 20 30 1619 50 35000 0 092672 2 354 3 0891 3 7069 40158 4 1189 2098 5512 2 2 aux Tr ER SP 360 W ENCODER FOLDED MO 11784 32F MO 11343 32F MO 09200 350 8 9 IMT 3528 297CF 34 0 28 24 2165 29 14286
120. 75 2 082 05 103 25 B01 2239 15 256 10 3 295 1125 2 5 16 18 POS eee n ue o seem jn rox qp eme up coc lese Loose ee Ei Boos inr pe 1 wee 213 pr ee io ix dp oue prose 1 25 0 375 B01 25200 1000 20 1 16mm 8mm 7mm 0 75 0 5 2001 24535 6 0 20 19 07 1 125 0 1875 0 375 0 375 0 375 0 375 20 1 5 375 0 1 5 tS Co X01 15343 0 1 19 X01 16137 50 1 037 055 0 375 38 16217 2 145 06257 045 0 5 1 0 5 40 B01 27072 1 5 1 05 05 18 15 0 5 This print is the property of Cleveland Motion Controls Inc and is furnished as confidential information only It must not be copied traced or reproduced in any manner nor submitted to any outside parties for any purpose without our written permission Any use of this print without written permission of Cleveland Motion Controls Inc is a violation of our exclusive rights UA Cleveland PARAMETERS Motion Controfs 200 COUNT MODULAR ENCODER X XXX 005 CAD DWG NO BO 9371C03 0WG ISIZEIDRAWING NUMBER REV IA ees B0 9371 N 10 MATERIAL SCALE REF DATE DATE nannte fy 9418 moal SHEET 3 OF 3 N CN ON ASNN xO C ho O 035 7mm 05 1125 055 055 0375 30 32 50 40
121. A 230 maximum on the interface card These are dry 3 A 30VDC maximum contacts 8 30 The other half of the Stop Cut contact Use the specification with the number of the interface board with suffix 18 32 Cut Sense input return MO 09489 2 use24VAC 15 mA MO 09489 0 use 115VAC 15 mA MO 09489 1 use 230VAC 15 mA AO 73290 PART 10 SPECIFICATIONS 1 2 5RS OPERATION AND MAINTENANCE MANUAL 34 ChassisGround Jov _ Neutral conductor of machine s power 011 source Input 34 35 Input for powering the 2 5RS from a 1 36 115 power source with the MO 115VAC 0 22 A 09499 010 drive cable in use Input for powering the 2 5RS from a 37 230V AC power source with the MO 230 0 11 A 09498 010 drive cable in use 2 5RS for SERVOPAK RATINGS MO 05798 0 1 or 2 INTERFACE CARD See pins 31 and 32 MO 09434 SPLITTER CABLE MO 09435 POWER OXY PIGTAIL DESCRIPTION RATINGS COLOR CONNECT open dry contacts 2 A 230V AC maximum contacts Start Cut contact These contacts can be configured as normally open or normally YELLOW 27 closed by jumper settings 17J and 18J 2 230VAC maximum on the interface card These are dry contacte 3 A 30VDC maximum YELLOW This is the other half of the Start Cut contact Stop Cut contacts These contacts can be configured as normally open or normally BLUE 9 oo 02790280 ba 230VAC maximum conta
122. A 120VAC 82 WIRES These normally open dry contacts 2 30VDC maximum WIRES contacts 2 30VDC maximum WIRES contacts 2 A 30VDC maximum BLU Cut On Sense input Signals the 2 5RS POVAN 5 gee Ihe pasta WIRES 31 32 that the cutting oxygen is operatin manual section MACHINE 8 INTERFACE SENSING INPUT AO 73290 PART 10 SPECIFICATIONS 23 2 5RS OPERATION AND MAINTENANCE MANUAL GRN 34 Protective ground from machine power Chassis Ground WIRE source WHT Neutral conductor of machine s power Input pin for powering the BURNY 2 5RS from a 115VAC machine power 115VAC 0 25 A Input source 2 5RS with MNJ 10380 PACKAGE using MO 09271 INTERFACE CARD MO 09272 INSTALLATION KIT MO 03561 CABLE KIT 2 5RS BACK PANEL 37 PIN EXT DRIVE CONNECTOR EXT DRIVE CONN DESCRIPTION RATINGS ECTOR ignal Ground ower Ground ositive supply power output 24VDC 40 mA 12V Supply input to encoders 6 JAmdogGrund Nominal 0 to 10 5V peak Limit 5 28 to Speed reference input 15 84V peak 0 15 mA Pins 12 and 13 can sink a combined 500 mA 50V but are isolated by diodes so that a signal on one pin will not affect the other pin If Burny signal selected output is 1 ma 15V If signal selected is customer signal from pin 15 then maximums are the same as for pin 15 Maximums 30VDC 2 or 60VDC Y drive reference input 0 5 A 120VAC 2 A
123. ABLE MO 07146 010 POWER DS DESCRIPTION RATINGS CABLEC CONNECT ONNECT OR PIN NO OR PIN NO Both inner and both outer 2 Power Ground OV shields of cable 8 9 14 I5 6 Analog Ground Nominal 0 to 5V peak or 0 to 5V 12 Speed reference input peak Limits 2 4 to 7 6V peak or 2 4 to 7 6V peak 0 1 mA Maximums 30VDC 2 A 7 2VDC 15 mA if Burny reference is used If customer signal is selected see pin 10 for specifications If Burny signal selected output is 1 ma 15V If signal selected is customer signal from pin 15 then maximums are the same as for pin 15 Burny speed reference output Y drive reference output AO 73290 PART 10 SPECIFICATIONS 15 2 5RS OPERATION AND MAINTENANCE MANUAL Maximums 30VDC 2 or Y drive reference input 60VDC 0 5 120VAC 2 A Logic is 4 90V minimum 24V maximum Logic LO is 1 35V 92 Ie Jog mal mus maximum 0 minimum 1 mA maximum If Burny signal selected output is 1 7 17 X drive reference output Dr Ir signal selected customer signal from pin 18 then maximums are the same as for pin 15 RE These normally open dry contacts 2 30VDC maximum i contacts 2 30VDC maximum contacts 2 30VDC maximum Sense return for pins 32 and 33 Input 115VAC 30 mA 115VAC 15 mA See operator 32 i oxygen Cut Sense input Signals 2 585 Manual MACHINE INTERFACE DUE SENSIN
124. AC maximum 2 30VDC maximum 31 Return for pin 32 See pin 32 Cut On Sense from the customer s machine 230V 15Ma See operator manual Signals 2 5RS that the cutting oxygen is MACHINE INTERFACE SENSING operating INPUT 230VAC 15 mA maximum See operator manual section MACHINE INTERFACE SENSING INPUT See operator manual section moving and shut off the cutting process non ATION and MACHINE INTERFACE SENSING INPUT 34 Protective ground from machine power source Chassis Ground 35 Neutral conductor of machine s power source JOVAC 0 25 A Input Input pin for powering the 2 5RS from a 38 115 machine power source ISA Input pin for powering the 2 5RS from a 230V AC machine power source 18 This is the X drive reference input 25 26 27 28 Start Cut contacts These are dry contacts 29 30 Enable Cut contacts These are dry contacts Stop input from the customer s machine Signalis supplied by the machine Lack of voltage on this pin causes the BURNY to stop 37 230VAC 0 110 A Input 2 5RS with MNJ 10380 using MO 04373 INTERFACE CARD MO 03561 CABLE 2 5RS BACK PANEL 37 PIN EXT DRIVE CONNECTOR EXT DRIVE CONNEC DESCRIPTION RATINGS TOR PIN NO Signal Ground 0V Power Ground 0V Positive supply power output 24VDC 40 mA Output Input to supply power to 12VDC powered See installation section of 2 5RS manual encoders for encoder setup Negative
125. AL The word NORMAL will be flashing If the ENTER key is pressed at this point it causes the part to be cut as it is programmed which basically means that SCALE 1 000 X MIRROR NO ROTATE 0 00 DEGREES Y MIRROR NO If the NORMAL geometry is selected the special geometry prompting ends Pressing the key will toggle between the NORMAL display and GEOMETRY SPECIAL Ifthe SPECIAL response is entered the prompting will then go on to the specific prompts for each operation Once a program is run with one of the special geometric operations used it will not show the NORMAL prompt again until the special option is set back to the normal conditions RUN 2 1 SCALING If the SCALING option is enabled on the system a prompt for the scale factor will appear as SCALE XX XXX The value displayed will be the scale factor used the last time the particular program was run The scale factor is used to enlarge or reduce the size of the entire part either to produce a different size part or to allow a test run to be drawn on a smaller sheet of paper The value entered is used as a multiplier for all the part dimensions therefore IF SCALE 1 000 THE PART WILL BE THE ORIGINAL 1 1 SIZE IF SCALE 10 000 THE PART WILL BE 10 TIMES ORIGINAL SIZE IF SCALE 125 THE PART WILL BE 1 8 ORIGINAL SIZE SCALE VALUES MAY RANGE FROM 0 001 TO 65 000 USE 1 000 FOR ACTUAL SIZE PART 2 RUN 2 AO 73290 SYSTEM OPERATIONS
126. AND 2 OF 6PL 6PL F 6 2 This contact is connected to the cutting circuit in such a way that it can initiate the HIGH PREHEAT FUNCTION of the gas controls This contact will only operate when AUTO oxy fuel cutting is selected in MANUAL cutting the contact will remain open This contact will close for the PREHEAT time specified by the operator and then open for the remainder of the cut If the 2 5RS is in OVERRIDE this contact will remain open AO 73290 PART 7 INTERFACE 5 2 5RS OPERATION AND MAINTENANCE MANUAL MACH 2 8 PLASMA INTERFACE If the 2 5RS is set for PLASMA CUTTING the following relay sequencing will be used The following table shows the changes in assignment for the relay contacts and the sensing input CONTACTS OXY FUEL PLASMA CONTACT 6PL 1 2 HI PREHEAT HEIGHT SENSOR DISABLE CONTACT 6PL 3 4 OXY START PLASMA START CONTACT 6PL 5 6 OXY ENABLE PLASMA ENABLE INPUT 6PL 7 8 OXY CUT SWITCH PLASMA ARC ON SENSE MACH 2 9 PLASMA ARC ON GO INPUT PINS 7 AND 8 OF 6PL SENSING 6PL 8 6PL 7 CIRCUIT This input is used for sensing when the arc has transferred to the plate and motion along the cut path can begin It operates much the same as the OXY SENSE INPUT described earlier in that it must be in an OFF state before the plasma circuit will be enabled Also motion along the cut begins when the input goes Since some plasma units do not have a ARC ON
127. ANDARD SHAPES the part dimensions may be entered in either INCHES or MILLIMETERS regardless of the operating system selection This allows a user who normally operates in inch values to input a metric part directly without needing to convert first This manual is used with both inch and metric systems therefore dimensions will generally not be described as inches or millimeters but are assumed to be in the unit selected by the system PART 1 OPSUMMARY 2 AO 73290 SYSTEM OVERVIEW GENERAL OPERATION SUMMARY 2 5RS GENERAL OPERATION SUMMARY OPSUMMARY 1 NC TRACER SWITCHING There is no power on off switch on the 2 5RS CONTROL it is ON any time the CUTTING MACHINE HAS POWER To use the normal TRACING CUTTING functions of the machine without the 2 5RS CONTROL press the NC RUN button to turn off the LED located in the corner of the button This causes the 2 5RS CONTROL to return all control of the cutting and drive tracer functions to the manual controls and allows normal tracer operation Pressing the NC RUN button again will cause the LED to light and return control of the drives and cutting functions to the 2 5RS CONTROL OPSUMMARY 2 OPTIONAL LANGUAGE FEATURE The 2 5RS control has an alternate language that is available as a option The 2 5RS normally prompts the operator in the English language However there are several other optional languages which can be installed in the unit French German Finnish Swedish Spanish and Portuguese
128. AO 73290 PART 3 EDIT 1 2 5RS OPERATION AND MAINTENANCE MANUAL If the block number entered is past the end of the program or if the SCROLL keys are used to step past the end or beginning of the program a brief message appears indicating the condition and then the previous block is displayed If the program end is reached the display shows PROGRAM END then backs up to the last block in the program If the scrolling moves past the beginning of the program the display shows PROGRAM TOP and then displays the first program block During the MAIN DATA BLOCK DISPLAY MODE the left side of the display shows the block number while the right side shows a variety of information depending on the type of block LINE ARC or FUNCTION For these examples assume that the data block displayed is the 5TH internal block in the program For LINE moves the display shows B0005 LINE X Y This means that the block causes a linear movement The remainder of the block indicates which dimensions are present in the block and the sign of the dimension The actual dimensions are not shown at this point so that the operator can quickly scan through the data blocks without having to look for specific dimensions To look at the actual X Y dimensions the block must be selected for editing as described later For ARC moves the display alternates between B0005 CW CCW ARC and B0005 X Y I J The first display shows the direction of
129. ARTING CORNER and REPEAT DIRECTION parameters can be directly entered with the numeric keypad Direction arrows are provided for quick reference When defining the LEAD IN ANGLE 0 degrees is parallel to the Y axis and 90 degrees is parallel to the X axis The LEAD OUT position is determined by the direction of the cut It is either parallel to the last side cut as shown or 45 degrees from the last cut direction When running the resulting NC part program position the torches at the corner of the plate regardless of the REPEAT MODE selected From this corner the program moves out to the actual pierce point PART 2 SHAPES 56 AO 73290 SYSTEM OPERATION SHAPES SHAPES3 52 SHAPE 32 CIRCLE REPEAT PATTERNS AUTO MANUAL PLATE SIDE LEFT RIGHT KE 1 CUT DIRECTION OD CLOCKWISE OR COUNTER CLOCKWISE 2 STARTING POSITION 1 OF 8 CORNERS 3 DIAMETER DIMENSION INCHES MILLIMETERS 4 LEAD IN DIMENSION INCHES OR MILLIMETERS 5 LEAD OUT DIMENSION INCHES OR MILLIMETERS 6 LEAD OUT TYPE 0 OR 1 7 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 8 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 9 REPEAT MODE AUTOMATIC OR MANUAL POSITIONING IF AUTO REPEAT MODE IF MANUAL REPEAT MODE I0 VERIFY YES NO 10 REPEAT DIRECTION 1 OF 4 POINTS II VERIFY YES NO NOTES The STARTING CORNER and REPEAT DIRECTION parameters can be directly entered with
130. ARY 9 DISPLAY KEY The DSPY key may be used at any time to enter the display select menu function described in the chapter DISPLAY MODES Pressing this key does not affect the operation of the machine in any way and so may be used at any time even while a part is being cut Once pressed the current display is removed and the display select menu is presented Select the desired display see SCROLLING OPERATIONS To exit the display mode and resume normal operation SELECT display DSPY00 EXIT MODE When this is entered the control returns to the operation that was active before the display function was used PART 1 OPSUMMARY 8 AO 73290 SYSTEM OVERVIEW GENERAL OPERATION SUMMARY OPSUMMARY 10 PART RETURN KEY The PART RET key is used to return to one of 3 starting positions on a part in cases where the cut was lost or must be repeated over a portion of the part Pressing the PART RET key the first time returns to the most recent pierce point on the part Pressing the PART RET key a second time returns to the start point of the current part Pressing the PART RET button a third time will return to the home position on the selected cutting table Pressing SHF PART RET returns to the table 1 0 0 home reference position OPSUMMARY 11 BACKUP KEY The BACKUP key is also used to re start lost cuts When pressed it stops the cutting process and retraces the cut path in reverse Once the correct point is
131. ASMA HEIGHT SENSOR DISABLE 70 INCH PROGRAMMING 71 METRIC PROGRAMMING 11 MARKER 1 OFFSET ON 79 CUTTING TABLE HOME SELECT 12 MARKER 1 OFFSET OFF 81 INCREMENTAL PROGRAMMING 29 KERF OFFSET LEFT 82 ABSOLUTE PROGRAMMING 30 KERF OFFSET RIGHT 90 PROGRAM END NO REWIND 38 CANCEL KERF OFFSET 97 SET PROGRAM REPEAT POINTER 39 PROGRAM FEEDRATE 98 REPEAT AT PGM POINTER 40 PROGRAMMABLE KERF 99 PROGRAM END REWIND 41 PROGRAMMABLE DWELL 103 AUTO RELOAD FOR LOAD RUN 00 03 04 07 08 11 PROGRAM STOP causes machine operation to halt and all cutting functions to be turned off Pressing the CYCLE START key resumes operation The 2 5RS ignores all data between these two codes Usually they are used for comments and instructions which only appear on the program printout CUTTING ON initiates the start sequence for selected cutting system While cut is on machine moves at the speed set by the operator CUTTING OFF turns off cutting pocess after performing any cut off sequencing machine moves at high traverse speed to next pierce location PLATE MARKER 1 OFFSET ON causes the machine to move by the distances entered for the MARKER 1 X Y OFFSET dimension during the SETUP AND INSTALLATION procedure In this way the part program does not have to compensate for the physical offset between the marker and torch Optionally followed by a 1 to 8 causing offsets 1 8 as specified by SD80 96 to be used See INSTALLATION amp
132. ATIONS 21 2 5RS OPERATION AND MAINTENANCE MANUAL Neutral conductor of machine s power source JOVAC 0 25 A Input Input pin for powering the 2 5RS from a 20 115VAC machine power source IDEE Input pin for powering the 2 5RS from a 230V AC machine power source PNA shi 2 5RS WITH MNJ 11126 using MO 04359 INTERFACE CARD 2 5RS BACK PANEL 37 PIN EXT DRIVE CONNECTOR DESCRIPTION NOMINAL RATINGS NN Power Ground 0V Nominal 0 to 2 17V peak or 0 to 2 17V peak Limits 1 98 to 2 36V peak or 1 98 to 2 36V peak 0 04 mA Speed reference input Output to the Burny control relay coil on KS07 equipment acts as pull down to turn on Sinks 500 mA 50V the relay If Burny signal selected output is 1 ma 15V If signal selected is customer signal from pin 15 then maximums are the same as for pin 15 Maximums 30VDC 2 A or 60VDC a 0 5 A 120VAC 8 2 Logic is 4 90V minimum 24V X and Y Enable Drive input maximum Logic LO is 1 35V maximum 0 V minimum 25 A maximum Y drive reference output Y drive reference input If Burny signal selected output is 1 ma 15V If signal selected is customer signal from pin 18 then maximums are the same as for pin 15 Maximums 30VDC 2 A or 60VDC a 0 5 A 120VAC 2 Preheat Gas solenoid power contacts These 2 230VAC maximum or are normally open dry contacts 2 A 30VDC maximum 2 220V AC maximum or 2
133. Analog Supply input Analog Supply input Speed reference input from customer s speed potentiometer Enable Drive input 1 Enable Drive input 2 Enable Drive input 3 NC Run Low output low true This is the Y drive reference output This is the Y drive reference input Enable X and Y Drives Input This is the X drive reference output PART 10 SPECIFICATIONS 10 20VDC to 30VDC 2V ripple maximum 20VDC to 30VDC 2V ripple maximum Nominal 0 to 2 5V peak or 0 to 2 5V Limits 1 2 to 3 8V peak or 1 2 to 3 8V peak 08 mA These inputs are isolated from each other with common anode diodes Logic low 0 to 1 35V Logic High 4 2 to 5V Sinks 500 mA 50V High impedance to negative voltages 50V maximum If Burny signal selected output is 1 ma 15V If signal selected is customer signal from pin 15 then maximums are the same as for pin 15 Maximums 30VDC 2 A or 60VDC 0 5 120VAC 2 Logic HI is 4 90V minimum 24V maximum Logic LO is 1 35V maximum 0 V minimum 1 mA maximum If Burny signal selected output is 1 ma 15V If signal selected is customer AO 73290 PRODUCT SPECIFICATIONS same as for pin 15 Maximums 30VDC 2 or 60VDC 0 5 120VAC 22 Preheat Gas solenoid power contacts These 2 230VAC maximum or are normally open dry contacts 2 A 30VDC maximum 2 230V AC maximum or 2 A 30VDC maximum 2 230V
134. BENDS DEBURR ALL HOLES DO NOT CHAMFER 1 BREAK ALL SHARP EDGES NOTE UNLESS OTHERWISE SPECIFIED 6 5 4 CABINET MUST_BE DUST TIGHT 3 2 10 REFERENCES USED ON MO 03376 MO 05573 06879 MO 11691 9 SILKSCREEN SPECIFIED PER ORDER USE P N 42 23130 8 MATERIAL 0 06 0 003 ALUMINUM SECTION SCALE 1 1 PROTECTIVE CONDUCTIVE PLATING THIS SURFACE AND INSIDE OF CABINET DO NOT PAINT THIS SURFACE DETAI SCALE 1 5 DIA THRU DETAI SCALE NO 25 0 149 f f f f f f f f f f f f f f f f f f f j f f 7 NO 16 0 177 DR THRU 0 125 DIA THRU 2 HOLES 0 485 Num DIA THRU 2 HOLES 0 969 PUN 0 875 DIA THRU 0 484 0 875 DIA THRU DETAIL DETAIL E i SCALE 1 1 SCALE 1 1 NO 22 0 157 DR THRU 2 HOLES 1 969 0 985 150 DIA THRU 2 HOLES 1 437 0 875 DIA THRU 7 DETAIL D SCALE 1 1 5 DR THRU 8 52 1 HOLE B ER 5 37 1 38 AN DETAIL C 2 PLACES SEE DETAIL D 1 PLACE B NO 30 0 1285 DR THRU 4 HOLES A _ MASK 0 38 TO 0 50 CIRCLE AROUND BLIND NO PAINT IN THREADS 3 PLACES DD D Z 2 000 A 7 16 0 4375 DR THRU 1 HOLE G IA
135. BITS STANDARD CHAR TYPE 4 EP8D ASCII EVEN PARITY 8 DATA BITS CHAR TYPE 5 OP7D ASCII ODD PARITY 7 DATA BITS CHAR TYPE 6 OP8D ASCII ODD PARITY 8 DATA BITS CHAR TYPE 7 EIA EIA RS244 ODD PARITY FORMAT Note Two 2 stop bits always sent 1 or 2 may be received If the BAUD RATE parameter is set to 0 the operator must select the BAUD RATE for the communication from the following menu For 2 5RS Add this column for 2 5 Plus BAUD RATE 1 110 BAUD RATE 8 192K BAUD RATE 2 300 BAUD RATE 9 28 8K BAUD RATE 3 600 BAUD RATE A 38 4K BAUD RATE 4 1200 BAUD RATE B 57 6 BAUD RATE 5 2400 BAUD RATE C 115 2K BAUD RATE 6 4800 BAUD RATE D 230K BAUD RATE 7 9600 See SETUP AND CONFIGURATION section of this manual on 5050 AO 73290 PART 5 SERIAL 3 2 5RS OPERATION AND MAINTENANCE MANUAL Once all the parameters are set the 2 5RS initiates the transmission by setting it s output status line to the active condition and then waits for the external device to enable it s port A WAITING message is displayed until the external device comes ON LINE The 2 5RS then delays for 1 second and begins the communication If the RECYCLE key is pressed before the operation is complete the process is aborted and a RECYCLE ABORT is displayed Press the RECYCLE key again to return to the top menu selection During a LOAD or STORE operation the display shows the actual number of bytes being used
136. BURNY 2 5RS 2 5Plus Operation and Maintenance Manual Revision Mar 2001 For use with software version 9 25 97 and later AO 73290 Cleveland w MO Jon Controls This documentation may be not be copied photocopied reproduced translated or reduced to any electronic medium or machine readable format without explicit written permission from the BURNY DIVISION OF CLEVELAND MOTION CONTROLS 2001 Cleveland Motion Controls Burny Division 7550 Hub Parkway Cleveland Ohio 44125 Telephone 216 524 8800 TABLE OF CONTENTS TABLE OF CONTENTS TABLE OF nun II WARRANTY AND LIMITATION OF LIABILITY U nnne nnn nnn nn nnn nnne nnn XVII PART 1 SYSTEM OVERVIEW 2 amp 2 22322282 22 2 20 1 SYSTEM OVERVIEW 1 INTRODUCTION Re 1 2 5RS GENERAL OPERATION 5 3 2 5RS GENERAL OPERATION 5 saa na sane anne 3 OPSUMMARY 1 NC TRACER SWITCHING 6 3 OPSUMMARY 2 OPTIONAL LANGUAGE 0 0 4 0 4 0 1 3 OPSUMMARY 3 A
137. CH process allows parts to be taught in either a chain cut mode or as a pierce step and repeat type part To allow for the initial move from the corner of the plate to the first part any positioning moves before the first cut are onlyperformed the first time and are not repeated on each part TEACH 3 TEACHING A PROGRAM WHERE EACH PART IS PIERCED To TEACH a pierce and cut type part the tracer should be positioned at a point on the template that represents the location of the corner of the plate before the enter button is pressed to start the teach process Then the tracer should be moved to the pierce location for the first cut The X Y COORDINATES OF THIS POINT SHOULD BE WRITTEN DOWN as they will be needed later to teach the repeat to the next part Turn the lt lt CUT ON gt gt and lead the tracer into the pattern Continue to trace around the pattern to the end of the CUT Then turn the lt lt CUT OFF gt gt Move the tracer to the next cut segment and repeat the cut on trace cut off sequence until all the cutouts and the outside profile of the part are taught The final operation is to teach the repeat step move by positioning the tracer at the new pierce location for the next part This can either be done by marking the template with the next pierce point and moving the tracer over that point However a more accurate method is to use the X Y readouts to position the machine exactly at the desired location This can be calculated by adding the t
138. CONFIGURATION SD62 SYSTEM CONFIGURATION 2 SD63 SYSTEM CONFIGURATION 3 SD68 SPEED RANGE SD69 ALTERNATE LANGUAGE SELECTION SD70 KNIFE DIAMETER SD71 KNIFE BP ANGLE SD74 X OFFSET TABLE 1 TO TABLE 2 HOME POSITION SD75 Y OFFSET TABLE 1 TO TABLE 2 HOME POSITION SD76 X OFFSET TABLE 1 TO TABLE 3 HOME POSITION SD77 Y OFFSET TABLE 1 TO TABLE 3 HOME POSITION SD78 X OFFSET TABLE 1 TO TABLE 4 HOME POSITION SD79 Y OFFSET TABLE 1 TO TABLE 4 HOME POSITION PART 7 SETUP AND CONFIG 8 AO 73290 SETUP AND CONFIGURATION SD80 X OFFSET 1 SD81 Y OFFSET 1 SD82 X OFFSET 2 SD83 Y OFFSET 2 SD84 X OFFSET 3 SD85 Y OFFSET 3 SD86 X OFFSET 4 SD87 Y OFFSET 4 SD88 X OFFSET 5 SD98 Y OFFSET 5 SD90 X OFFSET 6 SD91 Y OFFSET 6 SD92 X OFFSET 7 SD93 Y OFFSET 7 SD94 X OFFSET 8 SD95 Y OFFSET 8 SD96 X OFFSET FROM TABLE 1 TO X HOME LIMIT SWITCH POSITION SD97 Y OFFSET FROM TABLE 1 TO Y HOME LIMIT SWITCH POSITION SDA0 X BACKLASH SDAI Y BACKLASH SDA2 LASH RATE ALL variables marked with are also in the overlay tables See Detailed Menu for further information IMPORTANT All values in parenthesis appear in the display but have no function in this control In the display of each menu item below each parameter label is the unit of measure for that value All times are entered in SECONDS Any distance or speed values are entered in the units selected by the OPERATING SYSTEM parameter SD
139. CR gt lt LF gt where represents one of the 3 digit status codes listed at the end of this section The 2 5RS then sends an lt XOFF gt lt ROFF gt and then turns off it s OUTPUT STATUS LINE PART 5 SERIAL 18 AO 73290 SERIAL COMMUNICATIONS SERIAL SERIAL 8 6 CAD LINK CLINK PROTOCOL CLINK is another special communications protocol which allows the 2 5RS to send and receive part cutting programs from a remote computer via commands sent through the RS 232 port The host computer can be programmed to use this protocol to provide a totally automatic link no operator is required at the host computer Currently there are four basic commands that are supported 1 lt ESC gt FD FILE DATA COMMAND 2 lt ESC gt FG FILE GET COMMAND 3 lt ESC gt FQ FILE QUEUE COMMAND 4 lt ESC gt QQ FILE QUIT COMMAND CLINK utilizes XON XOFF software handshaking to control the flow of data between the two devices character by character check for XON or XOFF gt 11 amp gt 13 codes is done 2 5RS does not currently support any block type protocols SERIAL 8 7 FILE DATA lt ESC gt FD FILE DATA This command is used in two different ways For the 2 5RS control to send a program to the remote computer the program data must be proceeded by a FILE DATA command string The message is a sequence of characters incorporating the desired program number For example for the 2 5RS to send program number 8765 to the remote computer th
140. D MAINTENANCE MANUAL FLOPPY 5 SAVING FILES TO FLOPPY DISK Storing a file to 2 5RS PORTABLE DISK DRIVE is accomplished by pressing the key on the keypad which selects STORE TO FLOPPY Press the ENTER key The 2 5RS prompts the operator for a numeric program number 8 digits maximum Enter the desired program number to be stored on the floppy disk then press the ENTER key The 2 5RS control displays the prompt INSERT DISK PRESS ENTER TO CONTINUE Insert a formatted 3 5 floppy disk into the drive and close the door Press the ENTER key to continue At this point the 2 5RS control does one of two things If D2 of SD50 SERIAL DEFINITION which is the programming language select digit is set to 0 prompting for the program type occurs If D2 of SD50 SERIAL DEFINITION is preset to some value the program begins the process of storing to the floppy disk A LED indicator light on the disk drive begins to flash indicating there is some disk activity When the transfer is completed the 2 5RS control changes to display STORING COMPLETE PART 3 FLOPPY 4 AO 73290 PART 4 PART PROGRAMMING Tab Page Part 4 PART PROGRAMMING PROGRAMMING PROGRAMMING THE NC CONTROL The 2 5RS accepts the two major programming languages used for X Y shape cutting machines Word Address as per EIA RS 274 specification and ESSI In addition several variations of each of these languages are avail
141. DC mains should be AWG 18 or larger Each cable is either supplied by designed by or approved by Burny The system and all other electrical devices associated with and in the proximity of the system have been properly grounded AO 73290 PART 6 SERVICE 3 2 5RS OPERATION AND MAINTENANCE MANUAL ends of every cable have a ground clamp attached snugly to the cable shield e Every ground clamp is attached to the component in the proper manner The system programs and files are backed up properly SERVICE 1 4 FUNCTIONAL TESTING OF THE SYSTEM AFTER INSTALLATION Functional testing of the 2 5RS after installation is recommended Each installed system can have a unique design therefore a unique test may be required for the installed system The test should be designed to ensure that e The equipment has been properly integrated e The 2 5RS is suitable for and functions correctly in its environment e Protective devices and control devices operate as intended The 2 5RS is compatible with other equipment The 2 5RS can perform to specifications when interconnected The 2 5RS has sufficient range in its controls e The system programs and files are backed up properly PART 6 SERVICE 4 AO 73290 SERVICE INSTALLATION 2 LIST OF DIAGNOSTICS AND TESTS OF THE 2 5RS This is a list of diagnostics and tests contained in this manual that will assist in checking various functions of the Burny 2 5 RS SUBJECT TITLE
142. DI Sale air 28 AO 73290 Table of Contents vii 2 5RS OPERATION AND MAINTENANCE MANUAL SETUP amp CONFIG 4 2 43 SD52 SPECIAL EOP a a a 34 SETUP amp CONFIG 4 2 44 SD53 FILE EXTEN 36 SETUP amp CONFIG 4 2 45 SD60 OPERATING SYS 37 SETUP amp CONFIG 4 2 46 SD61 SYSTEM CONFIGURATION 1 37 SETUP amp CONFIG 4 2 47 SD62 SYSTEM CONFIGURATION 2 38 SD62 SYSTEM CONFIGURATION Penn ann re ttt ann Deed E ee s 38 PROGRAM FORMAT 5062 tette ttt ttt rtt rt 42 SETUP amp CONFIG 4 2 48 SD63 SYSTEM CONFIGURATION 3 46 SETUP amp GONFIG 4 2 49 565 tee ee eere etie ee exeo Ca exea cb dnx ee hen 46 SETUP amp CONFIG 4 2 50 SD68 SPEED RANGE 47 SETUP amp CONFIG 4 2 51 SD69 LANGUAGE SEL a a 48 SETUP amp CONFIG 4 2 52 SD70 KNIFE DIA in mm 49 SETUP amp CONFIG 4 2 53 SD71 KNIFE BP ANGLE nnn 49 SETUP amp CONFIG 4 2 54 5080 5095 PROGRAMMABLE OFFSETS in mm 49 SETUP amp
143. E Er nem SP 720 W ENCODER REV INLINE 0 10070 NONE 250 6 4 MTE 4237 138BF 47 87 SP 720 W ENCODER REV INLINE MO 10071 NONE TE 4237 138BF 47 87 5 2502 30000 po d pre 4 s EM USER er This print is the property of Cleveland Motion Controls Inc and is furnished as confidential information only It must not be copied traced or reproduced in any manner nor submitted to any outside parties for any purpose without our written permission Any use of this print without written permission of Cleveland Motion Controls Inc is a violation of our exclusive rights 7 N Cleveland PARAMETERS DECIMAL LL motion Controls 200 COUNT MODULAR ENCODER 030 C ADD NEW P N 12590 KAP 07 98 015 An mE Company DWG no BO 9371C01 0WG SIZE DRAWING NUMBER REV ADD ANGULAR 7550 HUB PARKWAY CLEVELAND OHIO BO 9371 Se eo ee eee EI ay may SHEET 1 OF 3 BLANK STEP 1 CALCULATE NUMBER OF MOTOR REVOLUTIONS FOR SPECIFIED NUMBER OF ENCODER LINES SD22 STEP 2 CALCULATE NUMBER OF OUTPUT SHAFT REVOLUTIONS BASED ON NUMBER OF MOTOR REVOLUTIONS STEP 3 CALCULATE HOW FAR THE MACHINE TRAVELS BASED ON THE NUMBER OF OUTPUT SHAFT REVOLUTIONS AND THE DIAMETER OF THE PINION GEAR SD22 ENC LIN REV ACTUAL ENCODER LINES REV
144. E 5153 BRL 05 85 1 1 SHEET 1 OF 1 05 gt BLANK
145. E F X 4X gt STANDARD X gt 4X gt Y X gt X Y gt Y X gt X Y gt Y X gt Y Y gt X X gt Y Y gt X X gt Y Y gt X Y gt X Disable of the latched jog function X gt X Y gt Y amp Disable latched jog function X gt X Y gt Y amp Disable latched jog function X gt X Y gt Y amp Disable latched jog function X gt Y Y gt X amp Disable latched jog function X gt Y Y gt X amp Disable latched jog function X gt Y Y gt X amp Disable latched jog function X gt Y Y gt X amp Disable latched jog function PART 7 SETUP AND CONFIG 42 x xixi AO 73290 SETUP AND CONFIGURATION SD62 SYSTEM CONFIGURATION 2 D7 selects DRIFT COMPENSATION LATCHED BACKUP ENABLE BACKLASH COMPENSATION ENABLE and enables the Series 1000 tracer NC jog controls The LATCHED BACKUP ENABLE causes the Back button to change to a toggle action instead of the normal momentary operation Pressing the button while the program is running forward will cause the machine to stop and reverse direction with the cutting process turned off The button can be released at this point and the backup motion will continue When the desired position is reached press and release the Backup button again to cause the machine to reverse directions again and begin traveling in the forward pro
146. EEDRATE 6 SETUP amp CONFIG 4 1 5 SERVO05 SYS 5 5 SETUP amp CONFIG 4 1 6 SERV10 DSPY10 SYS DATA SETUP amp CONFIG 4 2 SYSTEM DATA PARAMETERS 7 SETUP amp CONFIG 4 2 1 SDO1 ARC ON DELAY 10 SETUP amp CONFIG 4 2 2 SD02 BLEEDOFF TIME 10 SETUP amp CONFIG 4 2 3 SDO3 ACCEL TIME seconds multiple parameter 10 SETUP amp CONFIG 4 2 4 SD04 MAXIMUM DRIVE SPEED 10 SETUP amp CONFIG 4 2 5 SD06 BACKUP SPEED 11 SETUP amp CONFIG 4 2 8 SDO7 CORNER SPEED multiple parameter 11 SETUP amp CONFIG 4 2 7 SD08 MINIMUM HOLD SPEED ipm MPM 12 SETUP amp CONFIG 4 2 8 SD09 ERROR SPEED MAXIMUM 13 SETUP amp CONFIG 4 2 9 SD10 RUN SPD LIMIT multiple parameter 13 SETUP amp CONFIG 4 2 10 SD11 TRAVERSE SPEED LIMIT 13 SETUP amp CONFIG 4 2 11 SD12 MIN ACCEL Seconds eene 13 SETUP amp CONFIG 4 2 12 SD14 GAIN BREAK encoder counts multiple parameter
147. EFT RIGHT N 13 M Jef ENF NX NES lt a 60 DEGREE ANGLE TO CENTERS 1 CUT DIRECTION OD CLOCKWISE OR COUNTERCLOCKWISE 2 STARTING POSITION 1 OF 8 POINTS 3 DIAMETER DIMENSION INCHES OR MILLIMETERS 4 LEADIN DIMENSION INCHES OR MILLIMETERS 5 LEADOUT DIMENSION INCHES OR MILLIMETERS 6 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 7 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 8 REPEAT MODE AUTOMATIC OR MANUAL POSITIONING IF AUTO REPEAT MODE IF MANUAL REPEAT MODE 9 VERIFY YES NO 9 REPEAT DIRECTION 1 OF 4 POINTS 10 VERIFY YES NO NOTES The STARTING POSITION and REPEAT DIRECTION parameters can be directly entered with the numeric keypad Direction arrows are provided for quick reference The actual LEADOUT position is determined by the direction of the cut The figure above shows the LEADOUT position assuming a clockwise cutting direction has been selected When running the resulting NC part program position the torches at the CENTER of the first part regardless of the REPEAT MODE selected From this position the program moves out to the actual pierce point When performing AUTO REPEAT mode operations parts are shifted to the left and right at a 60 degree angle to minimize the amount of scrap between parts AO 73290 PARTS 2 SHAPES 7 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 3 SHAPE 3 RING REPEAT PATTERNS 3 EGG ma
148. EL or PLASMA cutting is being done prompts for the values which control the automatic piercing cycle appears next These include Preheat Pierce Ramp and Part Count RUN 4 1 2 1 HIGH PREHEAT OXY FUEL If Oxy Fuel cutting has been selected the operator is first prompted for the duration of the High Preheat cycle The display shows PREHEAT XXX XX Enter the time in seconds for the high preheat cycle When the control moves to a new pierce point it automatically turns on the High Preheat solenoids for the time specified When the preheat cycle is complete the High preheat solenoids turn off and the Cutting Oxygen is turned on RUN 4 1 2 2 PIERCE RAMP OXY FUEL OR PLASMA Regardless of whether Oxy Fuel or Plasma cutting is selected the operator is prompted for the PIERCE RAMP time See the description under MANUAL CUT MODE regarding the PIERCE RAMP TIME PART 2 RUN 6 AO 73290 SYSTEM OPERATIONS RUNNING A PROGRAM RUN 4 1 2 3 PART COUNT ALL CUTTING PROCESS For all cutting processes a prompt for HOW MANY XXX appears Enter the desired number of part cycles to produce the required parts Example 100 parts required with 4 torches cutting Enter 25 to get correct count If an additional part is required after the preset count is reached press START CYCLE to cut one more part RUN 4 2 TEST RUN Test Run allows the same machine movements as during a cut however all cutting outputs are prohibited This is useful
149. ER V42 BLETME DISPLAYS BLEEDOFF TIMER V43 MRKTME DISPLAYS MARKER ON DELAY TIMER PART 7 SETUP AND CONFIG 58 AO 73290 SETUP AND CONFIGURATION SETUP amp CONFIG 4 4 18 V50 BP INPUT This display shows the current state of the 8 signal inputs from the interface card and main card The data is displayed as an 8 bit binary value A 1 shows that the input is ON while a 0 indicates OFF BP INPT 00000000 NON VOL DATA BIT 1 FOR OPERATE 0 FOR ESTOP NOT USED Y EXTERNAL JOG REQUEST X EXTERNAL JOG REQUEST 1 FOR CUT TOOL ON SENSE SETUP amp CONFIG 4 4 19 V54 XCNTR Shows 8 bit hexadecimal value of X axis encoder counter Can be used to check encoder input circuitry by making sure counter counts smoothly when encoder is being turned SETUP amp CONFIG 4 4 20 V55 YCNTR Shows 8 bit hexadecimal value of Y axis encoder See V54 SETUP amp CONFIG 4 4 21 V60 BP OUT Shows an 8 digit binary display of drive control output and relay control bits being sent to the interface card circuitry Each digit controls a different function BP OUT XXXX0000 1 FOR CUT START 0 ON FOR PREHEAT 1 0 SPARE 0 ON FOR CUT OFF 1 0 X D A SIGN BIT Y D A SIGN BIT FOR INTERNAL REF 0 FOR SPEED DIAL FOR LOW SPEED RANGE 0 FOR NORMAL AO 73290 PART 7 SETUP AND CONFIG 59 2 5RS OPERATION AND MAINTENANCE MANUAL SETUP amp CONFIG 4 4 22 V72 X BACKLASH SETUP amp CONFIG 4 4 23 V7
150. ES PART 7 SETUP AND CONFIG 36 AO 73290 SETUP AND CONFIGURATION SETUP amp CONFIG 4 2 45 SD60 OPERATING SYS This parameter selects between an INCH BASED OPERATING SYSTEM or a METRIC MILLIMETER BASED SYSTEM Use the key to toggle the selection The type of system selected determines the following IF INCH OPERATING SYSTEM IS SELECTED All Dimension and Distances for both Displays and Entered values are in INCHES All Speed displays and entries are in INCHES PER MINUTE IPM All Standard Shape Programs prompt for INCH part dimensions IF METRIC OPERATING SYSTEM IS SELECTED All Dimensions and Distances for both Displays and entered data are in MILLIMETERS All Speed displays and entered values are in MILLIMETERS PER MINUTE MPM All Standard Shape Programs prompt for MILLIMETER part dimensions IMPORTANT Although the 2 5RS switches from inches to millimeters changing from one to another does not convert the dimensions in the program The 2 5RS setup parameters along with the programs stored in the control are not re adjusted to inches or millimeters SETUP amp CONFIG 4 2 46 SD61 SYSTEM CONFIGURATION 1 The SD61 SYS CONFG1 Primary system configuration flag is used to select the desired system operation for the machine it is being installed on Since the 2 5RS can be used on several different types of special purpose cutting machines there are individual sp
151. ES OR MILLIMETERS RAIL DISTANCE TO NEXT HOLE CROSS DISTANCE TO NEXT HOLE WIDTH OF CUTTING TOOL PATH INCHES OR MILLIMETERS INCHES OR MILLIMETERS YES OR NO NOTES The X and Y MOVE DISTANCE values are used to define the center to center distance between holes From this center position the program moves the machine to the pierce point determined by the LEAD IN DIMENSION LEAD IN DIMENSION must be less than the DIAMETER DIMENSION PART 2 SHAPES 40 AO 73290 SHAPES3 36 NOV gt OQ gt BASE WIDTH WIDTH HEIGHT DIMENSION LEFT SHOULDER RIGHT SHOULDER LEFT OFFSET KERF DIMENSION SCRAP DIMENSION 9 LEAD IN DIMENSION 10 LEAD OUT DIMENSION 11 VERIFY YES NO SYSTEM OPERATION SHAPES SHAPE 36 BEAM SUPPORT REPEAT PATTERNS PLATE SIDE LEFT RIGHT FEE i d PH E LS vy Leys ee INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS WIDTH OF CUTTING TOOL PATH DISTANCE BETWEEN PARTS IN MM INCHES OR MILLIMETERS INCHES OR MILLIMETERS YES OR NO NOTES Like others this part is cut with the BASE at the upper position As a result the prompts used to label the top and sides assume the part is rotated 180 degrees The only difference between parts created with LEFT P
152. ES OR MILLIMETERS 4 COLLAR WIDTH INCHES OR MILLIMETERS 5 TOP WIDTH INCHES OR MILLIMETERS 6 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 7 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 8 LEAD IN DIMENSION INCHES OR MILLIMETERS 9 LEAD OUT DIMENSION INCHES OR MILLIMETERS 10 VERIFY YES NO YES OR NO NOTES Like others this part is cut with the BASE at the upper position As a result the prompts used to label the top and sides assume the part is rotated 180 degrees The only difference between parts created with LEFT PLATE or RIGHT PLATE enabled occurs in the traverse move to the first pierce point PART 2 SHAPES 26 AO 73290 SYSTEM OPERATION SHAPES SHAPES3 22 SHAPE 22 OCTAGON REPEAT PATTERNS 1 PLATE SIDE Nd LEFT RIGHT I er 2 4 y f ke lt lt x ant Y y S p f x 4 1 WIDTH DIMENSION INCHES OR MILLIMETERS 2 HEIGHT DIMENSION INCHES OR MILLIMETERS 3 HOLE DIAMETER INCHES OR MILLIMETERS 4 BEVEL LENGTH INCHES OR MILLIMETERS 5 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 6 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 7 LEAD IN DIMENSION INCHES OR MILLIMETERS 8 LEAD OUT DIMENSION INCHES OR MILLIMETERS 9 VERIFY YES NO YES OR NO NOTES Ifa HOLE DIAMETER of 0 Is defined no center hole is cut AO 73290 PARTS 2 SHAPES 27 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 23
153. ESET MODE ONLY message is displayed and the operation does not execute To perform the desired operation the current operation must be stopped by pressing the RECYCLE key and then re selecting the function AO 73290 PART 8 ERROR 3 2 5RS OPERATION AND MAINTENANCE MANUAL ERROR 2 RUN TIME ERRORS These error messages only appear while a part program is actually running ERROR 2 1 MEMORY TRIP WHILE RUNNING The protection circuitry for program memory constantly monitors various circuit conditions for any problems Ifan error develops it trips a protection latch which prevents any data from being written into the program memory This message occurs while running a part and indicates that an error condition has been detected To reset the error first return the machine to the original start position so the part can be re run Then press the RECYCLE key to re enable the memory The test run mode can be used to re trace the machine path back to where the operation was halted The desired cutting mode can then be selected and operation resumed ERROR 2 2 PATH ERROR The 2 5RS constantly monitors the machine position while a part is being run If it detects that the path has deviated by more that a preset value selected during installation it issues a warning message accompanied by a beeping sequence This warning does not stop the machine only warns the operator that the part being cut is not within the preset error distance ERROR 3
154. FEATURES This manual covers all aspects of the operation both STANDARD and OPTIONAL so certain parts of this manual may not apply to all units NOTE The 2 5RS has the ability to operate as a RS 422 device or a RS 232 device This manual refers to the control acting as a RS 232 device except where noted The system has extensive SERVICE DIAGNOSTIC UTILITIES which allow many of the operating values to be displayed and modified In addition all setup variables acceleration rates speeds gains etc are stored in non volatile memory devices which retain the values permanently even in the event of simultaneous battery and power failure Note that the Custom Auxiliary Code tables and user programs are not saved in non volatile devices but are preserved by the battery backup system Several places throughout this manual will refer to a value which is entered during INSTALLATION amp SETUP In these cases consult the INSTALLATION section of this manual for further details This manual describes SETUP INSTALLATION and NORMAL procedures required for day to day operation The 2 5RS control can operate using either an inch or metric operating system AO 73290 PART 1 OPSUMMARY 1 2 5RS OPERATION AND MAINTENANCE MANUAL This selection is made during the SETUP and INSTALLATION All prompts and system variables will switch to the selected system and appear as either INCH or MILLIMETER values When entering values for ST
155. FQ The FILE QUEUE command allows the 2 5RS to make a request to the storage computer for the next program in its queue There is no program number sent with the FILE QUEUE command The storage computer must acknowledge the lt ESC gt FQ request with lt ESC gt FDHHHHHHHH lt CR gt lt LF gt pause one second then send the program that is next on the queue IMPORTANT Acknowledgment of lt ESC gt FD lt CR gt lt LF gt with no program number also works However the actual file that is sent to the 2 5RS MUST CONTAIN A PROGRAM NUMBER BLOCK such as P12345678 for Word Address If no program number block is included in the program the 2 5RS creates a program number of FFFFFFFF for that file AO 73290 PART 5 SERIAL 21 2 5RS OPERATION AND MAINTENANCE MANUAL SERIAL 8 10 FILE QUIT lt ESC gt QQ Once a file has been transferred from the storage computer to the 2 5RS the 2 5RS sends an lt ESC gt QQ followed by a three digit status code The status codes are listed at the end of this section For example the 2 5RS operator requests program number 12345 from the storage computer lt ESC gt FG12345 lt CR gt lt LF gt Request message sent to storage computer by 2 5RS lt ESC gt FD12345 lt CR gt lt LF gt Storage computer sends acknowledgment to 2 5RS PAUSES FOR 1 SECOND lt CR gt lt LF gt SENDS lt CR gt lt LF gt BEFORE lt CR gt lt LF gt STORAGE COMPUTER BEGINS TO SEND ASCII FILE PROGRAM DATA SENT
156. G 4 1 1 SERV00 DSPY00 EXIT MODE This selection is used to exit the SERVICE and DISPLAY modes and return to normal operation NOTE If Service or Display mode is used while a part is actually running the EXIT MODE must be used to return to the normal operation before the cutting mode AUTO TEST MANUA L can be changed SETUP amp CONFIG 4 1 2 SERV01 DSPY01 X Y DISPLAY Displays THE CURRENT X Y axis positions If used while a part is running the dimensions reflect the distances from the initial start position At other times the readouts can be cleared and used for X Y measuring See section DISPLAY MODES for further details AO 73290 PART 7 SETUP AND CONFIG 5 2 5RS OPERATION AND MAINTENANCE MANUAL SETUP amp CONFIG 4 1 3 SERV02 DSPY02 PARTS CUT When running a program this display shows the number of part cycles performed Multiply by the number of torches for the actual number of parts cut SETUP amp CONFIG 4 1 4 SERV03 DSPY03 FEEDRATE Shows the current setting of the operators speed dial For correct operation this number must be within 5 of the actual machine speed If it is significantly different the operation becomes erratic See SER V54 for calibrating feedrate input If the digital feedrate feature is enabled see SD62 SYSCFG2 selecting DSPY03 first displays the current FEEDRATE setting and then allows the digitally controlled feedrate to be varied The SCROLL arrows can be used to increase or decrea
157. G INPUT 115VAC 15 mA See operator manual section SD61 33 33 2 ipd SYSTEM CONFIGURATION and JEN MACHINE INTERFACE SENSING INPUT Protective ground from machine power Chassis Ground source Input Neutral conductor of machine s power OVAC 0 25 A source Input Input pin for powering the 2 5RS from a 115V machine power source Input MONACO VZ Input pin for powering the 2 5RS from a 230V AC machine power source Input ZOE DUE 2 5RS with MNJ 10380 using MO 04459 INTERFACE CARD MO 03561 CABLE 2 5RS BACK PANEL 37 PIN EXT DRIVE CONNECTOR Description Ratings Signal Ground OV Power Ground OV Positive supply power output 24VDC 40 mA Negative supply power output 24VDC 40 mA Analog Ground 0 PART 10 SPECIFICATIONS 16 AO 73290 AO 73290 Speed reference input from customer potentiometer Reference input Burny speed reference output NC Run output low true input Y drive reference output Y drive reference input Jog enable input X drive reference output X drive reference input Preheat Gas solenoid power contacts These are normally open dry contacts Start Cut contacts These are dry contacts Enable Cut contacts These are dry contacts Sense return for pins 32 and 33 Input Oxygen Cut Sense input Signals 2 5RS that the cutting oxygen is operating Sense input Protective ground from machine power source Input Neutral cond
158. HAPES3 1 SHAPE 1 RECTANGLE 4 REPEAT PATTERNS x AUTO MANUAL 2 3 7 N fi 5 1 CUT DIRECTION CLOCKWISE OR COUNTERCLOCKWISE 2 STARTING POSITION 1 OF4 CORNERS DIMENSION 3 INCHES OR MILLIMETERS 4 Y DIMENSION INCHES OR MILLIMETERS 5 LEADIN DIMENSION INCHES OR MILLIMETERS 6 LEADIN ANGLE DEGS 0 TO 90 DEGREES 7 LEADOUT DIMENSION INCHES OR MILLIMETERS 8 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 9 KERF DIMENSION i WIDTH OF CUTTING TOOL PATH 10 REPEAT MODE AUTOMATIC OR MANUAL POSITIONING IF AUTO REPEAT MODE IF MANUAL REPEAT MODE 11 VERIFY YES NO 11 REPEAT DIRECTION 1 OF 4 SIDES 12 VERIFY YES NO NOTES The STARTING CORNER and REPEAT DIRECTION parameters can be directly entered with the numeric keypad Direction arrows are provided for quick reference When defining the LEADIN ANGLE 0 degrees is parallel to the Y axis and 90 degrees is parallel to the X axis The LEADOUT position is determined by the direction of the cut It is either parallel to the last side cut as shown or 45 degrees from the last cut direction When running the resulting NC part program position the torches at the STARTING CORNER of the first part regardless of the REPEAT MODE selected From this corner the program moves out to the actual pierce point PART 2 SHAPES 6 AO 73290 SYSTEM OPERATION SHAPES SHAPES3 2 SHAPE 2 CIRCLE REPEAT PATTERNS AUTO MANUAL PLATE SIDE L
159. HOME limit switch and SD97 Y offset from table 1 to Y HOME limit switch are used to establish the 0 0 position of the machine at a fixed offset from the home switch index locations This allows the switches to be located anywhere in the PART 7 SETUP AND CONFIG 38 AO 73290 SETUP AND CONFIGURATION machines s travel but allow the 0 0 position to be established at a logical point for the actual oi oa Tos os s or s cutting process ppp r P at a xmomwer LL SE xix LTT gt 73290 PART 7 SETUP AND CONFIG 39 2 5RS OPERATION AND MAINTENANCE MANUAL SD62 SYSTEM CONFIGURATION 2 D4 sets the search direction for the machine once FNC16 SET HOME function has been selected and home limit switches have been enabled D4 also specifies how the high preheat relay will behave during Oxy Fuel cutting There are 3 choices for the high preheat relays behavior it can be selected to turn off at the end of the PREHEAT time it can be set to remain on during the PREHEAT and the PIERCE RAMP time or it can be set to turn on at the start of the PREHEAT time and remain on during the entire cutting cycle and turn off when the cutting oxygen turns off at the end of the path oi oa os os vs os v ow PART 7 SETUP AND CONFIG 40 AO 73290 SETUP AND CONFIGURATION
160. ICE 3 1 FAULT FINDING AND TROUBLESHOOTING sese 7 SERVICE 3 2 SPARE PARTS e Eme EE an qaas tA 8 SERVICE 4 SPECIAL TOOLS ne tete ite tee nne ee m e eee re iD ie do alte 8 SERVICE 5 BACKUP OF PROGRAMS AND TABLES STORED IN BURNY CONTROLS 8 SERVICE 6 REPLACING THE BURNY 2 5RS MEMORY BATTERY nennen 9 AO 73290 Table of Contents vi TABLE OF CONTENTS SERVICE 7 BEFORE CALLING 8 nn 11 PART 7 SYSTEM SETUP AND 7 SYSTEM SETUP AND CONFIGURATION I 1 SETUP amp CONFIG T SERVICE KEY sasi 1 SETUP amp CONFIG 2 DISPLAY 1 SETUP amp CONFIG 3 POWER UP 3 SETUP amp CONFIG 4 SERVICE AND DISPLAY 5 4 SETUP amp CONFIG 4 1 SERVICE AND DISPLAY MODE 5 SERVICE MODES IN THE 2 5RS dr ite precepit o ex eene canted e Du pro de esee ve Rn acre 5 SETUP amp CONFIG 4 1 1 SERVOO DSPYOO EXIT MODE L 5 SETUP amp CONFIG 4 1 2 SERVO1 DSPYO1 X Y 5 SETUP amp CONFIG 4 1 3 SERV02 DSPYO2 PARTS 6 SETUP amp CONFIG 4 1 4 SERVO3 DSPYO3 F
161. IED IN MO 11124 INTERNAL CONDUCTORS ENCODER CONNECTOR SHIELD KIT ENCODER CABLE This print is the property of Cleveland Motion Controls Inc and is furnished as confidential information only It must not be copied traced or reproduced in any manner nor submitted to any outside parties for any purpose without our written permission Any use of this print without written permission of Cleveland Motion Controls Inc is a violation of our exclusive rights CUSTOMER INSTRUCTIONS leveland p ni ENCODER CONNECTOR SHIELD Motion Controls INSTALLATION X XXX 005 CAD DWG NO AO 72107BADWG SIZE DRAWING NUMBER REV mamas EI 00 72107 A AS RELEASED GB 12 95 ExL m eee ef 0 12 95 SHEET 1 OF 1 BLANK WITH CABLES DISCONNECTED SLIDE METAL BRAID COMPLETLY ONTO THE TRACER CABLE PLUG THE CONNECTORS TOGETHER AND SLIDE THE BRAID OVER THE CONNECTORS AS SHOWN APPLY METAL CLAMPS AND USE SUPPLIED HARDWARE TO GROUND BRAID TO EXTERNAL CABLE SHIELD METAL BRAID BURNY ETEK TRACER UNIT BRAID CLAMPS AND HARDWARE SUPPLIED IN 11125 TRACER CONNECTOR SHIELD TRACER EXTENSION CABLE 9744 This print is the property of Cleveland Motion Controls Inc and is furnished confidential information only It must not be copied traced or reproduced in any manner nor submitted to any outside parties for any purpose without our written permission Any use of this print withou
162. IMETERS 4 ARC DEPTH INCHES OR MILLIMETERS 5 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 6 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 7 LEAD IN DIMENSION INCHES OR MILLIMETERS 8 LEAD OUT DIMENSION INCHES OR MILLIMETERS 9 VERIFY YES NO YES OR NO NOTES The only difference between parts created with LEFT PLATE or RIGHT PLATE enabled occurs in the traverse move to the first pierce point AO 73290 PARTS 2 SHAPES 21 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 17 SHAPE 17 SLANT PIPE SUPPORT REPEAT PATTERNS 1 PLATE SIDE LEFT RIGHT N A 2 EC 4 1 3 a G N 1 BASE WIDTH I INCHES OR MILLIMETERS 2 HEIGHT DIMENSION INCHES OR MILLIMETERS 3 TOP WIDTH INCHES OR MILLIMETERS 4 RADIUS DIMENSION INCHES OR MILLIMETERS 5 ARC DEPTH i INCHES OR MILLIMETERS 6 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 7 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 8 LEAD IN DIMENSION INCHES OR MILLIMETERS 9 LEAD OUT DIMENSION INCHES OR MILLIMETERS 10 VERIFY YES NO YES OR NO NOTES Like others this part is cut with the BASE at the upper position As a result the prompts used to label the top and sides assume the part is rotated 180 degrees The only difference between parts created with LEFT PLATE or RIGHT PLATE enabled occurs in the traverse move to the first pierce point PART 2 SHAPES 22 AO 73290 SYSTEM OPERATION SHAPES
163. IR to the opposite NORM REV setting If the machine moves in the cross axis the wires to the drives are crossed Correct the wiring re enter the preset values and go on 2 Jog the machine in the Y direction The machine should move in the cross axis to the left If the machine moves to the Right when the Y Jog is pressed reverse the setting of SD26 Y DRIVE DIR to the opposite NORM REV setting PART 7 SETUP AND CONFIG 78 AO 73290 SETUP AND CONFIGURATION 5 Now that the drives are moving in the right direction the direction of the encoders must be set Use the SERVOI X Y DSPLY to show the X and Y positions and press the CE key to clear the X and Y values Now plug in the X axis encoder cable only do not plug in the Y encoder yet Jog the machine in the X direction to move down the rail If the X readout counts positive the X axis encoder direction is correct If the X position counts NEGATIVE reverse the setting of SD23 X ENC DIR to the opposite NORM REV value If the Y position counts when the X axis is moved the encoder cables are interchanged 4 Plug in the Y axis encoder and jog in the Y direction If the Y position counts positive the Y encoder direction is correct If the Y position counts NEGATIVE reverse the setting of SD24 Y ENC DIR to the opposite NORM REV value 5 Select SERV54 AUTOMATIC REFERENCE ADJUSTMENT Turn the opera
164. ITION MACHINES WITH HOME LIMIT SWITCHES NOTE FOR PROPER OPERATION SD62 SYS CONFG2 MUST BE SET FOR HOME SWITCHES SEE THE SECTION OF THIS MANUAL COVERING SD62 SYS CONFG2 The Table 1 home position is set by selecting the FNC 16 SET HOME special function The display changes to PRESS CYCLE START FOR HOME SEARCH Once CYCLE START is pressed the 2 5RS control commands the machine to begin a search for the home position It first moves in a direction specified by SD62 CONFG2 to find the Y home switch at about 100 ipm When the switch is found it reverses direction and backs off the switch at 5 ipm As soon as the switch input is removed the 2 5RS control begins to search for the Y index pulse from the encoder Once the index pulse is found it stops and repeats the same process for the X axis PART 3 SPECIAL FUNCTIONS 10 AO 73290 SYSTEM UTILITIES SPECIAL FUNCTIONS SPECFUNC 3 2 SETTING TABLE 1 HOME POSITION MACHINES WITHOUT HOME LIMIT SWITCHES This method is used when the machine does not have home indexing switches installed So that this alignment can be as accurate as possible some type of scribe mark end stop alignment pin or other device should be installed on the machine so the operator can accurately move the X and Y axes to a fixed location using the jog controls To manually set table 1 home reference position first jog the machine to the alignment position Locate it as accurately as possible since t
165. ITOR EDITOR EDITOR 1 PROGRAM TEXT EDITOR The EDIT NEW function allows the 2 5RS to create and edit programs in PART STORAGE MEMORY To enter this mode press the ENTER key when EDIT NEW is displayed The display changes to EDIT with the last used program displayed Select the desired program number from those in memory or enter a new program number that does not exist to create a new program and press ENTER Once a program is selected the first data block is displayed and editing can begin EDITOR 1 1 MAIN DATA BLOCK DISPLAY The editor has the ability to do two basic operations it can display a list of data blocks in memory and it can edit a specific block of information In the DISPLAY MODE the readout shows the INTERNAL BLOCK NUMBER on the left This number indicates the position of the block in the program For example the 5 block in any part program is displayed as 0005 To display a particular block the scroll keys can be used to move up or down through the program Each time a scroll key is pressed the new block number and the type of information contained in the block is shown The numeric keypad can also be used to quickly access a particular block Enter the desired block number on the keypad When the first digit is pressed the readout changes to GO TO After the correct value is displayed press ENTER The specified block is found and displayed
166. LATE or RIGHT PLATE enabled occurs in the traverse move to the first pierce point as shown AO 73290 PARTS 2 SHAPES 41 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 37 SHAPE 37 TRUSS SUPPORT REPEAT PATTERNS 1 PLATE SIDE LEFT RIGHT DES CES lt 1 BASE WIDTH INCHES OR MILLIMETERS 2 TOP WIDTH INCHES OR MILLIMETERS 3 HEIGHT DIMENSION INCHES OR MILLIMETERS 4 SHOULDER HEIGHT INCHES OR MILLIMETERS 5 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 6 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 7 LEAD IN DIMENSION INCHES OR MILLIMETERS 8 LEAD OUT DIMENSION INCHES OR MILLIMETERS 9 VERIFY YES NO YES OR NO NOTES Like others this part is cut with the BASE at the upper position As a result the prompts used to label the top and sides assume the part is rotated 180 degrees The only difference between parts created with LEFT PLATE or RIGHT PLATE enabled occurs in the traverse move to the first pierce point as shown PART 2 SHAPES 42 AO 73290 SYSTEM OPERATION SHAPES SHAPES3 38 SHAPE 38 ANGULAR TRUSS REPEAT PATTERNS a 1 ar PLATE SIDE M RZ LEFT RIGHT 3 4 7 2 3 1 BASE WIDTH INCHES OR MILLIMETERS 2 HEIGHT DIMENSION INCHES OR MILLIMETERS 3 SHOULDER HEIGHT INCHES OR MILLIMETERS 4 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 5 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 6 LEAD IN DIMENSIO
167. LINE 26 98 command causes program to repeat from point where G97 command was used LINE 27 End of Program Command AO 73290 PART 4 WADR 17 2 5RS OPERATION AND MAINTENANCE MANUAL PART DRAWING SAMPLE PROGRAM 1 Dimensions inch millimeter w PLATE EDGE _ CUT ON CUTTING MOVE CUT ON LEADIN LEADOUT CUT OFF TRAVERSE MOVE Letters in circles denote data block letters in the program example PART 4 WADR 18 AO 73290 PART PROGRAMMING ESSI ESSI PROGRAMMING ESSI 2 ESSI PROGRAMMING ESSI part programming uses 3 types of data blocks for the program LINE MOVES ARC MOVES AUXILIARY FUNCTIONS ESSI 2 1 LINE AND ARC BLOCK SPECIFICATIONS Both the LINE and ARC BLOCKS are made up of a series of signed dimensions IN ESSI PROGRAMMING the number of signs in a data block determines whether it is an arc or a line The dimensions for the block do not contain any decimal points rather the number of decimal places are defined as follows For INCH programming Two decimal places are assumed Example 200 equals a dimension of 2 00 inches 5 equals dimension of 0 05 inches 9999999 maximum dimension is 999999 99 inches For METRIC programming one decimal place is assumed with the unit value being 0 1 millimeters Example 200 equals a dimension of 20 0 millimeters 5 equals a dimension of 0 5 millimeters 39999999 maximum dimension is 999999 9 millimeters AO 73290
168. LINEANDLEADOUT De weevez N24X1524Y15725 P MOVE TO NEXTPART Pas nasos REPEATPROGRAM Ex sooo ENDOFPROGRAM AO 73290 PART 4 WADR 15 2 5RS OPERATION AND MAINTENANCE MANUAL LINE 1 LINE 2 LINE 3 LINE 4 LINE 5 LINE 6 LINE 7 LINE 8 LINE 9 LINE 10 INE 11 INE 12 INE 13 INE 14 INE 15 E ges cn S e tiles INE 17 INE 18 INE 19 INE 20 INE 21 INE 22 ri dpt speed p The first line ofa WORD ADDRESS program must contain only a percent sign This serves as the program start indicator Any characters before the are ignored If the is not present or has other data in the same block the program will not load correctly This line contains the optional PROGRAM NUMBER identifier When the program is loaded this number is compared to the requested program number to insure that the correct program was loaded If a PROGRAM NUMBER is used in a program it must appear in the second line immediately after the The G46 T2 is used to select overlay parameter table 2 Any data blocks after the G46 code uses overlay parameter table number 2 until another G46 T is given Initial move from corner of plate to pierce point on first part Due to the placement of the G97 code this block is not repeated on subsequent parts The G97 pointer is used to indicate where the program repeat should o
169. MENU 2 LOAD FROM STD SHABE 2 FUNCMENU 3 8 23225 an Den 2 FUNCMENU 4 DUP PGM ff HHHHF 2 FUNCMENU 5 LOAD CUSTOM SHAPE FROM FROM RS 232 3 FUNCMENU 6 STORE FROM RS 222 a a a 3 FUNCMENU 7 TEACH PROGRAM a a a a a 4 FUNCMENU 8 aan 4 FUNCMENU 9 EDIT NEW PROGRAM 4 FUNCMENU 10 STORE TO FLOPPY 5 FUNCMENU 11 LOAD FROM FFLOPPY a a a a 5 FUNCMENU 12 LOAD RUN RS 232 a 5 FUNCMENU 13 LOAD RUN FROM FLOPPY a a 5 STANDARD SHAPE SELECTION U u 1 SHAPE 1 SHAPE SEEEGTION u Tt u ee ik S en een 1 SHAPES 2 DIMENSIONS COMMON TO MOST SHAPES 3 SHAPES 3 53 STANDARD SHAPES 5 3 1 1
170. MILLIMETERS 2 HEIGHT DIMENSION INCHES OR MILLIMETERS 3 VERTICAL THICKNESS INCHES OR MILLIMETERS 4 HORIZONAL THICKNESS INCHES OR MILLIMETERS 5 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 6 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 7 LEAD IN DIMENSION INCHES OR MILLIMETERS 8 LEAD OUT DIMENSION INCHES OR MILLIMETERS 9 VERIFY YES NO YES OR NO NOTES All chain cut parts start from the plate corner closest to the operator The PLATE SIDE is defined through SYSTEM SETUP DATA Although parts are created in pairs to minimize scrap each part is individually counted when cut If part dimensions make it impossible to create part pairs without overlap use shape 48 L BRACKET 2 PART 2 SHAPES 52 AO 73290 SHAPES3 48 WIDTH DIMENSION HEIGHT DIMENSION VERTICAL THICKNESS HORIZONAL THICKNESS KERF DIMENSION SCRAP DIMENSION LEAD IN DIMENSION LEAD OUT DIMENSION VERIFY YES NO SYSTEM OPERATION SHAPES SHAPE 48 L BRACKET 2 REPEAT PATTERNS PLATE SIDE LEFT RIGHT mi INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS WIDTH OF CUTTING TOOL PATH DISTANCE BETWEEN PARTS IN MM INCHES OR MILLIMETERS INCHES OR MILLIMETERS YES OR NO NOTES All chain cut parts start from the plate corner closest to the operator The PLATE SIDE is
171. N INCHES OR MILLIMETERS 7 LEAD OUT DIMENSION INCHES OR MILLIMETERS 8 VERIFY YES NO YES OR NO NOTES Like others this part is cut with the BASE at the upper position The only difference between parts created with LEFT PLATE or RIGHT PLATE enabled occurs in the traverse move to the first pierce point as shown AO 73290 PARTS 2 SHAPES 43 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 39 SHAPE 39 TRIANGLE REPEAT PATTERNS PLATE SIDE 6 LEFT RIGHT 1 BASE WIDTH INCHES OR MILLIMETERS 2 HEIGHT DIMENSION INCHES OR MILLIMETERS 3 LEFT OFFSET INCHES OR MILLIMETERS 4 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 5 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 6 LEAD IN DIMENSION INCHES OR MILLIMETERS 7 LEAD OUT DIMENSION INCHES OR MILLIMETERS 8 VERIFY YES NO YES OR NO NOTES Like others this part is cut with the BASE at the upper position However the LEFT OFFSET is actually on the left side of the part as shown When LEFT OFFSET is greater than 0 angle A is greater than 90 degrees and when it is less than 0 angle A is less than 90 degrees The only difference between parts created with LEFT PLATE or RIGHT PLATE enabled occurs in the traverse move to the first pierce point as shown PART 2 SHAPES 44 AO 73290 SYSTEM OPERATION SHAPES SHAPES3 40 SHAPE 40 BEVELED RECTANGLE REPEAT PATTERNS PLATE SIDE 7 LEFT RIGHT 4
172. NDIRECT OR CONSEQUENTIAL DAMAGES OF ANY KIND UNDER THIS CONTRACT OR OTHERWISE THE COMPANY S LIABILITY SHALL BE LIMITED EXCLUSIVELY TO REPLACING OR REPAIRING WITHOUT CHARGE AT ITS FACTORY OR ELSEWHERE AT ITS DISCRETION ANY MATERIAL OR WORKMANSHIP DEFECTS WHICH BECOME APPARENT WITHIN ONE YEAR FROM THE DATE ON WHICH THE EQUIPMENT WAS SHIPPED AND THE COMPANY SHALL HAVE NO LIABILITY FOR DAMAGES OF ANY KIND ARISING FROM THE INSTALLATION AND OR USE OF THE APPARATUS BY ANYONE THE BUYER BY THE ACCEPTANCE OF THE EQUIPMENT WILL ASSUME ALL LIABILITY FOR ANY DAMAGES WHICH MAY RESULT FROM ITS USE OR MISUSE BY THE BUYER HIS OR ITS EMPLOYEES OR BY OTHERS THE WARRANTIES OF THE COMPANY DO NOT COVER AND THE COMPANY MAKES NO WARRANTY WITH RESPECT TO ANY DEFECT FAILURE DEFICIENCY OR ERROR WHICH IS A NOT REPORTED TO THE COMPANY WITHIN THE APPLICABLE WARRANTY PERIOD OR B DUE TO MISAPPLICATION MODIFICATION DISASSEMBLY ABUSE IMPROPER INSTALLATION BY OTHERS ABNORMAL CONDITIONS OF TEMPERATURE DIRT OR CORROSIVE MATTER OR C DUE TO OPERATION EITHER INTENTIONAL OR OTHERWISE ABOVE RATED CAPACITIES OR IN AN OTHERWISE IMPROPER MANNER THERE ARE NO OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITYAND FITNESS FOR A PARTICULAR PURPOSE AO 73290 WARRANTY xvii 2 5RS OPERATION AND MAINTENANCE MANUAL BLANK WARRANTY xviii AO 73290 PART 1 SYSTEM OVERVIEW Tab Page Part 1 SYSTEM OVERVIEW GENE
173. NER RADIUS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS 10 T RIGHT INNER RADIUS INCHES OR MILLIMETERS 11 B RIGHT INNER RADIUS INCHES OR MILLIMETERS 12 BEVEL CORNERS YES OR NO 1 WIDTH DIMENSION INCHES OR MILLIMETERS 2 HEIGHT DIMENSION INCHES OR MILLIMETERS 3 SYMMETRY YES OR NO 4 BOTTOM THICKNESS INCHES OR MILLIMETERS 5 LEFT THICKNESS INCHES OR MILLIMETERS 6 TOP THICKNESS INCHES OR MILLIMETERS 7 8 LOS LS rn rm 13 CONVEX YES OR NO 14 B LEFT OUTER RADIUS INCHES OR MILLIMETERS 15 T LEFT OUTER RADIUS INCHES OR MILLIMETERS 16 T RIGHT OUTER RADIUS INCHES OR MILLIMETERS 17 B RIGHT OUTER RADIUS INCHES OR MILLIMETERS 18 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 19 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 20 LEAD IN DIMENSION INCHES OR MILLIMETERS 21 LEAD OUT DIMENSION INCHES OR MILLIMETERS 22 VERIFY YES NO YES OR NO NOTES When SYMMETRY YES is selected values for THICKNESS INNER RADIUS and OUTER RADIUS are automatically preloaded from 4 8 and 14 to define a symmetrical part The CONVEX prompt line only appears when BEVEL CORNERS NO is selected PART 2 SHAPES 36 AO 73290 SYSTEM OPERATION SHAPES SHAPES3 32 SHAPE 32 RECTANGULAR HOLE REPEAT PATTERNS MANUAL REPEAT ALL DIRECTIONS ALLOWED 7 8 1 WIDTH DIMENSION INCHES OR MILLIMETERS 2 HEIGHT DIMENSION INCHES OR MILLIMETERS 3 C
174. NER RADIUS of 0 is defined sharp corners are cut PART 2 SHAPES 50 AO 73290 SYSTEM OPERATION SHAPES SHAPES3 46 SHAPE 46 CAM REPEAT PATTERNS PLATE SIDE LEFT RIGHT 1 WIDTH DIMENSION INCHES OR MILLIMETERS 2 LEFT RADIUS INCHES OR MILLIMETERS 3 RIGHT RADIUS INCHES OR MILLIMETERS 4 LEFT HOLE DIAMETER INCHES OR MILLIMETERS 5 RIGHT HOLE DIAMETER INCHES OR MILLIMETERS 6 CENTER DISTANCE INCHES OR MILLIMETERS 7 LEFT OFFSET INCHES OR MILLIMETERS 8 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 9 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 10 LEAD IN DIMENSION INCHES OR MILLIMETERS 11 LEAD OUT DIMENSION INCHES OR MILLIMETERS 12 VERIFY YES NO YES OR NO NOTES If a LEFT HOLE DIAMETER of 0 is defined no holes are cut in the part If a RIGHT HOLE DIAMETER of 0 is defined only the LEFT HOLE is cut The LEAD IN and LEAD OUT DINENSIONS always apply on the outside of the part They also apply in the holes if they are equal to or smaller than the radius of the hole If not the radius is used AO 73290 PARTS 2 SHAPES 51 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 47 SHAPE 47 L BRACKET 1 REPEAT PATTERNS 1 PLATE SIDE LEFT RIGHT r I 6 ia 7 8 Eu ler 1 WIDTH DIMENSION INCHES OR
175. NFIG 13 2 5RS OPERATION AND MAINTENANCE MANUAL SETUP amp CONFIG 4 2 12 SD14 GAIN BREAK encoder counts multiple parameter This parameter may help to improve the cutting accuracy of a system by increasing the gain of the system for small position errors without increasing the overall gain of the systems and causing oscillation The value entered specifies a fixed gain region on either side of the correct zero error path where the loop gain of the system is forced It is entered as encoder counts not inches or millimeters Any path error within this region causes a correction to be generated as if it is already at the specified number of encoder counts Errors outside this region are unaffected Example If the system loop gain is set to 2 00 ipm count Error in Correction Speed Correction Speed encoder counts with GAIN BRK 0 with GAIN BRK 4 0 0 00 ipm 0 00 ipm 1 2 00 ipm 8 00 ipm 2 4 00 ipm 8 00 ipm 3 6 00 ipm 8 00 ipm 4 8 00 ipm 8 00 ipm 5 10 00 ipm 10 00 ipm After 4 counts both results are the same with GAIN set to 4 00 SETUP amp CONFIG 4 2 13 SD15 ERROR WARNING DISTANCE in mm The 2 5RS constantly monitors the PATH ERROR DISTANCE while running a part The value entered in this parameter may be a positive or negative value Ifa positive value is entered and the error exceeds the value set for this parameter a WARNING MESSAGE is displayed and BEEPING OCCURS This indicates that the machine is not responding to posit
176. NFIG 80 AO 73290 SETUP AND CONFIGURATION Press the hidden SERVICE button and select SERV54 REF ADJUST either enter 54 or scroll down to SER V54 Press the ENTER button The screen will change to prompt the operator to SET SPD DIAL 0 THEN PRESS ENTER OR CE TO CANCEL The operator should turn the machine speed dial fully CCW to it s 0 speed setting and turn any speed range switch on the machine to LOW or OFF This allows the control to measure any offset voltage at the zero setting of the pot so it does not affect the speed settings on the machine Press ENTER after the speed dial is set to 0 At this point if there is significant offset voltage present over 50 mv the control will not accept the 0 speed setting on the pot and will issue a series of 5 warning beeps The display will remain on the SET SPD DIAL 0 prompt This can occur if the speed dial is not set fully CCW correct the problem turn the pot to it s full CCW setting and press the ENTER button again To bypass this 0 speed voltage adjustment press the CE button This will cancel any previous 0 volt adjusment and go on to the MAX pot setting NOTE Some machines will not use a speed pot the cutting speed is controlled using Digital Feedrate input only In this case pressing the CE button will bypass the 0 pot adjustment and continue on to adjust for the MAX pot setting Once the 0 pot setting is accepted the prompt will change
177. NG MOVE CUT ON LEADIN LEADOUT CUT OFF TRAVERSE MOVE Letters in circles denote data block letters in the program example PART 4 ESSI 28 AO 73290 PART 5 SERIAL COMMUNICATIONS Tab Page Part 5 SERIAL COMMUNICATIONS SERIAL SERIAL COMMUNICATIONS NOTE SERIAL COMMUNICATIONS is an optional feature of the 2 5RS and must be enabled for operation CAD LINK CLINK and COMMUNICATION ENHANCEMENT are special protocols used with the communication option These must also be enabled before they will operate The options may be easily checked to see if they are enabled by using the DSPY 80 CONFIGURE mode which displays the system Serial Number Software Version and the amount of memory installed in the unit Pressing the Enter button jumps to a list of all the available options for the system with an ON or OFF displayed next to the option name indicating whether it has been enabled in the unit or not Press ENTER or use the scroll keys to step through the options to check if they are enabled For more information on DISPLAY 80 see the DISPLAY MODES section RS SERIAL COMMUNICATIONS is a standard feature in the CAD LINK CLINK and COMMUNICATION ENHANCEMENT are special protocols used with SERIAL COMMUNICATIONS These must be enabled before they will operate The options may be easily checked to see if they are enabled by using the DSPY 80 CONFIGURE mode which displays the sys
178. NO B0 9371C02 DWG X SIZE DRAWING NUMBER C ERES ANGULAR 7550 HUB PARKWAY CLEVELAND OHIO EN B0 9371 0 5 dy aly a SHEET 2 OF 3 BLANK BORE FACE NO TEETH HUB_DA HUB PROJ SEL SCRW 1 tes 3 os os 4 we 1 2 20 3 gt 2 174 20 01 15673 310p 25 05 4 085 2 10 32 0 625 2 8 32 7 225 2 8 32 0 4375 2 5 16 18 2 5 16 18 s0 158 4 mp 20 25 075 0 625 2 10 32 8 6 180p 15 075 05 2 516 18 08 10223 10 20 15 05 2 5 16 18 wN 814 4886 5 590 20 19 075 0 625 2 3 8 16 4 B01 18864 25 CR 145 20 140 075 0 625 2 3 8 16 0 625 2 5 16 18 16 B01 19876 2 0 MOD 213 2 468 175 2 3 8 16 8 32 18 81 195 0 10 05 6 0842 0 5 2 1 4 20 19 81 272 6 090 20 10 05 3 168 1425 2 5 16 18 20 01 21960 25CR 45 20 10 075 25 168 125 2 5 16 18 21 80 225 59 20 10 075 3 168 1142 2 5 16 18 22 80 25 20 20 10 075 8 1025 2 5 16 18 23 B01 2299 20 20 19 07 gt 168 105 2 5 16 18 24 84 259 45 10 5 0
179. NO OPERATION USE TO IGNORE AUX FUNCTIONS CLOCKWISE ARC DIRECTION COUNTER CLOCKWISE ARC CHAIN TOP CHAIN BOTTOM CUT OFF CUTON KERF OFF KERF LEFT KERF RIGHT MARKER 1 OFF MARKER 1 ON MARKER OFFSET OFF MARKER OFFSET ON PROGRAMMING IN INCH UNITS PROGRAMMING IN MILLIMETER UNITS ABSOLUTE PROGRAM DIMENSIONS ABSOLUTE REGISTER PRELOAD INCREMENTAL PROGRAM DIMENSIONS PROGRAMMABLE DWELL SPECIAL LEAD IN BLOCK PROGRAM STOP PROGRAM END PROGRAM END WITH REWIND TAPE IGNORING ON TAPE IGNORING OFF AUXILIARY OUTPUT ON AUXILIARY OUTPUT OFF MARKER OFFSET 2 ON MARKER OFFSET 72 OFF SELECT TO RUN AT CUTTING SPEED SELECT TO RUN AT HI TRAVERSE SPEED NOT USED NOT USED EXTERNAL VARIABLE LOAD NOT USED NOT USED NOT USED NOT USED OVERLAY PARAMETER TABLE SELECT GO TO TABLE HOME TOOL SELECT PROGRAMMABLE KERF DIMENSION PROGRAM FEEDRATE PLASMA HEIGHT DISABLE PLASMA HEIGHT ENABLE AUTO LOAD RUN SINGLE PUNCH MARK ON MARKERI SINGLE PUNCH MARK ON MARKER2 NO OPERATION INCREMENT PART COUNT AO 73290 SETUP AND CONFIGURATION w IMPORTANT If any table location is loaded with a TVVFF value of 00000 THE SOFTWARE DOES NOT SCAN PAST THAT LOCATION For example if table location AUX22 contains 00000 no conversion codes contained in AUX23 through AUX50 are processed Therefore do not enter 00000 as the TV VFF code for any table location unless none of the following lo
180. NT SIGN AO 73290 PART 4 WADR 1 2 5RS OPERATION AND MAINTENANCE MANUAL WADR 1 2 N LINE NUMBER The N key character is used for documentation purposes only It does not affect program execution and therefore the 2 5RS does not store these values When the 2 5RS loads a program through serial I O these values are discarded to conserve memory space WADR 1 3 P PROGRAM NUMBER This is an optional KEY CHARACTER that allows an 8 digit program number to be included in program If a program is loaded containing a program number it is automatically loaded in memory as that number WADR 1 4 X DIMENSION FOR LINES OR ARCS Incremental programming distance from the start point to the end point of a move along the X rail axis Absolute programming distance from the zero point to the endpoint of the new move along the X rail axis NOTE The following are the maximum values that can be used for the X value 99 999 9999 inches 999 999 999 millimeters IMPORTANT X values that exceed these limits produce a SYNTAX ERR when loaded through the serial port PART 4 WADR 2 AO 73290 PART PROGRAMMING WORD ADDRESS WADR 1 5 Y DIMENSION Incremental programming distance from the start point to the end point of a move along the Y cross axis Absolute programming distance from the zero point to the endpoint ofthe new move along the Y cross axis NOTE The following are the ma
181. OR DISPLAY SEE V06 XERSCL SETUP amp CONFIG 4 4 14 V17 Y HOME Displays the distance from the HOME ALIGNMENT REFERENCE POSITION in the Y axis AO 73290 PART 7 SETUP AND CONFIG 57 2 5RS OPERATION AND MAINTENANCE MANUAL SETUP amp CONFIG 4 4 15 V20 RADERR in mm While an ARC program block is being run this shows the path error from the CORRECT ARC RADIUS A positive value indicates that the machine is outside the correct radius Negative values indicate that the error is inside the correct radius This value can be used in the same way as the X ERROR and Y ERROR displays described in V05 to determine the cause if a part is inaccurate This display shows the Path Error while running an ARC data block See V05 for details on possible causes SETUP amp CONFIG 4 4 16 V21 RADSCL This value also pertains to running arc blocks and shows the commanded speed percentage after the LOOP GAIN has SCALED any radius error AS DISPLAYED IN V20 See V06 for a description of this type of display Once this value is calculated it is divided between the XERSCL V06 and YERSCL V16 values depending on the position of the machine along the arc SETUP amp CONFIG 4 4 17 VARIABLES 22 49 TEST ONLY Not needed during normal installation and servicing V22 ENDDST ENDPOINT DISTANCE V23 ARCBND ARC ENDPT BOUNDARY DISTANCE V30 ACCSCL ACCEL DECEL SCALE VALUE V40 PRETME DISPLAYS PREHEAT TIMER V41 ARCTME DISPLAYS ARC ON DELAY TIM
182. OR MESSAGES This section contains the various ERROR MESSAGES which may occur during operation In some cases the error is merely an incorrect number entry while others indicate a hardware or software error which should not occur under any circumstances ERROR 1 ERRORS FROM PROGRAM OPERATIONS These errors can occur during any of the selection operations for the major program functions RUN LOAD ETC ERROR 1 1 DUPLICATE PROGRAM When LOAD or TEACH is selected and a program number is entered as the number to be used in storing the data it is checked to make sure that no other program already stored in memory has the same number If a duplicate number is found this error is displayed At this point either use the DELETE function to erase the duplicate or enter a different program number for the new program ERROR 1 2 PROGRAM LIST EMPTY This error indicates that no programs are stored in memory It occurs for instance when the DELETE function is used and there are no programs to delete ERROR 1 3 ENTER PROGRAM NUMBER This message occurs when a program number of 00000000 is entered for any function Zero may not be used for a program number AO 73290 PART 8 ERROR 1 2 5RS OPERATION AND MAINTENANCE MANUAL ERROR 1 4 NO PROGRAM FOUND If either RUN DELETE or STORE is selected and the entered program number is not in memory NO PGM XXXXXXXX message is displayed Correct the program nu
183. ORNER RADIUS INCHES OR MILLIMETERS 4 MOVE DISTANCE RAIL DISTANCE TO NEXT HOLE 5 Y MOVE DISTANCE CROSS DISTANCE TO NEXT HOLE 6 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 7 LEAD IN DIMENSION INCHES OR MILLIMETERS 8 LEAD OUT DIMENSION INCHES OR MILLIMETERS 9 VERIFY YES NO YES OR NO NOTES The X and Y MOVE DISTANCE values are used to define the center to center distance between holes From this center position the program moves the machine to the pierce point determined by the LEADIN DIMENSION LEADIN DIMENSION must be less than the WIDTH DIMENSION For the first hole the torch should be positioned by the operator AO 73290 PARTS 2 SHAPES 37 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 33 SHAPE 33 VERTICAL HOLE REPEAT PATTERNS MANUAL REPEAT ALL DIRECTIONS ALLOWED 5 1 IE S 2 6 1 X START INCHES OR MILLIMETERS 2 Y START i INCHES OR MILLIMETERS 3 SLOT WIDTH INCHES OR MILLIMETERS 4 SLOT HEIGHT INCHES OR MILLIMETERS 5 X MOVE DISTANCE RAIL DISTANCE TO NEXT HOLE 6 Y MOVE DISTANCE CROSS DISTANCE TO NEXT HOLE 7 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 8 LEAD IN DIMENSION INCHES OR MILLIMETERS 9 LEAD OUT DIMENSION INCHES OR MILLIMETERS 10 VERIFY YES NO YES OR NO NOTES The X and Y START values are used to define the center to center distance between holes From this center position the program moves the machine to the pierce point dete
184. PAGE Testing machine movements RUN 4 PART 2 RUN 7 without cutting TEST RUN Testing the Cutting Oxygen Enable SPECFUNC 2 1 2 PART 3 SPECIAL FUNCTIONS 3 OXY ENABLE Testing the Cutting Oxygen Start SPECFUNC 2 1 3 PART 3 SPECIAL FUNCTIONS 4 OXY START Testing the High Preheat Relay SPECFUNC 2 1 4 PART 3 SPECIAL FUNCTIONS 4 PREHEAT Testing the Plasma Torch hardware SPECFUNC 2 2 1 PART 3 SPECIAL FUNCTIONS 5 PLASMA CUT Testing the Plasma Enable Relay SPECFUNC 2 2 3 PART 3 SPECIAL FUNCTIONS 6 PLASMA ENABLE Testing the Plasma Start Relay SPECFUNC 2 2 4 PART 3 SPECIAL FUNCTIONS 6 PLASMA START Testing the Plasma Height Sensor SPECFUNC 2 2 5 PART 3 SPECIAL FUNCTIONS 6 Disable Relay HEIGHT DISABLE Power up Self Diagnostics SETUP amp CONFIG 3 PART 7 SETUP AND CONFIG 3 POWER UP DIAGNOSTICS ASCII CODES ASCII CODES PART 7 SETUP AND CONFIG 35 Encoder operation SETUP amp CONFIG 4 4 19 PART 7 SETUP AND CONFIG 60 V54 XCNTR Displaying of Variables Test Tool SETUP amp CONFIG 4 4 PART 7 SETUP AND CONFIG 55 SYSTEM VARIABLE DISPLAY Speed problems SETUP amp CONFIG 4 4 1 PART 7 SETUP AND CONFIG 55 V01 X DRIVE Distance problems SETUP amp CONFIG 4 4 5 PART 7 SETUP AND CONFIG 56 V05 X ERROR SETUP amp CONFIG 2 0 0 0 0 1 PART 7 SETUP AND CONFIG 58 V15 Y ERROR SETUP amp CONFIG 4 4 15 PART 7 SETUP AND CONFIG 58 V20 RADERR Memory Display Utilities SETUP amp CONFIG 4 5 PART 7 SETUP AND CONFIG 60 MEMORY DISPLAY UTILITIES Debugging Aid f
185. PE 43 LAP JOINT REPEAT PATTERNS 22510 PLATE SIDE u o LEFT 2999 OOOO E 6 4 1 WIDTH DIMENSION INCHES OR MILLIMETERS 2 HEIGHT DIMENSION INCHES OR MILLIMETERS 3 NUMBER OF COLUMNS COUNT 0 TO 99 4 COLUMN DISTANCE INCHES OR MILLIMETERS 5 BOLT HOLE DISTANCE INCHES OR MILLIMETERS 6 BOLT HOLE DIAMETER INCHES OR MILLIMETERS 7 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 8 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 9 LEAD IN DIMENSION INCHES OR MILLIMETERS 10 LEAD OUT DIMENSION INCHES OR MILLIMETERS 11 VERIFY YES NO YES OR NO NOTES The hole pattern defined is automatically centered on the part from top to bottom and left to right To create a part with a single row of holes use shape number 44 SLOTTED PLATE with a SLOT HEIGHT equal to the SLOT WIDTH PART 2 SHAPES 48 AO 73290 SHAPES3 44 1 O 4 6 WIDTH DIMENSION HEIGHT DIMENSION NUMBER OF SLOTS SLOT WIDTH SLOT HEIGHT SLOT DISTANCE KERF DIMENSION SCRAP DIMENSION 9 LEAD IN DIMENSION 10 LEAD OUT DIMENSION 11 VERIFY YES NO SYSTEM OPERATION SHAPES SHAPE 44 SLOTTED PLATE REPEAT PATTERNS PLATE SIDE LEFT RIGHT INCHES OR MILLIMETERS INCHES OR MILLIMETERS COUNT 0 TO 99 INCHES OR MILLIMETERS
186. R MILLIMETERS YES OR NO NOTES Like others this part is cut with the BASE at the upper position As a result the prompts used to label the top and sides assume the part is rotated 180 degrees The only difference between parts created with LEFT PLATE or RIGHT PLATE enabled occurs in the traverse move to the first pierce point PART 2 SHAPES 24 AO 73290 SYSTEM OPERATION SHAPES SHAPES3 20 SHAPE 20 VERTICAL SLOT REPEAT PATTERNS J PLATE SIDE f LEFT RIGHT 8 21 TR I 4 T 1 WIDTH DIMENSION INCHES OR MILLIMETERS 2 HEIGHT DIMENSION INCHES OR MILLIMETERS 3 COLLAR HEIGHT INCHES OR MILLIMETERS 4 COLLAR WIDTH INCHES OR MILLIMETERS 5 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 6 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 7 LEAD IN DIMENSION INCHES OR MILLIMETERS 7 LEAD OUT DIMENSION INCHES OR MILLIMETERS 8 VERIFY YES NO YES OR NO NOTES The only difference between parts created with LEFT PLATE or RIGHT PLATE enabled occurs in the traverse move to the first plerce point AO 73290 PARTS 2 SHAPES 25 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 21 SHAPE 21 SLANT SLOT REPEAT PATTERNS 4 PLATE SIDE LEFT RIGHT 9 uut 4 ft 1 BASE WIDTH INCHES OR MILLIMETERS 2 HEIGHT DIMENSION INCHES OR MILLIMETERS 3 COLLAR HEIGHT INCH
187. RAL OPERATION SUMMARY SYSTEM OVERVIEW INTRODUCTION The Burny 2 5 RS control with the new front panel and the Burny 2 5Plus control have identical operating functions and physical layouts The two versions of this control differ only in the appearance of the front panel and in their processor card The processor card in the Burny 2 5Plus operates at a much higher speed This manual covers both versions of the control with spare parts lists and drawings for both Both front panels appear on Page PART 1 OPSUMMARY 6 The 2 5RS control is designed for use with optical tracing systems on a variety of 2 axis shape cutting machines With its extensive STANDARD SHAPE LIBRARY many parts can be cut without the need for a template In addition the TEMPLATE TEACH UTILITY learns a part outline by tracing the template one time Then the part may be repeated any number of times without re tracing the template When the 2 5RS control is added to a tracing system the tracer is not affected in any way and all other machine functions remain operational The optional RS 232 422 gives the control the ability to communicate with other devices such as CAD Systems and other RS 232 or 422 compatible devices The 2 5RS has the ability to prompt the operator in a second language in addition to the standard English Current languages available are German French Finnish Spanish Swedish and Portuguese The 2 5RS control has a variety of STANDARD as well as many OPTIONAL
188. RS serial port can be configured for either RS 232 or RS 422 level signals The RS232 RS422 status LED s on the unit indicate the current settings To change the selection the MO 06354 enclosure must be unfastened from the 2 5RS enclosure See the information and WARNING on the next page before attempting this procedure IMPORTANT Do not turn the screws on the MO 06354 output adaptor itself as this could loosen some of the internal hardware and require the entire unit to be disassembled To avoid loss of programs read the section of this manual entitled Backup of Programs Stored in Burny Controls See the drawing below for information about removing the output adaptor AO 73290 PART 5 SERIAL 5 2 5RS OPERATION AND MAINTENANCE MANUAL WARNING When considering any type of disassembly please note HIGH VOLTAGES ARE PRESENT IN BURNY SYSTEMS THAT CAN INJURE AND KILL ONLY QUALIFIED PERSONS SHOULD OPEN OR DISASSEMBLE ANY PART OF THE BURNY SYSTEM TURN OFF AND RED TAG ALL POWER SOURCES DURING SERVICE BE CERTAIN THAT UNAWARE PERSONS DO NOT TURN ON THE POWER DURING SERVICE USE A VOLTMETER TO BE CERTAIN THAT ALL POWER SOURCES HAVE BEEN TURNED OFF The MO 06354 is held onto the 2 5RS enclosure by two hex nuts actually hex standoffs located inside the 2 5RS enclosure Remove these two hex standoffs inside the 2 5RS box and pull the MO 06354 away UNSCREW TWO HEX STANDOFFS INSIDE CABINET TO REMOVE MO 06354
189. S Although the REPEAT PATTERN creates parts in pairs to minimize scrap and reduce cutting time each part is individually counted when cut PART 2 SHAPES 10 AO 73290 SHAPES3 6 Y Na 1 1 DIAMETER DIMENSION 2 LEADIN DIMENSION 3 SCRAP DIMENSION 4 KERF DIMENSION 5 VERIFY YES NO SYSTEM OPERATION SHAPES SHAPE 6 CHAIN CIRCLE REPEAT PATTERNS PLATE SIDE LEFT RIGHT bt E Ma 552 _ N lt EDS N Z Ni S E d x _ INCHES OR MILLIMETERS INCHES OR MILLIMETERS DISTANCE BETWEEN PARTS IN MM WIDTH OF CUTTING TOOL PATH YES OR NO NOTES All chain cut parts start from the plate corner closest to the operator The PLATE SIDE is defined through SYSTEM SETUP DATA AO 73290 PARTS 2 SHAPES 11 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 7 SHAPE 7 RIP MODE REPEAT PATTERNS PLATE SIDE LEFT RIGHT 3 L vy 4 1 X DIMENSION INCHES OR MILLIMETERS 2 Y DIMENSION INCHES OR MILLIMETERS 3 LEADIN DIMENSION INCHES OR MILLIMETERS 4 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 5 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 6 VERIFY YES NO YES OR NO NOTES This part is designed for use with multiple torches All RIP MODE cuts start at the corner of the plate closest to the operator The PLATE SIDE is defined through SYSTEM SETUP DATA The cutting sequence also depends on the
190. S DIMENSION INCHES OR MILLIMETERS 5 RADIUS DIMENSION INCHES OR MILLIMETERS 6 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 7 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 8 LEAD IN DIMENSION INCHES OR MILLIMETERS 9 LEAD OUT DIMENSION INCHES OR MILLIMETERS 10 LEAD IN POINT 1 P1 YES OR NO 11 VERIFY YES NO YES OR NO NOTES If an INNER DIAMETER of 0 is defined no hole is cut If NO is selected for the LEADIN POINT 1 position prompt the default LEADIN POINT 0 position is used AO 73290 PARTS 2 SHAPES 55 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 51 SHAPE 51 RECTANGLE REPEAT PATTERNS 4 AUTO MANUAL 3 gt 4 11H 6 1 2 3 PLATE SIDE LEFT RIGHT 9 NT i 1 CUT DIRECTION CLOCKWISE OR COUNTER CLOCKWISE 2 STARTING POSITION 1 OF 4 CORNERS 3 X DIMENSION I INCHES OR MILLIMETERS 4 Y DIMENSION INCHES OR MILLIMETERS 5 LEAD IN DIMENSION INCHES OR MILLIMETERS 6 LEAD IN ANGLE DEGS 0 TO 90 DEGREES 7 LEAD OUT DIMENSION INCHES OR MILLIMETERS 8 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 9 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 10 REPEAT MODE AUTO OR MANUAL POSITIONING IF AUTO REPEAT MODE IF MANUAL REPEAT MODE 11 VERIFY YES NO 11 REPEAT DIRECTION 1 OF 4 SIDES 12 VERIFY YES NO NOTES The ST
191. SETUP SD80 96 OFFSETS PART 4 ESSI 22 AO 73290 12 29 30 38 39 40 41 PART PROGRAMMING ESSI PLATE MARKER 1 OFFSET OFF cancels the offset and moves the cutting torch back to the programmed position Optionally followed by a 1 to 8 causing offsets 1 8 as specified by SD80 96 to be used See INSTALLATION amp SETUP SD80 96 OFFSETS These 3 commands are used by the DIAL IN routine to compensate the cutting path for the amount of material removed by the cutting process The KERF directions LEFT 29 or RIGHT 30 are based on which way the centerline of the torch needs to be offset as it travels along the cutting path The 38 code is provided to cancel the kerf however it is not needed in the program since the KERF IS AUTOMATICALLY TURNED OFF when not cutting IMPORTANT See the description for Word Address codes G41 and G42 for details of the memory allocation for programs containing Kerf Left or Kerf Right commands Programmable Feedrate command followed by a numeric value in same resolution Example 3942500 is program feedrate of 25 00 ipm In MM 3972500 is program feedrate of 250 mpm PROGRAMMABLE KERF This code along with a value in inches or millimeters depending on the type of system configuration allows feedrate commands to be inserted directly into a program Example 40 200 in inches the programmable kerf is 2 inches In millimeters the program kerf would be 20 millimeters This
192. SI programs However Program must be set to INTL for internal format type programs this replaces the normal WADR or ESSI program format selection Custom Shape Programs have numeric file names for example 9892 CNC However once the program loads it will appear as BDF09892 in program memory to mark it as a special Binary Data Format Custom Shape program instead of a regular part program To use the custom shape you must first RUN the program Select RUN and scroll down to the program number BDF09892 and press enter The Running process will detect that it is one of the new custom shape programs and will set it up to be used The display will change to GENERIC XFER OK which indicates the file has transferred to the standard shape memory correctly The display then changes to the normal prompt to LOAD xxxxxxxx This is the normal prompt for loading a program into memory Enter the program number that you want to create and press enter For example LOAD 00000123 The display then goes to the Shape Selection screen and the custom shape number will appear as the first shape For example SH9892 WELD You can press Enter to select this shape or you can use the scroll buttons or numeric keys to go through the list of standard and custom shapes There can be more than one custom shape loaded at one time For example if you scroll down the display will show Shapes 1 to Shape 53 and then go to SH9892 The custom shapes
193. SS SCROLL DOWN UNTIL FNC 06 CUTON IS DISPLAYED PRESS ENTER B 0002 CUTON F06 is now displayed To add a new block PRESS SHF AND SCROLL DOWN The control will now display INSERT LIN ARC Change this to INSERT FUNCTION by PRESSING To add a function PRESS ENTER The control will display FNG 00 PGMNOP PRESS SCROLL DOWN UNTIL FNC 08 KRFLFT IS DISPLAYED THEN PRESS ENTER B 0003 KRFLFT F08 is now displayed AO 73290 PART 3 EDIT 13 2 5RS OPERATION AND MAINTENANCE MANUAL To add a new block PRESS SHF AND SCROLL DOWN The control will now display INSERT LIN ARC PRESS ENTER X DIM 0000 is displayed Use the numeric keypad to enter the dimension 100 PRESS ENTER and Y DIM 0000 is displayed PRESS ENTER T DIM 0000 is displayed PRESS ENTER J DIM 0000 is displayed PRESS ENTER VERIFY YES is displayed PRESS VERIFY NO is displayed PRESS ENTER B 0004 LINE X is displayed To add a new block PRESS SHF AND SCROLL DOWN The control will now display INSERT LIN ARC PRESS ENTER X DIM 0000 is displayed Use the numeric keypad to enter the dimension 80 and PRESS ENTER Y DIM 0000 is displayed PRESS ENTER T DIM 0000 is displayed Use the numberic keypad to enter the dimension 40 and PRESS ENTER J DIM 0000 is displayed PRESS ENTER ARC DIRECT CW is displayed PRESS ENTER VERIFY YES is displa
194. T OFFSET is actually on the left side of the part as shown When LEFT OFFSET is greater than 0 angle A is greater than 90 degrees and when it is less than 0 angle A is less than 90 degrees The only difference between parts created with LEFT PLATE or RIGHT PLATE enabled occurs in the traverse move to the first pierce point as shown PART 2 SHAPES 46 AO 73290 SHAPES3 42 SHAPE 42 BASE WIDTH TOP WIDTH TOP OFFSET LEFT HEIGHT LEFT OFFSET RIGHT HEIGHT RIGHT OFFSET KERF DIMENSION 9 SCRAP DIMENSION 10 LEAD IN DIMENSION 11 LEAD OUT DIMENSION 12 VERIFY YES NO NA tn gt OQ AO 73290 SYSTEM OPERATION SHAPES QUAD SIDE REPEAT PATTERNS PLATE SIDE LEFT RIGHT INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS WIDTH OF CUTTING TOOL PATH DISTANCE BETWEEN PARTS IN MM INCHES OR MILLIMETERS INCHES OR MILLIMETERS YES OR NO NOTES Like others this part is cut with the BASE at the upper position As a result the prompts used to label the top and sides assume the part is rotated 180 degrees The only difference between parts created with LEFT PLATE or RIGHT PLATE enabled occurs in the traverse move to the first pierce point as shown PARTS 2 SHAPES 47 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 43 SHA
195. TENANCE MANUAL BLANK PART 2 FUNCTION MENU 6 AO 73290 SYSTEM OPERATION SHAPES STANDARD SHAPE SELECTION SHAPE 1 SHAPE SELECTION The LOAD FROM STD SHAPE function allows the operator of the 2 5RS to select a generic part from the STANDARD SHAPE LIBRARY and create a part program Press the ENTER key The display changes to LOAD 00000000 This is the PART PROGRAM NUMBER that will be assigned to the selected GENERIC SHAPE when the part dimensions are entered Once a program number is entered the shape selection process begins The 2 5RS shape library contains 50 SHAPE PROGRAMS which are referenced by SHAPE NUMBER The operator must first select the desired shape from the following chart either using the scroll keys or by entering the desired number directly Once the correct number and name are displayed press the ENTER key to select the shape Detailed drawings of each shape are located at the end of this section These give additional information about the various options for each shape and illustrate the required dimension inputs The STANDARD SHAPE programs are written in a GENERIC format which describes the shape of the part but leaves the part dimensions variable Once the shape has been selected the operator is required to answer a series of prompts which determines the final dimensions of the part The individual shape drawings at the end of this section help to illustrate the various dimensions These
196. TERED values a prompt will appear to POSITION TRACER and then the X and Y axis positions will be displayed Pressing the CE or CLR key will reset the position displays to 0 00 Use the readouts to position the tracer at the starting point for the program to be taught In most cases the program is taught starting from the corner of the plate When the tracer is in the correct position to start the program usually where the corner of the plate will be when it is cut make sure the machine cut switch is off and that the speed dial is set to 0 then press the ENTER key If the oxy cut switch is on the program will issue a warning message and an audible signal Turn off the oxy cut switch then press the ENTER key again If the machine speed dial is not set to 0 a different warning will be displayed along with an audible signal Set the machine speed dial to 0 and press the ENTER button again AO 73290 PART 3 TEACH 3 2 5RS OPERATION AND MAINTENANCE MANUAL The program is TAUGHT by running the tracing eye around the template just as if the part was actually being cut In addition the operator must indicate the cut should be on or off When the lt lt CUT OFF gt gt mode is selected the actual path is not stored only the final position This gives a straight line traverse from one cutting segment to the next When the eye is positioned at the next pierce location the operator should change to the lt lt CUT ON gt
197. TH OF CUTTING TOOL PATH DISTANCE BETWEEN PARTS IN MM INCHES OR MILLIMETERS INCHES OR MILLIMETERS YES OR NO NOTES The only difference between parts created with LEFT PLATE or RIGHT PLATE enabled occurs in the traverse move to the first pierce point AO 73290 PARTS 2 SHAPES 17 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 13 WIDTH DIMENSION HEIGHT DIMENSION BOLT HOLE CENTER HOLE DIAMETER SHOULDER HEIGHT RADIUS DIMENSION KERF DIMENSION SCRAP DIMENSION 9 LEAD IN DIMENSION 10 LEAD OUT DIMENSION 11 VERIFY YES NO O tn gt OQ SHAPE 13 SLANT LUG REPEAT PATTERNS PLATE SIDE LEFT RIGHT INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS WIDTH OF CUTTING TOOL PATH DISTANCE BETWEEN PARTS IN MM INCHES OR MILLIMETERS INCHES OR MILLIMETERS YES OR NO NOTES If a HOLE DIAMETER of 0 is defined no center hole is cut PART 2 SHAPES 18 AO 73290 SHAPES3 14 1 WIDTH DIMENSION 2 HEIGHT DIMENSION 3 HOLE DIAMETER 4 SHOULDER HEIGHT 5 RADIUS DIMENSION 6 KERF DIMENSION 7 SCRAP DIMENSION 8 LEAD IN DIMENSION 9 LEAD OUT DIMENSION 10 VERIFY YES NO SYSTEM OPERATION SHAPES SHAPE 14 LIFT LUG REPEAT PATTERNS PLATE SIDE LEFT RIGHT N He Me Ae ze b E
198. US RADIUS ERROR LINE REDUCTION KERF DIRECTION PART 3 2 This number which can range from 2 999 sets the allowable error boundary used to determine when a new point is created A value of 16 equals 0025 Making this number smaller will result in a more accurate representation of the part however it will create more points and therefore use more memory to store the program Making this number larger will result in less memory being used but with less accuracy in the program Sets a limit on the size of arcs which will be created by the teaching process This parameter is not usually altered and is mainly used for testing purposes Sets a limit on the minimum size radius which will be created by the teaching process Again it is used mainly for testing Used to convert a series of lines to an arc which saves memory To determine if an arc should be created the lines are tested to see if they fall along the same arc or are within the radius error distance ofthe arc Making this number larger will result in more lines being converted to arcs however there will be some rounding and smoothing of the shape Making it very small will limit the number of arcs created since the lines must be very close to the perfect radius This parameter is used by the teaching process to determine when a series of short straight lines can be replaced by one longer one thus saving memory It s value ranges from 2 999 with a value of 16 equa
199. WADR ESSLetc and handshaking protocol RTS XON etc do not have any effect on the loopback test PART 7 SETUP AND CONFIG 72 AO 73290 SETUP AND CONFIGURATION NOTE There is a short delay after every 10 character s sent from the 2 5RS The data displayed in the readout when the 2 5RS is looped back to itself pauses and allows it to be read and checked for proper operation This delay may be disabled by pressing the decimal point key SETUP amp CONFIG 4 5 12 SERV97 VARIABLE STORE This SERVICE FUNCTION allows the setup parameters adjusted with SERV 10 and the speed calibration and reference adjustment results from SERV41 SERV42 SERV43 SER V44 and 5 54 to be stored in a non volatile memory inside the 2 5RS If this function is not used all adjustments return to their previous values when the power to the system is turned off and on or the RECYCLE key is pressed to switch modes of operations The 2 5RS is equipped with a special NON VOLATILE memory which is used to store the SYSTEM DATA parameters setup with the SERV 10 procedure and also the calibration values resulting from the 5 1 speed calibration and SER V54 reference adjust This memory requires no battery or external power in order to REMEMBER the data The only way the data in the memory can be changed is by using the SERV97 procedure Since all data values are stored together
200. WIDTH INSIDE HEIGHT INSIDE RADIUS ARC RADIUS KERF DIMENSION SCRAP DIMENSION 9 LEAD IN DIMENSION 10 LEAD OUT DIMENSION 11 VERIFY YES NO NA tn OQ PATTERNS PLATE SIDE LEFT RIGHT x Ps INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS WIDTH OF CUTTING TOOL PATH DISTANCE BETWEEN PARTS IN MM INCHES OR MILLIMETERS INCHES OR MILLIMETERS YES OR NO NOTES The only difference between parts created with LEFT PLATE or RIGHT PLATE enabled occurs in the traverse move to the first pierce point as shown AO 73290 PARTS 2 SHAPES 33 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 29 SHAPE 29 SQUARE FRAME REPEAT PATTERNS 4 PLATE SIDE Xe LEFT RIGHT Eu EI ES 211 5 1 4 c BEEN e e 2 lt 5 Ea J 1 OUTSIDE WIDTH INCHES OR MILLIMETERS 2 OUTSIDE HEIGHT INCHES OR MILLIMETERS 3 INSIDE WIDTH INCHES OR MILLIMETERS 4 INSIDE HEIGHT INCHES OR MILLIMETERS 5 INSIDE RADIUS INCHES OR MILLIMETERS 6 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 7 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 8 LEAD IN DIMENSION INCHES OR MILLIMETERS 9 LEAD OUT DIMENSION INCHES OR MILLIMETERS 10 VERIFY YES NO YES OR NO
201. XIS 6 0 4 4040 0 0 3 OPSUMMARY 4 CUTTING SPEED 406000000 1 0 4 OPSUMMARY 5 JOG CONTROLS 4 OPSUMMARY 5 1 JOG CONTROLS OLD STYLE FRONT 5 OPSUMMARY 5 2 JOG AT MAXIMUM SPEED OLD STYLE FRONT PANEL 5 OPSUMMARY 5 3 JOG CONTROLS NEW STYLE FRONT PANEL 6 OPSUMMARY 5 4 JOG AT MAXIMUM SPEED NEW STYLE FRONT PANEL 7 OPSUMMARY 6 KEYBOARD OPERATIONS 7 OPSUMMARY 7 SCROLLING OPERATIONS a 8 OPSUMMARY 8 RECYCLE KEY a a a a 8 9 DISPLAY KEY a 8 OPSUMMARY 10 PART RETURN KEY 9 OPSUMMARY 11 BACKUP KE Y tite oett ah 9 PART 2 SYSTEM OPERATIONS 3 MAIN FUNCTION SELECTION MENU 1 FUNCMENU 1 RUN PROGRAM 2 FUNC
202. Y 16 BIT FIELD 16 bit hexadecimal display entry of any CRU location in the processors CRU address space The display for the SERV32 DSPY32 SHOW utility appears as CW XXXX HHHH The Address of the least significant bit of the 16 Bit CRU value is shown on the left The 16 Bit CRU value is shown as a 4 Digit Hex value on the right of the readout PART 7 SETUP AND CONFIG 62 AO 73290 SETUP AND CONFIGURATION SETUP amp CONFIG 4 5 4 SERV33 SINGLE BYTE MEMORY DISPLAY SINGLE BYTE 8 bit hexadecimal DISPLAY ENTRY of any memory location in the system The display for the SERV33 DSPY33 SHOW BYTE utility appears as MB XXXX BBBBBBBB The Address ofthe memory byte is shown on the Left ofthe readout The Data byte at the address is shown on the right of the readout in an 8 bit binary format SETUP amp CONFIG 4 5 5 SERV34 8 BIT CRU DISPLAY The display for the SERV34 DSPY34 SHOW CRUB utility appears as CB XXXX BBBBBBBB The Address of the least significant bit ofthe 8 Bit CRU value is shown on the left of the readout as a 4 Digit Hexadecimal number The 8 CRU data bits are shown in Binary format on the right of the readout Msb to Lsb SETUP amp CONFIG 4 5 6 SERV50 AXIS SPEED This function can only be accessed through the SERVICE MENU When selected the display continuously shows the X Y axis speeds This display is particularly useful in adjusting the machine servo drives W
203. a program using a optical tracer Delete a program from program memory Create or edit a program Store to Floppy drive Option must be enabled Load from Floppy drive Option must be enabled Load from a RS 232 device and run immediately Load from Floppy drive and immediately Run Floppy option must be enabled PART 2 FUNCTION MENU 1 2 5RS OPERATION AND MAINTENANCE MANUAL FUNCMENU 1 RUN PROGRAM Once this function is selected the prompt PRGM 00000000 is displayed At this point a different program number may be entered via the numeric keypad The scroll keys may also be used to select a part in program memory Press ENTER to select the program number The 2 5RS searches program memory for a part that has been assigned that number If the part program exists the run prompting begins See section RUNNING THE PROGRAM If the part program is not found a PGM NOT FOUND error is displayed and program selection must be repeated FUNCMENU 2 LOAD FROM STD SHAPE Once this function is selected the prompt PRGM 00000000 is displayed A program number is assigned to the selected GENERIC SHAPE to create a PART PROGRAM A PART PROGRAM is a runnable program that resides in program memory Enter a program number to be assigned to the GENERIC STANDARD SHAPE up to 8 digits and then press ENTER The operator should select the desired shape from the following menu and go to the manual section indicated for that s
204. able to be compatible with other existing equipment The choices for program type are either selected during installation and setup or can be selected by the operator when a particular operation is performed The choices are PGM TYPE 1 WADR Standard 2 5RS Word Address program PGM TYPE 2 ESSI Standard 2 5RS ESSI program PGM TYPE 3 INTL not for normal use test only TYPE 4 WADR1 Word Address program Type 1 PGM TYPE 5 WADR2 Word Address program Type 2 PGM TYPE 6 WADR3 Special Word Address custom aux and axis swap PGM TYPE 7 ESSI1 Special ESSI custom aux and axis swap Normally the first two formats WADR and ESSI are used for programming 2 5RS The and WADR2 formats are basically the same as the standard format with some re assignment of the auxiliary codes as indicated further on in this section The two SPECIAL formats WADR3 and ESSI1 make use of several conversion features of the 2 5RS so that programs that have been prepared for a different control or that use different auxiliary code definitions can be directly loaded into the 2 5RS without requiring re programming These two formats allow for the following conversions Change axis sign definitions X becomes X Allow axis interchange Permits X and Y axis to be swapped Custom Aux Code Conversion Allows re defining of all M G and ESSI auxiliary codes to match incoming program It also all
205. accidentally fall roll or slide Away from sources of heat Away from combustible vapors or gasses Located so that cables can be routed safely to the unit Sufficient clearance for cables to exit the cabinet Access to rear panel to permit dis connection of cables and reading of labels on rear panel e Field of view and physical environment of operator The unit must always be mounted on top of a flat surface using four mounting bolts lockwashers and nuts of 4 20 or M6 thread size Use the hole pattern shown in the cabinet drawing for the 2 5RS The 2 5RS is supplied with a plastic plug for the three inch diameter hole in the bottom The plastic plug should be removed only for the unusual installation where cables and wires must pass through the bottom wall of the cabinet AO 73290 PART 6 SERVICE 1 2 5RS OPERATION AND MAINTENANCE MANUAL When bolting the cabinet to the mounting surface the 2 5RS front panel should be opened and the bolts inserted from the inside of the cabinet Then the head of the bolt will be inside the cabinet and will not interfere with the internal components SERVICE 1 2 ELECTRICAL INSTALLATION OF THE BURNY 2 5RS The ground for the system should be carried throughout the entire electrical system into which the product is installed by suitable conductors and connections The conductors and connectors used for this should be in accordance with the National Electrical Code in the United States the IEC in CE in
206. actual Cutting Oxygen however once the Enable Relay is turned on the Cutting Oxygen Switch on the machine panel can be used to start the oxygen if desired Normally this function is used for testing the Enable relay output only Once selected the prompts indicate that the CYCLE START and CYCLE STOP keys are used to turn the Oxygen Enable Relay ON and OFF Pressing one of the SCROLL ARROW keys returns to the menu of available MANUAL CONTROL functions AO 73290 PART 3 SPECIAL FUNCTIONS 3 2 5RS OPERATION AND MAINTENANCE MANUAL SPECFUNC 2 1 3 OXY START This function is used for testing the CUTTING OXYGEN START RELAY only This does not actually start the flow of Cutting Oxygen gas since the Enable Relay described earlier is not turned on by this test Therefore this mode is used only to test the functioning of the relay output itself The prompting shows that the CYCLE START and CYCLE STOP keys are used to control the relay and the SCROLL ARROW keys return back to the menu SPECFUNC 2 1 4 PREHEAT This function is used for testing the HIGH PREHEAT RELAY output only Since this relay controls the High Preheat gasses directly when it is turned on the High Preheat gasses are turned on Therefore this mode could be used to check the High Preheat gas pressures before cutting a part program More commonly this mode is used to check the relay output for testing purposes The prompting shows that the CYCLE START
207. all adjustment of the SYSTEM DATA parameters and the speed calibration should be done before using the SER V97 procedure If any of the SYSTEM DATA parameters are re adjusted at a later date or if a second speed calibration is done this procedure should be used again to store the changes NOTE It is possible to try making adjustments to the System Data values without losing the original settings To do this use SERV 10 and SERV40 44 to make any desired changes once a part program is already running however do not use the SERV97 procedure to store them The 2 5RS uses the changed data until the RECYCLE key is pressed or the power is turned off When the power is re applied or the RECYCLE key is pressed the original values still stored in the Non Volatile memory are returned This can be a useful testing tool since the values can be changed while a part is running without worrying about permanently altering the machines performance When the SERV97 VAR STORE function 15 selected the display changes to a message which only says WARNING CHECK MANUAL At this point press the SHF key This stores the new values in the NON VOLATILE MEMORY When the storing is complete the unit returns to its normal operation AO 73290 PART 7 SETUP AND CONFIG 73 2 5RS OPERATION AND MAINTENANCE MANUAL SETUP amp CONFIG 4 5 13 SERV98 SYS RESET SERVICE MODE 98 SD98 SYS RESET cause
208. and CYCLE STOP keys are used to control the relay and the SCROLL ARROW keys return back to the menu SPECFUNC 2 2 PLASMA MANUAL CONTROL FUNCTIONS For PLASMA cutting the following manual control functions are available PLASMA CUT Enable plasma then Start plasma cut PLASMA JOG CUT JOG keys interlock with plasma cut PLASMA ENABLE Turn on Plasma enable relay only PLASMA START Turn on Plasma start relay only HEIGHT DISABLE Set for Plasma Height sensor disable PART 3 SPECIAL FUNCTIONS 4 AO 73290 SYSTEM UTILITIES SPECIAL FUNCTIONS SPECFUNC 2 2 1 PLASMA CUT This selection can be used to test fire the Plasma Torch cutting up scrap material or strip cutting a plate Once selected the control prompts the operator to press the CYCLE START key to ENABLE the plasma torch This does not cause the torch to fire it only activates the Plasma Enable relay which puts the plasma control circuitry in a state where it can be started by a separate Start input On some machines the Enable causes the torch to be lowered to the plate Once enabled the display changes to prompt the operator to press the CYCLE START key to actually fire the plasma torch Once the torch fires the jog keys on the machine can be used to move the machine to cut the desired pattern Note that the machine does not move automatically once the torch fires it is up to the operator to use the jog controls Since it is sometimes difficult to coordinate the jog
209. ar the value and allow it to be RE ENTERED Once the correct value is displayed press the ENTER key to continue If a negative value is required first enter the number and then press the key to make it negative AO 73290 PART 1 OPSUMMARY 7 2 5RS OPERATION AND MAINTENANCE MANUAL OPSUMMARY 7 SCROLLING OPERATIONS The 2 5RS uses a menu system to guide the operator through the various operations In this way the operation is broken into a series of simple steps with a limited number of choices at each step Usually when a menu of choices is available the operator is told to SELECT the desired function and press the ENTER key This selection is done by using the up and down arrow keys located to the right of the keypad to scroll through the displayed menu When the correct selection is displayed press the ENTER key to continue The LED indicator located below the scroll arrow keys lights when a menu of choices is available and shows that the scroll arrow keys can be used to make the selection Some of the menus use numbers to further identify each item If this is the case the desired number may be entered rather than scrolling to get directly to the correct selection OPSUMMARY 8 RECYCLE KEY After an operation is complete or at any time during any operation pressing the RECYCLE key stops the current operation turns off all cutting functions and returns to the beginning prompting sequence OPSUMM
210. as SD80 X offset 1 SD41 Same as SD81 Y offset 1 SD47 Same as SD82 X offset 2 SD48 Same as SD83 Y offset 2 There are a total of 8 X Y offset pairs supported by the 2 5RS These are specified by parameters SD80 SD95 To select one of these offsets the M71 is followed by a T value of 1 to 8 which selects one of the 8 offsets to be used The following are the valid program uses Data block Offset dimension parameters M71 5080 5 81 same as SD40 SD41 M71 TI SD80 SD81 same as SD40 SD41 M71 T2 SD82 SD83 same as SD47 SD48 M71 T3 SD84 SD85 M71 T4 SD86 SD87 M71 T5 SD88 SD89 M71 T6 SD90 SD91 M71 T7 SD92 SD93 M71 T8 SD94 SD95 Note that the offsets do not have to cancel each other and it is possible to offset more than once if necessary To end up back at the original position each OFFSET ON must be canceled by it s corresponding OFFSET OFF function Also the OFFSET OFF basically causes a negative OFFSET ON This means that an OFFSET OFF can be used to shift in the opposite direction of the setup parameter values and then the OFFSET ON function used to cancel the OFF move and return to the original position AO 73290 PART 4 WADR 13 2 5RS OPERATION AND MAINTENANCE MANUAL M72 OFFSET 2 OFF This command is maintained for compatiblity with older software It causes the machine to offset in the opposite direction of the dimensions specified in SD47 SD48 same as SD82 SD83 It is normally used to cancel the offset caus
211. ate the desired jog direction As soon as the jog direction key is pressed the plasma system is started However since the plasma system goes through a purge cycle the operator must continue to hold the jog direction number key until the arc fires The machine does not move during this time Once the arc fires the machine immediately begins moving in the selected jog direction at the speed set by the operators speed dial To stop the plasma cut the operator only needs to release the jog key Once the machine has stopped the jog motion the plasma torch is automatically turned off and the entire sequence must be repeated While the torch is cutting the operator can change the direction of cut by simply releasing the current jog direction key and pressing a new one However the new direction key must be pressed before the machine decelerates to a stop otherwise the torch is turned off as described above There is no need to use the CYCLE STOP key in this mode since releasing the jog direction key automatically stops the plasma Press the SCROLL UP or SCROLL DOWN arrow key to return to the MANUAL CONTROL menu to make a new selection SPECFUNC 2 2 3 PLASMA ENABLE This function is only used to test the PLASMA ENABLE RELAY output Once selected use the CYCLE START and CYCLE STOP keys to toggle the relay output Pressing one of the SCROLL ARROW keys returns to the MANUAL CONTROL menu SPECFUNC 2 2 4 PLASMA START This function is
212. atically assume that only OXY FUEL CUTTING is to be done and the relays will act accordingly Or if the cutting oxygen BLEEDOFF time is set to 0 00 the plasma cutting sequence will be assumed B If both the PLASMA and OXY FUEL setup parameters have values other than 0 00 entered it indicates that both systems are present on the machine In this case the operator will be prompted to enter the type of process being used either plasma or oxy fuel This will then select the appropriate relay sequencing However it does not switch the external circuitry to the desired system Thus the operator is responsible for making sure that the machine is set to use the same cutting process as is entered into the 2 5RS If the 2 5RS is set for oxy fuel cutting See Above the following are the definitions of the relays 2 RELAY CONTACTS The RELAY CONTACT outputs used for the cutting interface are capable of switching loads rated as in the Electrical Specifications section ofthis manual Since these are Power contacts it is not recommended that they be used for Dry circuit logic levels All contacts are Maintained type Ifa momentary action is required external circuitry must be used to perform it MACH 2 5 OXY ENABLE CONTACT If the 2 5RS is set for oxy fuel cutting See Above the following are the definitions of the relays PINS 5 AND 6 OF 6PL 6PL 6 L 6PL 5 This contact must be connected to the oxygen cu
213. ative supply power output Analog Ground Speed reference input from customer s speed potentiometer Speed potentiometer drive reference input used when the 2 5RS is not in control not in NC RUN BURNY speed reference output looped back signal from pin 10 when the BURNY is not in control Enable X and Y drives input low true This is the Y drive reference output Sync Reference input Input for scaling the X and Y outputs This is the X drive reference output Preheat Gas solenoid power contacts These are normally open dry contacts Start Cut contacts These are dry contacts Enable Cut contacts These are dry contacts Sense return for pin 32 Cut On Sense input from the machine Signals 2 5RS that the cutting oxygen is operating Protective ground from machine power source Neutral conductor of machine s power source CONNECTOR RATINGS OV 0 24VDC 40 mA maximum draw See installation section of 2 5RS manual for encoder setup 24VDC 40 mA maximum draw 0V Nominal 0 to 33V peak or 0 to 33V peak Limits 23 to 45V peak 23 to 45V peak 0 75 mA Maximums 30VDC 2 A or 60VDC a 0 5A 120VAC 62 Maximums 30VDC 2 A or 60VDC a 0 5 120VAC 2 Al Logic HI is 4 90 V minimum 24V maximum Logic LO is 1 35V maximum 0 V minimum 3VDC 5 Ma maximum JOVDC 1 mA maximum 3VDC 5 mA maximum 2 230V AC maximum or 2 30VDC
214. cations are used If the conversion information at a particular table location needs to be erased either use it for a new conversion or enter an unused auxiliary code as a PGMNOP command The following are several examples of typical conversion table TV VFF codes with an explanation of their function TVVFF 23302 CAUSES INCOMING G33 TO BE LOADED AS COUNTER CLOCKWISE ARC FLAG TVVFF 12206 CAUSES INCOMING ESSI 22 FUNCTION CODE TO BE LOADED AS CUT ON COMMAND TVVFF 36422 CAUSES INCOMING M64 TO BE LOADED AS PROGRAM END CODE TVVFF 31200 CAUSES INCOMING M12 TO HAVE NO FUNCTION CAUSES IT TO BE IGNORED TVVFF 26605 CAUSES INCOMING G66 TO BE LOADED AS CUT OFF COMMAND Normally functions do not control cutting functions however the conversion table even allows for this type of re assignment Once the data at a particular table location is displayed as shown above it s value may be changed as follows Using the Numeric Keypad enter the desired TV VFF code As soon as the numeric entry starts the display changes to TV VFF with the newly entered digits appearing in the XXXXX position on the readout When the ENTER key is pressed the display reverts back to the MODIFY ENTRY format and shows the result of the new TVVFF code just entered For Example if the display shows 32005 M20 CUTOFF To change this table position t
215. ccur Any data blocks before the G97 code are not repeated on subsequent parts Initiate the cutting process Cutting speed set by operators speed dial or digital feedrate This line leads in from the pierce location to the actual part Sets the Kerf Compensation to the Left of the cut This command causes the DIAL IN KERF option to offset the cutting path to the left and thus produce the correct size part Sets the arc direction CCW and cuts a 360 degree arc This line leads out away from the part before the cutting process is turned off If any melting occurs when the cutting process is stopped it occurs in the scrap away from the part Turn off the cutting process Move to next pierce point at high traverse speed Initiate cutting process for outside cut Line Leads In from pierce location to part Standard line format LINE 16 Arc format Direction is still CCW from previous G03 command Standard line format Standard line format Standard line format Standard line format Standard line format Standard ARC format Direction changed to CW by G02 command PART 4 WADR 16 AO 73290 PART PROGRAMMING WORD ADDRESS LINE 23 Standard line format Note Line is 5 inches longer than part This allows the line to also function as a Lead Out away from the part before turning off the cutting process LINE 24 Turn OFF the cutting process LINE 25 Move to first pierce location on next part
216. chine is moved the readout displays the machines position referenced from the point where it was cleared AO 73290 PART 3 DISPLAY MODES 1 2 5RS OPERATION AND MAINTENANCE MANUAL DISPLAY 2 1 DSPY02 PARTS CUT When a part program is being run this display shows the number of part cycles which were performed If only one torch is being used this is the actual number of parts produced However if multiple torches are used the actual number of parts is the displayed value multiplied by the number of torches DISPLAY 2 2 DSPY03 FEEDRATE This display shows the current setting of the machine s speed dial in either INCHES MINUTE or MILLIMETERS MINUTE depending on SD60 setting If Digital Feedrate or Programmable Feedrate is used DSPYO3 allows a new feedrate to be entered via the keypad DISPLAY 3 DSPY05 STATUS DSPY05 SYSTEM STATUS displays E STOP error messages and also displays which part program is being cut if it is selected while a part program is running DISPLAY 4 DSPY10 DSPY44 SERVICE DISPLAYS There are several service and diagnostic displays also available from the DISPLAY menu DSPY10 DSPY44 These functions are displays of service functions but do not allow data entry See the detailed descriptions in the INSTALLATION section of this manual PART 3 DISPLAY MODES 2 AO 73290 SYSTEM UTILITIES DISPLAY MODES DISPLAY 5 DSPY80 CONFIG DSPY 80 CONFIGURE is a display mode which displays the system serial number
217. code causes a SYSTEM DWELL to be performed During this time the machine is held in position and all control outputs remain in their current condition The DWELL TIME is set during the installation of the control and can be change by following ESSI code 40 with XXXX where DWELL time is spedcified in milliseconds Example 4171000 is a 1 second dwell AO 73290 PART 4 ESSI 23 2 5RS OPERATION AND MAINTENANCE MANUAL 65 67 68 70 71 79 81 82 90 97 98 64 99 103 Multiple parameter table select code This ESSI code along with a number between 0 and 4 selects one of the five available overlay data parameter tables Example 65 3 selects overlay table 3 Plasma Height Sensor Enable Plasma height Sensor Disable Indicates that all subsequent part dimensions are in inch units Indicates that all subsequent part dimensions are in metric millimeter units Cutting table home select code This code along with a value between 0 and 4 selects the corresponding table home position Example 7942 causes machine to move to table 2 home 0 0 position Indicates that all subsequent dimensions are in INCREMENTAL PROGRAM FORMAT Indicates that all subsequent dimensions are in ABSOLUTE PROGRAM FORMAT SEE SD51 PRGM FORMAT in the SETUP MANUAL for details regarding ABSOLUTE INCREMENTAL for the X and Y center dimensions in ABSOLUTE MODE PROGRAM END NO REWIND This code does not cause the tape to rewind at the end of the load p
218. cted is customer signal from pin 15 then maximums are the same as for pin 15 Maximums 30VDC 2 A or 60VDC a 0 5 A 120VAC 8 2 If Burny signal selected output is 1 ma 15V If signal selected is customer signal from pin 18 then maximums are the same as for pin 15 Maximums 30VDC 2 A or 60VDC 0 5 A 120VAC 2A 2 230V AC maximum or 2 30VDC maximum 2 230V AC maximum or 2 30VDC maximum 2 230V AC maximum or 2 30VDC maximum See pins 32 and 33 AO 73290 PRODUCT SPECIFICATIONS Use the specification with the number of the interface board with suffix MO 03502 2 24VAC 15 mA MO 03502 0 use 115 15 mA MO 03502 1 use 230VAC 15 mA See the operator manual section MACHINE INTERFACE SENSING INPUT and SD61 SYSTEM CONFIGURATION Use the specification with the number of the interface board with suffix MO 03502 2 use 24VAC 15 mA MO 03502 0 use 115VAC 15 mA MO 03502 1 use 230VAC 15 mA See the operator manual section MACHINE INTERFACE SENSING INPUT and SD61 SYSTEM CONFIGURATION 34 Protective ground from machine power source Chassis Ground 35 Neutral conductor of machine s power source Q 0 25 A Input Input pin for powering the 2 5RS from a 115VAC machine power source Input Input pin for powering the 2 5RS from a 230V AC machine power source Input Cut Sense input Sense input
219. cteristics can be permanently set into the unit by setting the appropriate value in the SD50 SERIAL DEFN see INSTALL section variable during the machine setup procedure If a value is set using this method it is automatically used any time a serial operation is performed This would be the case if the same serial device is used all the time or if a permanent connection to a remote computer is installed This requires the least input by the operator since the values are already set A zero value may be entered for any or all of the four selections during the setup procedure This causes the operator to be prompted for the particular characteristic each time a serial operation is performed Each parameter can be set independently allowing some to be entered each time while presetting others This would be useful if the same remote device were being used every time but with programs using both ESSI and WORD ADDRESS languages Everything but the program type could be preset requiring the operator to enter only the ESSI or WADR program type When the LOAD FROM RS 232 or STORE TO RS 232 operation is selected the preset value is checked and if all 4 parameters are set the system automatically goes on to the actual loading or storing procedure However if any or all of the parameters are set to 0 the system prompts the operator for the required selections If the PROTOCOL selection parameter is set to 0 the operator must select
220. ction calibrates the A D input circuitry and avoids a manual pot adjustment The calibration value is stored in the non volatile memory along with the other system parameters IMPORTANT The calibration value will return to the previously saved value if the RECYCLE key is pressed the system is turned off or power is lost unless the SERV97 VARSTOR function is used Read the section of this manual entitled SERV97 VAR STOR This procedure is used to adjust the input circuitry which converts the analog drive reference voltage into the numerical value used by the 2 5RS This procedure only needs to be done when the system is installed or when service work to the system which might alter the speed reference voltage The analog reference along with the digitally selected feedrate value are combined internally to generate the actual speed output to the drives Therefore this adjustment is very important for the correct operation of the system TO PERFORM THE AUTOMATIC REFERENCE ADJUSTMENT If the unit is equipped with a speed range selector switch HI LO OFF set the switch to the HI speed setting If no switch is preset continue at step 2 ELSE DIGFEED This procedure is used to adjust the input circuitry which converts the voltage from the operators speed dial into the numerical value used by the 2 5RS This procedure only needs to be done when the system is installed or when service work to the system which might alter the spee
221. cts 3 A 30VDC maximum BLUE This is the other half of the Stop Cut contacts Use the specification with the number of the interface board with ORANGE 31 Cut Sense input alle MO 05798 2 use 24VAC 15 mA MO 05798 0 use 115VAC 15 mA MO 05798 1 use 230VAC 15 mA GREEN Chassis Ground 0V WHITE Return for Pin 36 PART 10 SPECIFICATIONS 2 AO 73290 PRODUCT SPECIFICATIONS Input pin for powering the BURNY 2 5RS from a 115V AC machine power 115VAC 0 25 source 2 5RS MNJ 10379 PACKAGE using MO 03473 Interface Card MO 03562 Enclosure MO 06354 Serial Adaptor 2 5RS BACK PANEL 37 PIN EXT DRIVE CONNECTOR PIN DESCRIPTION RATINGS Cross ground Return for cross output 2 Input to cross A relay AGO 2 G OE OVDE ala 3 Input to cross relay 02 2 or 60 0 5 If Burny signal selected output is 1 ma 15V If signal selected is customer signal from pin 2 then maximums are the same as for pin 2 4 Output to cross A If Burny signal selected output is 1 ma 15V If signal selected is customer signal from pin 3 then maximums are the same as for pin 3 Rail ground Return for rail outputs pins 9 and 0 10 below 5 Output to cross 7 Input to rail A relay Pac 2 2A or OVDC 0 5 Maximums 30VDC 2 A or 60VDC 0 5 A 120VAC 2A If Burny signal selected output is 1 ma 15V If signal selected is cust
222. cts 2 30VDC maximum 2 230V AC maximum or 29 30 Enable Cut contacts These dry contacts 2 30VDC maximum Seepin32 n On Sense from the customer s machine 115VAC 15 mA maximum See operator Signals the 2 5RS that the cutting oxygen is manual MACHINE INTERFACE operating SENSING INPUT Stop input from the customer s machine 115VAC 15 mA maximum See operator Signalis supplied by the machine Lack of manual sections SD61 SYSTEM This is the Y drive reference output This is the X drive reference output AO 73290 PART 10 SPECIFICATIONS 9 2 5RS OPERATION AND MAINTENANCE MANUAL voltage on this pin causes the BURNY to stop moving and shut off the cutting process Protective ground from machine power source Neutral conductor of machine s power source Input pin for powering the 2 5RS from a 115VAC machine power source Input pin for powering the 2 5RS from a 230V AC machine power source DESCRIPTION Signal Ground Power Ground CONFIGURATION and MACHINE INTERFACE SENSING INPUT Chassis Ground 0 115 0 25 A Input 230VAC 0 110 A Input RATINGS me a eoo lt lt Positive supply power output Input supply power to 12VDC powered encoders 24VDC 40 mA Output See installation section of Burny 2 5RS manual for encoder setup Negative supply power output Analog Ground 24VDC 40 mA Output lt
223. d cutting speed This is acceptable for thinner material since it is pierced almost instantly when the process is turned on However on thicker material it takes a considerable amount of time to burn down through the metal If the machine moves too fast at this point the beginning portion of the part will not be cut off completely Entering a pierce ramp time causes the machine to slowly accelerate from the pierce location The machine starts from its halted position when the process is turned ON and accelerates up to the desired cutting speed in the time entered for the PIERCE RAMP TIME By setting this value sufficiently long the material is pierced during the leadin portion of the cut so that by the time the machine has reached the actual part the material is cutting all the way through NOTE The 2 5RS can also use the Pierce Ramp time as a HOLD TIME for OXY FUEL and or PLASMA CUTTING instead of a RAMP TIME This allows the operator to enter a pierce time which causes the machine to hold position instead of starting motion as soon as the cut starts See SD62 SYSTEM CONFIGURATION 2 D8 in INSTALLATION amp SETUP section This may be use with new plasma systems that require a delay before starting motion AO 73290 PART 2 RUN 5 2 5RS OPERATION AND MAINYENANCE MANUAL RUN 4 1 2 AUTO CUT The Auto Cut Mode allows the part to be cut with all preheat and cutting processes being started and stopped by the 2 5RS If OXY FU
224. d description of each program line The program is shown in both inch and metric units SAMPLE PROGRAM 71 LEE 7 7 3 2 u j fs mmm meo b fs 508 0 25440 381 1143 3814381 3814381 889 1270 0 635 635 2921 O 1016 1575 p 73290 PART 4 ESSI 25 2 5RS OPERATION AND MAINTENANCE MANUAL LINE 1 LINE 2 LINE 3 LINE 4 LINE 5 LINE 6 LINE 7 INE 8 INE 9 INE 10 INE 11 INE 12 INE 13 Ex Sp re I INE 14 INE 15 INE 16 INE 17 INE 18 pz gp pee Up PART 4 ESSI 26 Initial move from corner of plate to pierce point on first part Due to the placement of the 97 code this block does not repeat on subsequent parts The 97 pointer is used to indicate where the program repeat should occur Any data blocks before the 97 code do not repeat on subsequent parts Initiate the cutting process Cutting process plasma oxy fuel selected by operator Cutting speed set by operators speed dial This line leads in from the pierce location to the actual part Sets the Kerf Compensation to the Left of the cut This command causes the DIAL IN option to offset the cutting path to the left and thus produce the correct size part Standard ARC format Arc direction is CCW since 5 sign is Note zero dimensions 0 are include
225. d dial voltage has occurred The voltage from the speed dial is converted into a digital value which appears as the FEEDRATE XXXX when DSPYO3 is selected When the speed dial is set for maximum speed the value displayed on the readout should equal the number entered for the SD04 MAX SPEED parameter in the setup list If the displayed value is too low or if the speed dial must be turned quite a ways down before the numbers start dropping this procedure should be done TO PERFORM THE AUTOMATIC REFERENCE ADJUSTMENT 1 Turn the operators speed dial to the FULL SPEED maximum position Also if there are any speed range switches set them to the high speed setting so that the speed dial is now set for the maximum drive speed 2 Press the ENTER key The readout temporarily shows the DATA AND CALIBRATION VALUES and then changes to the normal PART 7 SETUP AND CONFIG 66 AO 73290 SETUP AND CONFIGURATION FEEDRATE At this point the value displayed on the readout should be the same as the value entered for the MAXIMUM DRIVE SPEED AS SD04 MAX SPD For the procedure for the 2 5 Plus see Part 7 Page 82 SETUP amp CONFIG 4 5 10 SERV70 CUSTOM AUX TABLES This SERVICE function is used to setup the data tables for the AUXILIARY CODE TRANSLATION These tables are used when programs are loaded using either WADDR3 or ESSI 1 program formats to translate the AUXILIARY CODES from the input values to the
226. d dial is displayed Do not press the CYCLE START key as the readout has instructed Instead press the RECYCLE key This aborts the Speed Calibration however the speeds have been preset to full speed After all the parameters are set the Speed Calibration can be done correctly Now select SERV 10 SYSTEM DATA Set the following parameters as indicated Note Some of the values are preset to an estimated value now and then fine tuned later These estimated values are typical entries for the parameter but are not to be taken as the only valid ones PART 7 SETUP AND CONFIG 74 AO 73290 SETUP AND CONFIGURATION TYPICAL SETUP EXAMPLE PARAMETER SET TO EXPLANATION Given information although this is not the first SD60 OPERSYS parameter it should be set first so that any other speed or distance values appear in the correct units SD61 SYS CONFIG EN Standard 2 5RS SD68 SPEED RANGE Maximum machine speed is 163 ipm SD01 ARC Must be set to 0 00 to disable PLASMA DELAY PROMPTING This estimated value represents a typical time for the oxygen manifold to BLEEDOFF after the cut is turned off When a part is actually cut ifthe time appears too long or short it can be re adjusted x ALTHOUGH the time is arbitrary it must be set SD02 to some non zero value at least 01 to automatically BLEEDOFF 2 00 EST select the oxy fuel cutting prompts If both the PLASMA and BLEEDOFF TIMERS are set to 0 00 or if both a
227. d for clarity Only the sign of the dimension is actually needed for the part This block cuts a 360 degree arc This line leads out away from the part before the cutting process is turned off If any melting occurs when the cutting process is stopped it occurs in the scrap away from the part Turn off the cutting process Move to next pierce point at high traverse speed Initiate cutting process for outside cut Line Leads In from pierce location to part Standard line format Standard Arc format Direction is CCW since 5 sign is Note zero dimensions 0 are included for clarity Only the sign is actually needed for the part program Standard line format Standard line format Standard line format Standard line format Standard line format AO 73290 PART PROGRAMMING ESSI LINE 19 Standard ARC format Direction is CW since 5 sign is LINE 20 Standard line format Note Line is 5 inches longer than part This allows the line to also function as a Lead Out away from the part before turning off the cutting process LINE 21 Turn off the cutting process LINE 22 Move to first pierce location on next part LINE 23 The 98 command causes program to repeat from point where 97 command was used LINE 24 End of Program Command AO 73290 PART 4 ESSI 27 2 5RS OPERATION AND MAINTENANCE MANUAL PART DRAWING SAMPLE PROGRAM 1 Dimensions inch millimeter w PLATE EDGE _ CUT ON CUTTI
228. d in a program the repeat returns to that point rather than the top of the program A prompt Value 1 0000 allows for optional loop programming Normally set to 0000 CHNBOT 04 CHAIN BOTTOM This code is placed at the end of a program to cause an automatic program repeat when the code is read If this code is omitted the program runs until it reaches the PROGRAM END code and then stops The operator has to press the START key to cut another part CUTOFF 05 CUTTING OFF Turns off the cutting process CUTON 06 CUTTING ON Turns on the cutting process KRFOFF 07 KERF OFF Kerf Off function is automatically done each time the cutting is turned off Thus there is normally no need for a separate Kerf Off code in the program It is normally only used with the Code Conversion option KRFLFT 08 KERF LEFT Sets the Kerf direction to the left of the path for the DIAL IN KERF function KRFRHT 09 KERF RIGHT Sets the Kerf direction to the right of the path for the DIAL IN KERF function MARKOFF 10 MARKER 1 OFF Turns OFF the 1 marking device MRKON 11 MARKER 1 ON Turns ON the 1 marking device PART 2 RUN 8 AO 73290 OFSOFF OFSON INCH MMETER ABSDIM AO 73290 SYSTEM UTILITIES PROGRAM TEXT EDITOR INTERNAL FUNCTION NAMES CODES CONT 12 13 14 15 16 OFFSET 1 OFF Cancels the 1 marker offset and moves the machine back to the cutting position The prompt VAL 1 0000 is u
229. d program number For example to request program number 12345 the 2 5RS sends the following sequence to the computer lt ESC gt FG12345 lt CR gt lt LF gt where ESC is the ASCII ESCAPE character is the ASCH EXCLAMATION point FG is the abbreviated command for FILE GET PART 5 SERIAL 20 AO 73290 SERIAL COMMUNICATIONS SERIAL 12345 is the program number requested from the storage computer The storage computer should interpret this command and send back the appropriate ascii file on the storage computer preceded by a FILE DATA command Thus the FILE GET command is always sent by the requesting device and the FILE DATA command always precedes transmission of the actual program for either storing or retrieving data to from the remote computer CR is the ASCII carriage return character lt LF gt is the ASCII line feed character NOTE At this time the remote computer cannot request a program from the 2 5RS control All transfers are initiated at the 2 5RS control only If the 2 5RS issues a FG request to the remote computer for a program 12345 for example which does not exist the remote computer should send the following response lt ESC gt FD12345 lt CR gt lt LF gt lt Z gt Where the 7 termination character is sent immediately after the FD header indicating the program does not exist The 2 5RS then displays PGM NOT FOUND in its display SERIAL 8 9 FILE QUEUE lt ESC gt
230. defined no center hole is cut AO 73290 PARTS 2 SHAPES 29 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 25 SHAPE 25 SQUARE WITH HOLE REPEAT PATTERNS PLATE SIDE k LEFT RIGHT 9 25 Y e BZ 7 1 WIDTH DIMENSION 2 INCHES OR MILLIMETERS 2 HEIGHT DIMENSION INCHES OR MILLIMETERS 3 HOLE DIAMETER INCHES OR MILLIMETERS 4 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 5 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 6 LEAD IN DIMENSION i INCHES OR MILLIMETERS 7 LEAD OUT DIMENSION 1 INCHES OR MILLIMETERS 8 VERIFY YES NO YES OR NO NOTES Ifa HOLE DIAMETER of 0 is defined no center hole is cut PART 2 SHAPES 30 AO 73290 SYSTEM OPERATION SHAPES SHAPES3 26 SHAPE 26 OCTAGONAL FRAME REPEAT PATTERNS 1 PLATE SIDE f LEFT RIGHT 9 p gt OX X 2 O A 4 4 gt x di y x 16 y 6 5 8 ec 3 ze 1 OUTSIDE WIDTH INCHES OR MILLIMETERS 2 OUTSIDE HEIGHT INCHES OR MILLIMETERS 3 INSIDE WIDTH INCHES OR MILLIMETERS 4 INSIDE HEIGHT INCHES OR MILLIMETERS 5 INSIDE RADIUS INCHES OR MILLIMETERS 6 BEVEL LENGTH i INCHES OR MILLIMETERS 7 KERF DIMENSION 2 WIDTH OF CUTTING TOOL PATH 8 SCRAP DIMENSION
231. der machines cannot travel as fast as the drive capacity without literally shaking themselves apart In these cases the RUN SPEED and TRAVERSE SPEED LIMITS are used The RUN SPEED LIMIT limits the maximum speed during cutting portions of the part program The TRAVERSE SPEED LIMIT SD11 limits the speed during non cutting traverse moves If no limiting is required set both the RUN SPD LIMIT and TRAVERSE SPEED LIMIT to the same speed as MAX SPD SD04 SETUP amp CONFIG 4 2 10 SD11 TRAVERSE SPEED LIMIT ipm MPM This value acts the same as RUN SPD LIMIT SD10 However it limits the speed during non cutting fast traverse moves See description for SD10 RUN SPEED LIMIT SETUP amp CONFIG 4 2 11 SD12 MIN ACCEL Seconds This parameter specifies the minimum time which will be used for an acceleration from one speed to another Ifthe bit in SD62 is set to use Speed Dependent Accel time the value entered for SD03 ACCEL TIME is used as the time for accelerating from 0 to Max Speed Ifthe control is operated at a lower feedrate the acceleration time will be lowered proportionately When the machine is operated at a very low speed the acceleration time can get very short which doesn t work well on some machine frames This parameter specifies a minimum acceleration time so that regardless of the feedrate affect on the accel time the control will always use at least this minimum time amount AO 73290 PART 7 SETUP AND CO
232. drawings should be referred to when answering the various prompts If a dimension is requested use the numeric keypad along with the decimal point and CE or CLR keys to enter the desired value Once it is correct press ENTER Since the 2 5RS can operate in either a metric or inch system the standard units for the dimensions are those selected for the operating system during installation by 5060 However dimensions can be entered in either unit by using a special key sequence In this way an occasional metric part can be entered directly even though the system is set for inch units To enter a dimension in the opposite unit from the system default press the SHIFT key first The displayed value is converted to the opposite unit inch mm and the number of decimal places will change 2 for inch 1 for mm Pressing the same key again changes the value back to the original units This key only changes the value being entered and does not switch the units for the entire system Each dimension must be converted individually as required If a count such as number of holes or other integer value is requested use the numeric keypad and clear key to enter the desired number Once the value is correct press ENTER AO 73290 PARTS 2 SHAPES 1 2 5RS OPERATION AND MAINTENANCE MANUAL If a selection such as CW CCW YES NO etc is requested the displayed response may be toggled by using the key Press ENTER
233. e PART RETURN key is used Normally if this key is pressed 3 times it will return to the starting home position for the entire program However since there are now multiple home positions the 3 press of the key will only return to the most recent Table home position Additional presses of the button have no affect This was done to make it easy to restart a part at a particular table home position To recycle the entire part program and return to the original starting position it is necessary to first return to the local Table home position as described above and then press SHF then PART RETURN This will return to the original starting location Note this special SHF operation is only needed if the part program contains table home commands Normal existing part programs have no difference in their operation or Part returns functioning AO 73290 PART 3 SPECIAL FUNCTIONS 9 2 5RS OPERATION AND MAINTENANCE MANUAL SPECFUNC 3 FNC 16 SET HOME As described in FNC 15 above the 2 5RS remembers Table 1 0 0 home position as long as the power to the unit remains ON When a power failure occurs or the unit is turned off or reset by SERV98 SYS RESET the table 1 home position must be re defined The 2 5RS has two methods of defining the table 1 home position One method is used on machines that has home limit switches installed The other method is used on machines that has no home limit switches SPECFUNC 3 1 SETTING TABLE 1 HOME POS
234. e are 4 choices for WORD ADDRESS program types they are basically the same The major difference is in the assignment of auxiliary function codes These differences allow the 2 5RS to be compatible with other controls and programming systems Some of the special formats could even be the same as the standard 2 5RS program type In most cases the standard format for the system should be used The WADR3 special format as described above allows complete re definition of the auxiliary code functions and axis definitions This section deals with the STANDARD WADR WADRI and WADR2 form WADR 1 1 WORD ADDRESS DATA BLOCK SPECIFICATION The WORD ADDRESS data block is made up of KEY CHARACTERS and VALUES A KEY CHARACTER is a letter that means something special to the 2 5RS control The KEY CHARACTERS that are supported are as per RS274 FOR INCH 0 2 54 54 1154 54 M3 T4 K 24 F54 08 FOR 0 G3 X 63 V 63 1163 J 63 M3 4 K 33 F63 08 KEY CHARACTERS except for the sign require a numerical value directly after them These values further described the KEY CHARACTER to the 2 5RS control Any word address character not described here is ignored IMPORTANT AS PER RS274 ALL PROGRAMS MUST START WITH A DATA BLOCK CONTAINING ONLY A PERCE
235. e characters 0 9 and A Z followed by a CR LF This pattern is sent continuously as long as the Clear to Send CTS input line is in the active state The display contains two data fields The left side of the screen shows the characters which are being received on the RS 232 port while the right side shows the status of the CTS line Ifthe CTS line is high which allows the 2 5RS to transmit data the right side shows CTS Ifthe CTS line goes low the right side shows NOCTS The unit can be connected to a simple monitor or a computer running CROSS TALK or a similar terminal emulation software package and the data link in both directions can be verified Also by looping the 2 5RS back to itself it provides a sort of self check If the screen shows that it is receiving the data being transmitted it probably indicates that the RS 232 port of the 2 5RS is ok When the fiber optic modems are used the loopback can be done at two locations Either a single fiber can be looped between the transmit and receive port of the modem inside the 2 5RS or the modem at the other end of the link can have it s RS 232 signals looped back so that the data being sent by the 2 5RS goes out and back through both modems The selection of BAUD RATE and CHARACTER FORMAT is similar to the operation of the program downloading software The values stored in SD50 appears as the defaults when the LOOPBACK routine is called The selections for program type
236. e covered in one revolution of X DIST REV I X axis encoder SD21 Y 4 990 Given value for distance covered in one revolution of DIST REV i Y axis encoder 75 EST No Plasma in use oxygen only SD22 ENC LIN REV 500 Encoders specified as 500 lines rev SD23 X ENC DIR X CANNOT BE PRESET SET BY TEST SD24 Y ENC DIR X CANNOT BE PRESET CAN IN IN SD25 X DRIVE X INOT BE PRESET DIR x Y DRIVE X CANNOT BE PRESET SD27 PLATE SIDE Relay is used for Plasma auto height disable Not used SD28 HEIGHT RELAY in OXY FUEL cutting SD29 SLWDWN Nominal SLOWDOWN RADIUS although this value 2 00 RAD seems correct for many machines SD30 MIN RAD 20 00 Typical Minimum Radius Speeds are 10 30 ipm SPD Adjusted later if necessary SD32 MIN SLW 10 Typical value for most machines PART 7 SETUP AND CONFIG 76 AO 73290 Information given states that plate to be cut is to the RIGHT RIGHT of the operator SETUP AND CONFIGURATION SD33 MAX SLW Typical value for most machines SD46 MIN OFF 50 EST NOMINAL VALUE gives 5 SEC delay after any DLY function is turned off SD60 OPER SYS INCH Given information Given information SD62 SYS SD63 SYSTEM CONFIGURATIO Set to zero N3 SD65 OVERLAY CFG SD31 PLASMA Oxy Fuel only was specified TB1 SD40 X MARKER Nomak OFFSET 1 SD41 Y MARKER Nasnadeer OFFSET 1 SD42 MARKING SPEED Not used No marker in this contro
237. e data is displayed on the left of the readout indicated by XXXX The address may be changed when it is flashing by entering the desired value on the keyboard The Data at the displayed address is shown here interpreted as ASCII data The Data at the displayed address is shown here as a 4 Digit Hexadecimal value To Enter a new data value only possible if entered through SERV30 first press the ENTER key This causes the address value to stop flashing and the Data value to start flashing Now any value entered on the keypad alters the Data value Press the ENTER key when the value is correct This places the new data at the indicated address The Data field continues to flash so the Data value can be changed again and again To return to the Address selection mode press the ENTER key again The Data value stops flashing and the Address value starts flashing indicating that a new address may be entered AO 73290 PART 7 SETUP AND CONFIG 61 2 5RS OPERATION AND MAINTENANCE MANUAL SETUP amp CONFIG 4 5 2 SERV31 DOUBLE WORD MEMORY DISPLAY DOUBLE WORD 32 bit hexadecimal display entry of any memory location in the system The display for the SERV31 DSPY31 SHOW DBL utility appears as MD XXXX HHHHHHHH The Address ofthe 2 word data is shown on the Left side of the readout as a 4 Digit Hex value The Data is shown on the Right of the readout as an 8 Digit Hexadecimal value SETUP amp CONFIG 4 5 3 SERV32 16 BIT CRU DISPLA
238. e following message would be sent first lt ESC gt FD8765 lt CR gt lt LF gt Where ESC isthe ASCH ESCAPE character is the ASCII EXCLAMATION point FD isthe abbreviated command for FILE DATA 8765 isthe program number stored in the 2 5RS control which is sent to the computer The number is sent as standard ASCII numeric characters lt CR gt is the ASCII carriage return character lt LF gt is the ASCII line feed character AO 73290 PART 5 SERIAL 19 2 5RS OPERATION AND MAINTENANCE MANUAL The 2 5RS then PAUSES FOR ONE SECOND and then begins to send program data as follows lt CR gt lt LF gt P8765 DATA PROGRAM DATA M30 lt CR gt lt LF gt NZ lt CR gt lt LF gt signal for end of program data lt ESC gt QQ lt CR gt lt LF gt status code sent by 2 5RS Where ESC 15 the ASCII ESCAPE character is the ASCH EXCLAMATION point is the abbreviated command for FILE QUIT is a three digit status code lt CR gt is the ASCII carriage return character lt LF gt is the ASCII line feed character SZ is the ASCII Control Z character SERIAL 8 8 FILE GET lt ESC gt FG FILE GET The 2 5RS control requests a program from the storage computer The 2 5RS control requests a program by specifying a program number of up to 8 numeric digits Currently only numeric file names are used no alphabetic characters are allowed The message is a sequence of characters incorporating the desire
239. e has been repaired or the defective component replaced the important programs can be re loaded from the Back up copy It is important that the backup copy is stored AWAY from the 2 5RS since in the case of a dropped plate or lightning strike the backup copy may be damaged along with the control PART 6 SERVICE 8 AO 73290 SERVICE Custom Auxiliary codes are saved by the battery backup system in the 2 5RS See the section in this manual concerning SERV70 CUSTOM AUX These code tables cannot be backed up by floppy disk or RS232 from the 2 5RS as are the user programs in the paragraphs below The original documentation for the Auxiliary Code Translation Tables should be retained to guard against the loss of battery backup or physical damage to the 2 5RS Ifthe original documentation has not been retained the files can be copied by hand from the 2 5RS screen See the section SERV70 custom AUX If programs are already stored on a host computer make sure there are back up copies of the computer data since a problem there such as a hard disk crash could cause the loss of program information If the programs are only stored inside the 2 5RS the RS232 port on the control can be used to store the programs to one of several sources If the unit is equipped with an internal floppy disk all important programs should be copied to a floppy disk which is then removed from the unit a second floppy disk containing the same information is advised also
240. e is that if a DISPLAY function is selected by pressing the DSPY key the values can be displayed but not changed If the same function is selected as a SERVICE function by pressing the SERVICE key the values are also displayed but may be altered by entering the desired values Some of the service functions are not available through the DISPLAY key AO 73290 PART 7 SETUP AND CONFIG 1 2 5RS OPERATION AND MAINTENANCE MANUAL SERVICE MODE KEY LOCATED HERE OLD STYLE FRONT PANEL SERVICE MODE KEY LOCATED HERE JEJE auc u ne E o NEW STYLE FRONT PANEL PART 7 SETUP AND CONFIG 2 AO 73290 SETUP AND CONFIGURATION SETUP amp CONFIG 3 POWER UP DIAGNOSTICS When the 2 5RS is first turned on it automatically performs several diagnostic checks These are indicated on the readout as they are being performed Normally it should continue to sequence through the various tests and then automatically start normal operation If a problem is detected the testing stops and an error message is displayed In most cases this indicates a problem with the actual circuitry and should be reported to the Burny service department for information on repair or replacement The final test before normal operation begins is a check of the keyboard to detect any shorted keys Since no keys are supposed to be pressed during the power up sequence the test routine checks that a
241. e process press the key to toggle the selection to YES then press ENTER The indicated block is erased from memory All following blocks move up one number so block 6 becomes block 5 etc The display now returns to the MAIN BLOCK DISPLAY EDITOR 1 4 INSERTING A DATA BLOCK The INSERT FUNCTION allows data blocks to be added to the program either above or below any other data block in the program no blocks may be added above the PROGRAM START or after the PROGRAM END To INSERT a block ABOVE the current block shown on the MAIN BLOCK DISPLAY first press SHF then the SCROLL UP arrow To INSERT a block BELOW the current block shown on the MAIN BLOCK DISPLAY first press SHF then the SCROLL DOWN arrow PART 2 RUN 6 AO 73290 SYSTEM UTILITIES PROGRAM TEXT EDITOR After the SCROLL UP DOWN key is pressed the display prompts for the type of block to be inserted either a LINE ARC BLOCK or a FUNCTION INSERT LINE ARC OR INSERT FUNCTION Since the only difference between line and arc blocks is the I and J dimensions they are considered the same for the INSERT function Use the key to toggle between the two selections and press ENTER when the desired one is displayed This inserts a blank block into the part program and then goes immediately to the editing function for that block If a LINE ARC was INSERTED the prompting goes to the X Y VJ CW CCW prompts with all the dimen
242. ecialized cutting and operating characteristics which are used for each machine Set SD61 to the desired system configuration as explained below Most machines with OXY FUEL and PLASMA Set SD61 to 0 Machines using the Burny 2 5RS E STOP function Set SD61 to 12 Machines used with Replicator Set SD61 to 16 AO 73290 PART 7 SETUP AND CONFIG 37 2 5RS OPERATION AND MAINTENANCE MANUAL SETUP amp CONFIG 4 2 47 SD62 SYSTEM CONFIGURATION 2 The SD62 SYS CONFIG Secondary system configuration flag is used to select the desired operation for the machine it is being installed on D1 should be set to 0 Ex os os os s os or s D2 Selects programmable feedrate programmable kerf digital feedrate home limit switch reading the Inhibit enable input and the NCRUN mode Inhibit also causes NCRUN mode to switch off oi oT ws os vs vs or oe ENABLE INHIBIT INPUT AND ALSO SWITCHES OFF NCRUN PROGRAMMABLE FEEDRATE AND puc er HH SD62 SYSTEM CONFIGURATION 2 3 manipulates the default condition for the X amp Y home index switches and the X amp home index inputs from the encoders These bits can also be used to bypass a particular input by setting the invert bit so that the input is detected as being ON when there is no device actually plugged in This is useful where a machine has only home switches but no home index inputs from the encoders SD96 X offset from table 1 to X
243. ecte 8 WADR 1 12 F FEEDRATE nente ttai rana re tana da aen da de rea ee stiegen 8 CODE DESCRIPTIONS 9 WADR 1 13 CODE DESCRIPTIONS 0 9 WADR 1 13 1 OVERALL PROGRAM 11 WADR 1 14 LOOP PROGRAMMING I 11 WADR 1 15 M CODE DESCRIPTIONS n esisiini 12 WADR 1 16 WORD ADDRESS SAMPLE PROGRAM 15 ESSI PROGRAMMING 2 222 19 ESSI 2 ESSI PROGRAMMING 19 ESSI 2 1 LINE AND ARC BLOCK SPECIFICATIONS u 19 ESSI 2 2 ESSI AUXILIARY 2 2 22 ESSI 2 3 ESSI SAMPLE PROGRAM 25 PART 5 SERIAL COMMUNICATIONS 5 SERIAL COMMUNICATIONS U U u u u 1 SERIAL 1 CONFIGURING THE COMMUNICATION 0 4 SERIAL 2 CONNECTING RS 232 7 SERIAL 3 RS 232 PIN 8 SERIAL 4 RS 232 FOR HARDWARE 5 9 SERIAL 5 RS 232 FOR SOFTWARE 11 SERIAL 6 CONNECTION TO RS 422 DEVICES 12 SERIAL 7 CHARACTER FORMMATS tinent nina dnas ce eade 14 SERIAL 8 HANDSHAKING PROTOCOL SPECIFICATIONS 15 SERIAL 8 1 RTS CTS HARDWARE PROTOCOL sse
244. ected by power failures NOTE This section describes certain parameters that are common to only one type of cutting such as BLEEDOFF time which is used in oxy fuel cutting or ARC DELAY which is for plasma cutting These may or may not be used on all cutting machines depending on the type of cutting tools installed Explanations are given for the majority of possible cutting tool configurations SETUP amp CONFIG 1 SERVICE MODE KEY Throughout this section there are references to the SERVICE key This key is not labeled on the operators panel since there is no need for it during normal operation On the 2 5RS the SERV ICE key is located approximately 3 inches from the right side of the panel and 1 5 inches from the top of the panel See the next page for illustrations showing the hidden location of this key on the new and old style front panels This key may be pressed at any time during any operation to enter the SERVICE mode main menu When the desired service function is complete press the SERVICE key and SER V00 EXIT to exit the service mode and return to the previous operation SETUP amp CONFIG 2 DISPLAY FUNCTIONS Most of the DISPLAY MODE functions are described in the main operators manual However several of the displays are not used during normal operation and so are not covered in the DISPLAY MODE section Most of the display functions are also available by pressing the SERVICE key The differenc
245. ection without any keys being pressed For latched jog use the direction keys in the upper right hand corner of the front panel First press the LATCH JOG then press the direction key to indicate the desired jog direction Each key must be pressed within 2 seconds of the previous one or the sequence is interrupted The machine begins moving in the selected direction at the speed set To stop the motion press CYCLE STOP or RECYCLE NOTE The Latched Jog feature may be disabled with SD62 SYS CONFG2 See Installation documentation on SD62 SYS CONFG2 OPSUMMARY 5 4 JOG AT MAXIMUM SPEED NEW STYLE FRONT PANEL A high speed jog may be initiated by a two key sequence First press the SHF then press the direction key The SCROLL led will flash indicating high speed jog mode The machine will move at the maximum traverse speed regardless of the feedrate setting unless the feedrate is set to 0 00 which causes the machine to stop Pressing again returns to the normal jog mode The Max Speed Jog function only works with momentary jogs Latch Jog cannot be used with Max Speed Jog OPSUMMARY 6 KEYBOARD OPERATIONS Throughout this manual the operator is instructed to enter numbers and values for the various selections This is done using the 0 9 numeric keypad along with the and DECIMAL POINT keys when required If an incorrect value is entered the clear entry key CLR or CE can be used to cle
246. ed by the M73 command after the marker 2 portion of the program is complete Note that this function could also be programmed by using M70 T2 as described above M79 GO TO TABLE This command instructs the 2 5RS control to move to the cutting table indicated by the value that follows the M79 For example M79 Go to Table 3 0 0 home position PART 4 WADR 14 AO 73290 PART PROGRAMMING WORD ADDRESS WADR 1 16 WORD ADDRESS SAMPLE PROGRAM The following is a word address program for SAMPLE PART 1 see the drawing below The REF letters on the program listing refer to the circled reference points on the part drawing After the program is a detailed description of each program line The program is shown in both inch and metric units This example assumes that overlay table 2 is used for the cutting process selected SAMPLE PROGRAM 1 INCH PROGRAM METRIC PROGRAM COMMENTS mp 6 Lm PROGRAM NUMBER Lm sewer OVERLAY TABLE Ls PRGMREPEATPOINTER Fw we ON Fw mewsxzvs LEADINLINE Fw won won Serene Poe Nacosr 7s _Nagosria1 C CUTCCWARCHOLE Pio D LEADOUT ri TURNOFFCUT ARC STILL COW r I S ws gt gt N21G02X5123725 N21GO2X1271633635 N arcow navas O
247. ed on the machine Parts can be cut at any location on the table programs can be downloaded kerfed etc and the optical tracing system can be used without affecting the location of the table 1 home position Only a power failure or turning the control off causes this location to be lost and require the FNC 16 SET HOME function to be re done In addition to the table 1 home position there are three additional TABLE HOME positions which are defined as offsets from the reference home position Table 1 These TABLE HOME offsets are entered as setup parameters SD74 through SD79 The TABLE 2 HOME OFFSET TABLE 3 HOME OFFSET and TABLE 4 HOME OFFSET parameters define a home position on each of possible cutting tables This feature is particularly useful for operations where the material is precut to fixed sizes and is always located at the same place on the cutting tables By defining these fixed table home positions the torch can accurately be positioned on each table Once a table GO HOME function is performed the home position on that table is considered 0 0 position for all subsequent operations The machine 0 0 1s not affected AO 73290 PART 3 SPECIAL FUNCTIONS 7 2 5RS OPERATION AND MAINTENANCE MANUAL SPECFUNC 2 1 GO HOME MENU When the FNC 15 GO HOME function has been selected the display changes to GO TO HOME 1 There are three possible choices for the GO HOME function GO TO TABLE HOME 1 Causes the machine to
248. ed path and then presses START CYCLE this display shows until the machine has moved back to the correct position This display also occurs if the machine drifts away from the correct position when it is supposed to be holding position waiting for cutting oxygen switch to be turned on IMPORTANT IF THIS DISPLAY APPEARS WHEN A PART PROGRAM IS RUNNING AND THE MACHINE APPEARS TO BE STALLED IT INDICATES THAT THE CONTROL IS UNABLE TO RETURN THE MACHINE TO THE CORRECT POSITION THIS CAN OCCUR IF THERE IS A LARGE AMOUNT OF DRIFT IN THE DRIVES OR IF THERE IS SOME KIND OF MECHANICAL BIND OR INTERFERENCE THE MECHANICS OF THE MACHINE SHOULD BE CHECKED FOR OPERATION IN ACCORDANCE WITH THE OPERATION MANUAL FOR THE MACHINE AND NEEDED ACTION SHOULD BE TAKEN TO CLEAR THE BINDING OR INTERFERENCE THE DRIVES SHOULD BE CHECKED ESPECIALLY FOR DRIFT ACCORDING TO THE DRIVE MANUFACTURER S INSTRUCTIONS RUN 8 RUNNING DESCRIPTION Due to the variations between cutting machines it is not possible to give an exact description of the operating sequences to be used while running a part The following descriptions serve to illustrate the various control functions and typical operating sequences If MANUAL CUT mode is selected the program moves to the pierce point and waits for the cut to be started by the operator At the end of the cut the cutting process stops automatically and the machine advances to the next pierce position When it reaches the
249. eference output signal from Black Red wire then maximums are the same as for Black Red wire Maximums 30VDC 2 A or 60VDC a 0 5 A Black Red Input for X Drive reference from Tracer 120VAC Q2 A TERMINAL BLOCK 1 1TB NUMBER DESCRIPTION RATING AC Supply input return AC Supply Return See pins 2 and 3 Input pin for powering the 2 5RS from a 115VAC machine power source IR Input pin for powering the 2 5RS from a 230V AC machine power source COP a System Ground MO 03435 POWER PIGTAIL DESCRIPTION RATING Preheat relay contacts 2 230V AC maximum or Dry contacts 2 30VDC maximum Dry contacts 2 30VDC maximum Enable cut output 2 230V AC maximum or Dry contacts 2 30VDC maximum Cut sense input AC return See pin 8 Return for Cut sense signal See pin 8 115VAC 15 mA maximum See operator manual MACHINE INTERFACE SENSING INPUT Cut sense input to signal the 2 5RS that cutting oxygen is operating 2 5RS with MNJ 09045 PACKAGE using MO 03374 Interface Card MO 03434 Drive Pigtail Output low 40 mA maximum pull down to 0 7 V maximum Output high will be pulled up to level of Cut Sense signal through 10 kOhm resistor Power Ground 20VDC Unregulated input 33VDC 2 A maximum 2A fuse PART 10 SPECIFICATIONS 6 AO 73290 PRODUCT SPECIFICATIONS Input to supply power to 12VDC powered See installation section of 2 5RS manual 12 Analog input f
250. elected output is 1 ma 15V If signal selected is customer signal from pin 15 then maximums are the same as for pin 15 Maximums 30VDC 2 A or 60VDC 0 5 This is the Y drive reference input 120VAC 2 Logic HI is 4 90 V minimum 24V 16 Enable X and Y Drives input maximum Logic LO is 1 35 V maximum 0 V minimum 1 mA maximum If Burny signal selected output is 1 ma 15V If signal selected is customer signal from pin 15 then maximums are the same as for pin 15 This is the X drive reference input Maximums 30 VDC 2 A or 60VDC 0 5 PART 10 SPECIFICATIONS 14 AO 73290 This is the Y drive reference output This is the X drive reference output PRODUCT SPECIFICATIONS LLL 20VAC Q2 A Preheat Gas solenoid power contacts These 2 230VAC maximum or are normally open dry contacts 2 A 30VDC maximum 25 26 31 Er Cut On Sense from fe customer s machine i 32 Signals 2 5RS that the cutting oxygen is manual MACHINE INTERFACE operating Input SENSING INPUT Protective ground from machine power source Chassis Ground Neutral conductor of machine s power source 0VAC 0 25 A Input Input pin for powering the 2 5RS from a 115 machine power source Input pin for powering the 2 5RS from 230VAC machine power source 230VAC 0 110 A 2 5RS with MNJ 10380 for ETEK NS3003 with SP150 using MO 03650 INTERFACE CARD MO 07146 010 POWER OXY C
251. ely placed in a static dissipative bag Warranty replacement repair or credit will not be issued on circuit cards returned without the proper antistatic packaging Contact Burny for specifications or help with any packaging SERVICE 3 1 FAULT FINDING AND TROUBLESHOOTING If a suspected malfunction is observed refer to the proper section of this manual to verify the observed problem is a malfunction The user is cautioned concerning activities directed toward finding components that are malfunctioning Without current schematics diagnostic equipment and training field engineers run the risk of damaging more components than were initially damaged This could extend down time and repair expense Always contact Burny Service when damage has occurred in order to prevent further electrical damage Burny service personnel can often assist via telephone concerning the advisability of swapping parts that are already on site Avoidance of damage to the swapped in part is a consideration here The on site person can be most valuable in diagnosing problems Being familiar with equipment and user manual Knowing conditions and events before a failure Being familiar with normal operation Observing and reporting damage accurately AO 73290 PART 6 SERVICE 7 2 5RS OPERATION AND MAINTENANCE MANUAL SERVICE 3 2 SPARE PARTS Contact Burny Service to obtain needed parts Always use replacement parts that are supplied designed or approved by Bu
252. en 4 RUN 4 CUTTING MODE SELECTION ee a 5 BUNA n MANUAL CUT a ee re ee 5 RUN 4 1 1 RAMP OXY FUEL OR PLASMA 5 RUNS AUTO CUPS Ded ecc en ne nalen an 6 RUN 4 1 2 1 HIGH PREHEAT OXY FUEL ssesseetttenn ttti 6 RUN 4 1 2 2 RAMP OXY FUEL OR 5 6 RUN 4 1 2 3 PART COUNT ALL CUTTING PROCESS 7 RUN 4 2 gt TESTRUN Me ern M ade nents MED LU E 7 SINGLE STEP Eee 7 RUN 5 START GY eL each E eu Rr 7 RUN 6 PLATE ALIGNMENT OPTION d 8 RUN 7 RUNNING DISPLAYS qu d ed 9 RUN 8 RUNNING DESCRIP TION eurem en ee Renta NEUE 11 PART 3 SYSTEM UTILITIES 22 4 u uu 3 EDITOR ea ee 1 EDITOR 1 PROGR MTEXTEDIT R see en ee ie 1 EDITOR 1 1 MAIN DATA BLOCK DISPLAY sse ttt tette 1 EDITOR 1 2 EDITING COMMANDS ee ee ee 3 EDITOR 12 1 LINE ARC BLOCK EDITING 4 AO 73290 Table of Contents iv TABLE OF CONTENTS EDITOR 1 2 2 ARC DIRECTION CW CCWW l 4 VERIFY YES NO essen ish dann anette 5 EDITOR 1 2 3 FUNCTION BLOCK EDITING ee 5 EDITOR 1 3 DELETING BLOCK nee ae ran
253. en activated This shuts down the 2 5RS drives WARNING THIS DOES NOT SHUT OFF THE AC POWER INPUT IT ONLY DISABLES THE DRIVES AND CUTTING FUNCTIONS Program execution has been stopped machine is holding position Program is executing a TEST RUN of the program Program is running OXYGEN BLEEDOFF TIMER is counting down machine is holding position Program is running current block is non cutting machine is running at high TRAVERSE SPEED Program is running machine is cutting in MANUAL OXY FUEL MODE MACHINE speed dial controls speed Program is running machine is holding position and AUTO CUTTING HIGH PREHEAT is in progress Program is running machine is cutting in AUTOMATIC OXY FUEL MODE Program is running operator has BACKUP key pressed causing machine to re trace cut path backward Speed is limited by setup value Program is running control is holding machine position and waiting for PROGRAMMED DWELL TIMER to reach 0 before continuing along programmed path PART 2 RUN 9 2 5RS OPERATION AND MAINYENANCE MANUAL WAIT CUT SW OFF WAIT CUT SW ON WAIT START XXX RUN PLASMA CUT RUN DELAY XXX X RUN ARCOFF XXX X RUN PLASMA START DNC28 INDENT 18 RUN TOOL 1 BLANK ENDIF DNC28 RUN PIERCE XXX X PART 2 RUN 10 Program is running cutting is selected Control is waiting for the cut switch to be turned on before starting to move on some systems the cut can be started by
254. er If the parameter requires a choice between two alternatives pressing the key switches between the two choices Examples Left Right Norm Rev Yes No SETUP amp CONFIG 4 2 SYSTEM DATA PARAMETERS MENU SD00 NOT USED SD01 ON PURGE DELAY SD02 BLEEDOFF TIME SD03 ACCEL TIME SD04 MAX DRIVE SPEED SD06 BACKUP SPEED SD07 CORNER SPEED SD08 MIN HOLD SPEED SD09 ERROR SPEED MAXIMUM SDIO RUN SPEED LIMIT SD11 TRAVERSE SPEED LIMIT SD12 MIN ACCEL SD14 GAIN BREAK SD15 ERROR WARNING DISTANCE SD16 LOOP GAIN SD17 ARC OFF DELAY SDI8 SLOWDOWN DISTANCE SD19 HEIGHT SENSOR DISABLE LOOKAHEAD SD20 X ENCODER DISTANCE REV SD21 Y ENCODER DISTANCE REV SD22 ENCODER LINES REV AO 73290 PART 7 SETUP AND CONFIG 7 2 5RS OPERATION AND MAINTENANCE MANUAL SD23 X ENCODER DIRECTION SD24 Y ENCODER DIRECTION SD25 X DRIVE DIRECTION SD26 Y DRIVE DIRECTION SD27 PLATE SIDE SD28 HEIGHT SENSOR RELAY SD29 SLOWDOWN RADIUS SD30 MINIMUM RADIUS SPEED SD31 PLASMA TABLE 1 SD32 MIN ANG SD33 MAX SLW ANG SD40 X MARKER OFFSET SD41 Y MARKER OFFSET SD42 MARKER SPEED Not used in this control SD43 MARKER DELAY Not used in this control SD45 DEFAULT DWELL SD46 MINIMUM OFF DELAY SD47 X MARKER OFFSET 2 SD48 Y MARKER OFFSET 2 SD49 START DELAY SD50 SERIAL DEFINITION SD51 PROGRAM FORMAT SD52 SPECIAL END OF PGM SD53 FILE EXTENSION SD60 OPERATING SYSTEM SD61 SYSTEM
255. erform the SERV52 MEMORY RESET function described in MEMORY RESET section of this manual Once the memory is cleared select the SER V70 CUSTOM AUX function and continue PART 7 SETUP AND CONFIG 68 AO 73290 SETUP AND CONFIGURATION There are 3 basic displays which are used in loading the data into the conversion table The first occurs when the table is first entered or after a value has been changed It shows which of the 50 TABLE ENTRIES is being displayed along with the current definition for that table value For example AUX01 M20 CUTOFF Shows that the first table location is being referenced and that a word address function code M20 is to be converted to perform the CUT OFF function of the control Another example AUX14 33 KRFOFF This indicates that TABLE POSITION 14 is defined to convert an ESSI 33 FUNCTION CODE to the KERF OFF OPERATION in the system At this point the desired table position can be reached by either pressing the numbered keys on the keypad or by using the SCROLL FUNCTION keys of the system If a numbered key is pressed the readout immediately changes to show the new table location Do not press the ENTER key when trying to select a particular table location but simply press the 2 digit number Once the desired TABLE LOCATION is displayed the actual conversion data definition can be displayed and later modified Press the ENTER key to change from t
256. esistor on the card There should not be a jumper across this resistor This resistor limits the maximum current drawn by the sensing input circuitry however the input will respond to much lower voltages Therefore care must be taken that when the input is supposed to be Off there are no low level leakage paths such as suppression capacitors across switches or relay contacts which could provide enough current to be sensed as an On input See also the Electrical Specifications section in this manual AO 73290 PART 7 INTERFACE 1 2 5RS OPERATION AND MAINTENANCE MANUAL MACH 1 2 E STOP SENSING INPUT Some of the interface cards for the 2 5RS include an additional sensing input circuit for monitoring the E STOP status of the cutting machine For those interfaces that provide this function the connections are E STOP MONITOR 6PL 7 same return as for other 9 SENSE INPUT sensing circuit described below This input can be configured for various voltages as described in the Electrical Specifications Sections of this manual and also above The E STOP monitoring function can be enabled or disabled depending on the settings of parameter SD61 Setting SD61 0 Disables the E STOP monitor input This setting should be used for interface cards that do not provide the E STOP input or for machines where this input is not wired Setting SD61 12 Enables the E STOP monitor input and requires the external machine wiring to provide an i
257. fore moving to the next cut If a machine uses PLASMA cutting only this parameter should be set to 0 SETUP amp CONFIG 4 2 3 SD03 ACCEL TIME seconds multiple parameter This value sets the acceleration time for the machine to go from 0 to full speed The value should be set as low as possible to minimize the delay which occurs when the machine negotiates a corner However it should not be set so low that an abrupt JUMP occurs after each corner Normally 2 to 1 0 SEC SETUP amp CONFIG 4 2 4 5 04 DRIVE SPEED ipm MPM This value must be set to the MAXIMUM DRIVE SPEED of the machine at full reference This value is used in many of the position loop gain and slowdown calculations and if not set correctly can seriously affect machine performance This value must be set to the capability of the drive system not the desired maximum speed The maximum speed value cannot exceed the speed range selected by parameter SD68 SPEED RANGE Consult the machine operation manual for the maximum machine speed To LIMIT THE SPEED see 5010 AND SD11 PART 7 SETUP AND CONFIG 10 AO 73290 SETUP AND CONFIGURATION SETUP amp CONFIG 4 2 5 SD06 BACKUP SPEED ipm MPM This value sets the speed of the machine when the BACKUP key is pressed This is the maximum speed when backing up however the speed can be set slower by lowering the operators speed dial There is no accel decel when backing up therefore this speed sho
258. from their standoffs AO 73290 PART 6 SERVICE 9 2 5RS OPERATION AND MAINTENANCE MANUAL 10 11 12 13 14 15 16 The liquid crystal display should be carefully pried from its socket s The prying operation should be performed bit by bit and the display kept nearly parallel with the circuit board at all times This will ensure that the display s machined connector pins do not shear Additionally the display will be more easily reinstalled if the pins are not bent The glue that is holding the battery in place should be cut with a hot scalpel The new battery can now be desoldered and the remaining solder removed from the holes in the circuit board It is important that the insulator found under the battery is reinstalled under the new battery The battery should be soldered and heat glue applied If a visual inspection indicates that the battery and insulator are in proper position the display can be reinstalled The display should be inspected for bent pins which should gently be straightened Gently place the display back on its socket s Ensure that each of the pins are perfectly positioned above each socket before starting to seat the display After just starting the insertion pause to check for pins that are bending instead of penetrating the sockets If all of the pins can be observed as having started insertion into their sockets then the display can be pushed into the fully seated positon The circui
259. ftware versions When these parameters are being entered the display shows SDxx nnnnnnn Example SD03 ACCEL TIME SERV41 Sets up overlay table 1 parameters The entry procedures are the same however the readout appears as 1 nnnnnnn to show that table 1 is being accessed Example 1 03 ACCEL TIME SERV42 Sets up overlay table 2 parameters The entry procedures are the same however the readout appears as 2 xx nnnnnnn to show that table 2 is being accessed Example 2 03 ACCEL TIME SERV43 Sets up overlay table 3 parameters The entry procedures are the same however the readout appears as 3 xx nnnnnnn to show that table 3 is being accessed Example 3 03 ACCEL TIME SERV44 Sets up overlay table 4 parameters The entry procedures are the same however the readout appears as 4 xx nnnnnnn to show that table 4 is being accessed Example 4 03 ACCEL TIME SERV40 First displays which table is currently selected and then allows that table to be changed It also permits a different table to be selected for testing purposes When SERVAO is first selected it displays CURRENT TABLE X where the X is a digit 0 4 This is the index of the table which is currently running the machine To adjust the parameters in this table press the ENTER key when the CURRENT TABLE display is showing The proper table is accessed and is changed just as if the SERV41 44 procedures listed above was used
260. g feature may be disabled with SD62 SYS CONFG2 See Installation documentation on SD62 SYS CONFG2 OPSUMMARY 5 2 JOG AT MAXIMUM SPEED OLD STYLE FRONT PANEL A high speed jog may be initiated by a three key sequence First press the II key then press the SHF before the jog direction is selected Upon pressing the number key the machine will move at the maximum traverse speed regardless of the feedrate setting unless the feedrate is set to 0 00 which causes the machine to stop Pressing the SHF also causes the SCROLL led to flash indicating high speed jog mode Pressing SHF again returns to the normal jog mode The Max Speed Jog function only works with momentary jogs where the operator must keep the button pressed It will not work with the latched jog AO 73290 PART 1 OPSUMMARY 5 2 5RS OPERATION AND MAINTENANCE MANUAL OPSUMMARY 5 3 JOG CONTROLS NEW STYLE FRONT PANEL GE Y NC RUN NEW STYLE FRONT PANEL Jog is accomplished by pressing one of the keys in the upper right hand corner of the front panel The machine jogs in the selected direction at the cutting speed as long as the direction key is held and will decel to a stop when it is released Diagonal jog is accomplished by using the latched jog function FRONT PANEL FOR 2 5 PLUS PART 1 OPSUMMARY 6 AO 73290 SYSTEM OVERVIEW GENERAL OPERATION SUMMARY The latched jog function allows the machine to continue to move in the selected dir
261. grammed directions Servo drives sometimes develop an offset or drift over a period of time or temperature change If drift becomes excessive especially when greater than the SD08 MIN HOLD SPD the drift will cause the software to stall the machine at pierce points DRIFT COMPENSATION is a special software routine that monitors X and Y axes servo drive drift and produces a voltage that exactly cancels the drift The monitoring function occurs when the system is not in the RUN mode after the RECYCLE button is pressed and continues to measure the drift even during RS 232 downloading operations To insure that the drift is canceled correctly when this feature is enabled press the RECYCLE button and then let the machine sit motionless for about 30 seconds while watching for drift This process should be repeated in 2 3 hours if the system has been cutting continuously since drift sometimes develops as servo drives warm up with use Use DSPY11 and display V08 X DRIFT and V18 YDRIFT to observe the drift compensation at any given time This display expresses drift compensation as a percentage of drive output BACKLASH COMPENSATION is another special software feature that helps compensate for unaccounted for motion between the feedback encoder and the actual machine For example if the system is using encoders mounted to the back of the drive motors and there is a gearbox between the motor and the drive pinion there could be backlash or lost mot
262. hape The selection of a shape can be made either by scrolling to the desired shape or by entering the shape number on the keypad Once the shape has been selected and the data entered the shape is assigned the 8 digit program number for future reference The standard shape library contains 53 generic shapes See the section Standard Shapes FUNCMENU 3 LOAD FROM RS 232 The LOAD FROM RS 232 function is used to download a part program via the serial port into 2 5RS memory Once the function is selected the prompt PRGM 00000000 is displayed Enter the program number to be used to store the part program data and press ENTER If the PROGRAM NUMBER selected does not exist the operator is prompted for additional information pertaining to serial communication parameters See section SERIAL COMMUNICATIONS for further information on LOADING FROM RS 232 If the program number requested already exists in program memory then a special prompt appears FUNCMENU 4 DUP PGM HHHHH If a duplicate program error is given either enter a different number or go back and DELETE the existing program then return to the LOAD operation PART 2 FUNCTION MENU 2 AO 73290 SYSTEM OPERATION SHAPES FUNCMENU 5 LOAD CUSTOM SHAPE FROM FROM RS 232 Custom Shape Programs must be created by CMC they are not customer programmable Custom Shape Programs are loaded using the same Serial loading method as normal Word address or ES
263. he DISPLAY MODE to the MODIFY ENTRY MODE In the first example where AUX01 M20 CUTOFF was displayed pressing the ENTER key causes the display to change to 32005 M20 CUTOFF The 5 digit number on the left is called the TV VFF code where the left most digit T indicates the auxiliary code type as 1 ESSI function code 2 WORD ADDRESS G function code 3 WORD ADDRESS M function code The next two digits V V contain the actual number of the ESSI or WORD ADDRESS M or G code In this example since an M20 was to be converted the digits were set to 20 The final two digits FF contain the INTERNAL FUNCTION CODE which is assigned to the input auxiliary code These numbers are selected from the following table AO 73290 PART 7 SETUP AND CONFIG 69 2 5RS OPERATION AND MAINTENANCE MANUAL FF CODE NAME 00 PGMNOP 01 CWARC 02 CCWARC 03 CHNTOP 04 CHNBOT 05 CUTOFF 06 CUTON 07 KRFOFF 08 KRFLFT 09 KRFRHT 10 MRKOFF 11 MRKON 12 OFSOFF 13 OFSON 14 INCH 15 MMETER 16 ABSDIM 17 ABSRPL 18 INCDIM 19 DWELL 20 LEADIN 21 PGMSTP 22 PGMEND 23 PGMRWD 24 SKPON 25 SKPOFF 26 MRK2ON 27 MRK2OF 28 OFS2ON 29 OFS2OF 30 CUTSPD 31 SPD 32 XFR RUN 33 A 34 V LOAD 35 X HOME 36 Y HOME 37 XHOMRT 38 YHOMRT 39 SEL 40 GOHOME 41 TOOL 42 KRFDIM 43 FEEDRT 44 HT DIS 45 HT ENA 46 LDAUTO 47 PMARKI 48 49 PGMNOP 50 COUNT PART 7 SETUP AND CONFIG 70 FUNCTION
264. he auxiliary output This second option would be used if the marker was to control a machine setup mode In this way the machine mode would not change just because recycle was pressed The auxiliary output will always turn off when the RECYCLE button is pressed The auxiliary output will also turn off if the Marker OFF code is pressed Eoi os os os s os or ws x mess foto A ENABLE KNIFE KERF OPTION KNIFE KERF OPTION ENABLE KNIFE KERF OPTION X AUX OUTPUT DOES NOT GET TURNED OFF BY CYCLE STOP MARKER RELAY BECOMES AN xx x x AUXILIARY OUTPUT Shaded columns apply only to 2 5 Plus Note Numbers not listed in the table should not be used Unused bits in SD63 and in all parameters should be set to zero SETUP amp CONFIG 4 2 49 SD65 This parameter is not used for normal operations ALL 4 DIGITS OF THIS PARAMETER MUST BE SET TO 0000 Note this parameter is also contained in the 4 overlay tables the value for SD65 in all 4 overlay tables must also be set to 0000 See instructions later in this manual for entering data in the overlay tables using SERVA 42 43 44 E oa os oe ALL 4 DIGITS OF THIS PARAMETER SD65 MUST BE SET TO 0000 PART 7 SETUP AND CONFIG 46 AO 73290 SETUP AND CONFIGURATION SETUP amp CONFIG 4 2 50 SD68 SPEED RANGE in mm The SPEED RANGE parameter allows the 15 bit speed range of the control to be scaled up or down to provide more resolution in the range that
265. he cut speed is set to 150 and D8 in SYSCFG2 is set to a 1 the machine accelerates to 150 ipm in 1 5 seconds When the cut speed is reduced to 75 ipm the machine accelerates to cutting speed in 75 seconds Setting SYSCFG2 bit D8 to 0 provides acceleration to cut speed based on the value of SD03 ACCEL TIME This is the same type of acceleration as in previous software versions TEACHABLE PREHEAT The 2 5RS has the ability to learn a preheat time When the correct bit is enabled a teachable preheat time is enabled The CYCLE START key is use to extend or shorten preheat time The new time is remembered and used on all subsequent pierces AO 73290 PART 7 SETUP AND CONFIG 45 2 5RS OPERATION AND MAINTENANCE MANUAL SETUP amp CONFIG 4 2 48 SD63 SYSTEM CONFIGURATION 3 The SD63 SYS CONFIG3 parameter settings are defined below This parameter allows using the optional Marker Relay output as a general purpose on off auxiliary output An auxiliary output can be used an auxiliary control for a cutting process If a marker output is reassigned as an auxiliary output it functions as a simple ON OFF output The same Word address M codes or ESSI function codes are used to turn the auxiliary output ON and Off however there are no marker delays and the marker speed parameters have no affect SD63 set the auxiliary output to be turned of by CYCLE STOP or it can keep the Cycle Stop from affecting t
266. he number 2 key Once these two points are identified the angle of the plate is calculated and displayed as ANGLE XXX XX then PRESS ENTER IF OK The angle is positive for CCW angles and negative for CW Press ENTER to align to this angle This sets the displayed angle as the plate alignment value and then returns the machine to the first corner Once the machine stops the prompting returns to the cut mode selection MANUAL AUTO ETC as detailed in CUTTING MODE SELECTION Enter the appropriate selection for the cutting mode and press ENTER The display now changes again to prompt for the CYCLE START key however it also displays the PLATE ANGLE PRESS CYCLE START PLATE ANG Press the CYCLE START key to begin the program The parts now follow the angle of the plate and cut correctly PART 2 RUN 8 AO 73290 RUN 7 SYSTEM OPERATIONS RUNNING A PROGRAM RUNNING DISPLAYS While cutting the part the display shows the current status of the machine In addition if a condition is preventing the operation from continuing a WAIT display is shown along with the condition causing the holdup Following is a list of these displays along with a brief explanation of each STOP E STOP STOP HOLD POS RUN TEST RUN RUN VENT XXX X RUN TRAVERSE RUN OXY CUT RUN PRHT XXX X RUN AUTO OXY CUT RUN BACKUP RUN DWELL XXX X AO 73290 The STOP has be
267. hen this service mode is selected the display shows the X and Y axis speeds ipm MPM on the readout These displays are much easier to use for checking the X and Y speeds than using a stopwatch or tachometer Not available through Display key Use this display to balance the X and Y speeds so they all run the same AO 73290 PART 7 SETUP AND CONFIG 63 2 5RS OPERATION AND MAINTENANCE MANUAL SETUP amp CONFIG 4 5 7SERV51 SPEED CALIBRATION This SERVICE MODE ONLY function performs an automatic speed calibration routine which matches the outputs from the 2 5RS to the servo drives This helps counteract any nonlinear characteristics of the drives and leads to a more consistent cutting speed regardless of the direction of travel Once the machine servos have been adjusted so that they run at the same speed in all directions SEE SERV50 ABOVE this function is used to balance the servo outputs of the 2 5RS This function actually performs 4 speed calibrations each at a different speed In this way any differences between the Hi and low speed operation of the machine can be accommodated For each of the four calibrations the readout displays SET SPD DIAL THEN CYCLE START SET XXX NNNNNN The operator should set the machine speed dial to the speed indicated by the XXX digits in the readout The current setting of the speed dial is displayed in the NNNNNN digits Once the speed dial is set pressing the CYCLE START key
268. hese values must be large enough to provide the necessary SCRAP between parts When running the resulting NC part program the machine moves from the starting corner to the pierce point defined by the LEAD IN DIMENSION AO 73290 PARTS 2 SHAPES 15 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 11 SHAPE 11 STRAIGHT LUG REPEAT PATTERNS 6 _ 1 PLATE SIDE LEFT RIGHT Scd NOS 2 7 X e ur 4 1 WIDTH DIMENSION INCHES OR MILLIMETERS 2 HEIGHT DIMENSION I INCHES OR MILLIMETERS 3 HOLE DIAMETER INCHES OR MILLIMETERS 4 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 5 SCRAP DIMENSION DISTANCE BETWEEN PARTS IN MM 6 LEAD IN DIMENSION INCHES OR MILLIMETERS 7 LEAD OUT DIMENSION INCHES OR MILLIMETERS 8 VERIFY YES NO YES OR NO NOTES If a HOLE DIAMETER of 0 is defined no center hole is cut The lead in distance for the center hole is automatically set to 1 2 of the HOLE DIAMETER value PART 2 SHAPES 16 AO 73290 SHAPES3 12 NOV gt OQ 3 6 4 A PIN 7 WIDTH DIMENSION HEIGHT DIMENSION THICKNESS DIMENSION KERF DIMENSION SCRAP DIMENSION LEAD IN DIMENSION LEAD OUT DIMENSION VERIFY YES NO SYSTEM OPERATION SHAPES SHAPE 12 LUG FRAME REPEAT PATTERNS PLATE SIDE LEFT RIGHT INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS WID
269. hipped with each 2 5RS DISK DRIVE contains a file that is used to configure the systems for the 2 5RS control The name of this file is EASIDSK SYS Normally the drive only needs to be configured once and this is done at the factory If the drive needs to be configured again place the FLOPPY UTILITIES amp TEST PROGRAMS disk in the drive with the power off When power is turned on to the 2 5RS control the disk drive reads the file EASIDSK SYS and automatically configures the ports baud rate parity data bits stop bits and a number of other parameters to the correct settings Once the system is configured the parameters are saved in non volatile memory FLOPPY 3 SERIAL CONNECTION The 2 5RS DISK DRIVE system port is factory configured as follows COM1 4800 baud EVEN parity 7 data bits 1 stop bit CTS RTS disabled and XON XOFF enabled A 3 wire RS 232 serial cable is required for connection between the 2 5RS and the external floppy drive The connection is as follows X ON X OFF SOFTWARE PROTOCOL 25 PIN D SUB AT PORTABLE DISK READER SERIAL I O PORT PART 3 FLOPPY 2 AO 73290 SYSTEM UTILITIES FLOPPY DRIVE FLOPPY 4 LOADING FILES FROM THE FLOPPY Loading a file from 2 5RS PORTABLE DISK DRIVE is accomplished by pressing the key which selects LOAD FROM FLOPPY Then press the ENTER key The 2 5RS prompts the operator for a numeric program number 8 digits maximum Enter the desired program number that
270. his affects both the reference home position and Table home positions Once the machine is located at the proper position select the FNC 16 SET HOME special function The display changes to YES SET HOME NO There are two verification prompts which must both be answered YES to actually set the home reference position This is done to guard against accidentally changing the home location When this prompt appears use the key to cause the or indicator to flash If the response is entered for either of the verification prompts the home position is not changed and the procedure aborts To set the home reference position use the key to make the sign by NO YOU SURE YES Again this second prompt must also be answered by the YES response Use the key to get the sign flashing and press ENTER This causes the current location of the machine to be defined as the TABLE 1 Home position The display shows the current encoder position as 0 00 0 00 Press the RECYCLE key to return to the main menu AO 73290 PART 3 SPECIAL FUNCTIONS 11 2 5RS OPERATION AND MAINTENANCE MANUAL BLANK PART 3 SPECIAL FUNCTIONS 12 AO 73290 SYSTEM UTILITIES FLOPPY DRIVE FLOPPY DRIVE OPERATION NOTE For proper operation of an externally mounted 2 5RS disk drive software option 5 must be enabled The 2 5RS control will only load programs with a preset file extension The file
271. ial swivel knife compensation routine that modifies the cut path to produce sharp corners rather than rounded corners caused by the knife s offset from center AO 73290 PART 2 RUN 3 2 5RS OPERATION AND MAINYENANCE MANUAL RUN 3 1 DIAL IN KERF The DIAL IN feature allows to be added to the shape to be cut A prompt to enter the desired KERF value is displayed as XX XXXX The value displayed is the KERF used the last time the part was run The KERF dimensions entered should be the total width of the path created by the cutting process This value can be derived by cutting a 4 square with no kerf entered and then measuring the actual size The difference between the actual size and the input dimension size is the kerf value Enter this value as a positive KERF DIMENSION This alters the cut path and causes the actual piece to have the correct dimensions The value entered for kerf is in inches for INCH operating systems and in millimeters for METRIC systems A negative kerf value can also be entered however this is normally not done If entered it shrinks the size of the part rather than increasing it This can be useful if a part is programmed with too large a kerf in the dimensions A negative kerf value counteracts the programmed kerf shrinking the part to the correct size In order for the prompt for DIAL IN KERF to appear the program must contain a KERF code such as KERF LEFT
272. installed in accordance with local statute The 2 5RS should be installed adjusted tested and serviced by qualified personnel familiar with electrical equipment and with the contents of this manual The 2 5RS is intended for use only as described in this manual These instructions have been prepared to ensure compliance with the European Community Electromagnetic Compatibility Directive and Low Voltage Directive SERVICE 1 1 PHYSICAL INSTALLATION OF THE BURNY 2 5RS Upon receipt of the unit unpack all pieces Retain all packaging until you have verified there is no physical damage to the contents and the system has been installed The contents of each shipping container should be recorded by model number and serial number if serialized It is further recommended that packaging be saved in case of future upgrade or service shipping needs All pieces should be carefully inspected for shipping damage loose parts and most importantly exposed uninsulated electrical parts Contact Burny immediately if any problems occur The location into which the 2 5RS will be installed should be chosen with consideration of many factors some of which are listed here Accordance with the Environmental Operating Specifications of the 2 5RS Away from sources of moisture Avoiding undue sources of dust and other particles if possible Located so that unit and operator are out of areas of travel Unit and operator are away from zones through which objects may
273. ion in the gearbox and to some degree between the pinion gear and the gear rack There are 3 system parameters which control the operation of this feature SDA0 X LASH SDAI Y LASH and SDA2 LASH RATE The X and Y lash values are the amount of lost motion measured in each of the X and Y axes and the Lash Rate parameter controls how quickly the lost motion is made up when the axis changes direction See SDAO SDA1 and SDA2 later in this section Use DSPY11 to display V72 XBKLSH and V73 YBKLSH to show the backlash compensation value being applied and removed as the machine is changing directions while moving along the part profile Note that backlash compensation is only used for cutting and not for jogging AO 73290 PART 7 SETUP AND CONFIG 43 2 5RS OPERATION AND MAINTENANCE MANUAL oi ws os vs os os 97 vs BACKLASH COMPENSATION ENABLE DRIFT COMPENSATION ENABLE iaronn accorsa TTT Ser PART 7 SETUP AND CONFIG 44 AO 73290 SETUP AND CONFIGURATION SD62 SYSTEM CONFIGURATION 2 D8 affects the acceleration time of the 2 5RS oi ws os os os os Por 98 5 ppp x Tat Ist Is IS gt mene nee reren oxri TLE Rx SPEED DEPENDENT ACCELERATION Setting this parameter to a value of 00000001 provides a speed dependent accel time For example SD03 ACCEL TIME 1 5 SECONDS SD04 MAXIMUM DRIVE SPEED 150 ipm When t
274. ioning commands and that the part being produced is out of tolerance If a negative value is entered and the error exceeds the value set for this parameter a CYCLE STOP in addition to the WARNING MESSAGE is displayed and BEEPING OCCURS The display then flashes WARNING PATH ERROR This indicates that the machine is not responding to positioning commands and has stopped The value should be large enough that the normal BUMPS and SHAKES associated with a cutting machine in a production shop do not cause NUISANCE tripping of the warning It s main purpose is to issue WARNING when something breaks or is jammed on the machine and causes a large offset from the correct path Typically set around 05in 1 25mm PART 7 SETUP AND CONFIG 14 AO 73290 SETUP AND CONFIGURATION SETUP amp CONFIG 4 2 14 SD16 LOOP GAIN multiple parameter This value is the most critical of all the setup parameters in affecting the machines performance while cutting a part The position loop constantly compares the position of the machine to the correct programmed path Any difference or PATH ERROR is multiplied by the LOOP GAIN value This result is then output to the drives which causes the machine to move back toward the correct path This value should be set to as large a value as possible to give the most accurate part However if it is set too high the machine becomes unstable and oscillates while moving around the part Thus adjusting this va
275. ipment acts as pull down to turn on the relay Y drive reference output Y drive reference input X and Y Enable Drive input X drive reference output X drive reference input Preheat Gas solenoid power contacts These are normally open dry contacts Start Cut contacts These are dry contacts Enable Cut contacts These are dry contacts Sense return for pin 32 Cut Sense input Signals the 2 5RS that the cutting oxygen is operating Protective ground from machine power source 24VDC 40 mA 0 Nominal 0 to 2 17V peak or 0 to 2 17V peak Limits 1 98 to 2 36V peak or 1 98 to 2 36V peak 0 04 mA Sinks 500 mA 50V If Burny signal selected output is 1 ma 15V If signal selected is customer signal from pin 15 then maximums are the same as for pin 15 Maximums 30VDC 2 A or 60VDC a 0 5 A 120VAC 6 2 Logic is 4 90V minimum 24V maximum Logic LO is 1 35V maximum 0 minimum 25 A maximum If Burny signal selected output is 1 ma 15V If signal selected is customer signal from pin 18 then maximums are the same as for pin 15 Maximums 30VDC 2 2 A or 60VDC a 0 5 A 120VAC 22 2 230V AC maximum or 2 A 30VDC maximum 2 230V AC maximum or 2 A 30VDC maximum 2 A 230 VAC maximum or 2 30VDC maximum 230VAC 15 mA See the operator manual section MACHINE INTERFACE SENSING INPUT Chassis Ground PART 10 SPECIFIC
276. irst before cutting the part AO 73290 PART 4 WADR 5 2 5RS OPERATION AND MAINTENANCE MANUAL WADR 1 9 G PREPARATORY FUNCTION SINGLE BLOCK FUNCTION NOTE 2 CIRCULAR INTERPOLATION CW CIRCULAR INTERPOLATION CCW DWELL KERF COMPENSATION CANCEL KERF COMPENSATION LEFT KERF COMPENSATION RIGHT LEAD IN TO KERF COMPENSATED PART Selects which overlay parameter should be used Example G46 T1 where T can be 0 1 2 3 and 4 INCH PROGRAMMING METRIC PROGRAMMING ABSOLUTE PROGRAMMING INCREMENTAL PROGRAMMING ABSOLUTE REGISTER PRELOAD SETS PROGRAM REPEAT POINTER G97 CAN FOLLOWED BY VALUE TO GENERATE A LOOP PROGRAM INITIATES PROGRAM REPEAT AT G97 AUTO ERASE AND LOAD NOTE 1 Function is retained until canceled or superseded by another command in the same letter group A B C etc NOTE 2 Function affects only the block which it appears in PART 4 WADR 6 AO 73290 PART PROGRAMMING WORD ADDRESS WADR 1 10 M MACHINE AUXILIARY FUNCTIONS The supported function definitions vary depending on the program format specified as illustrated in the following table In most cases the first column is the standard auxiliary code definitions for the 2 5RS SPECIAL SPECIAL WITH AFTER DESCRIPTION WADRI WADR2 BLOCK CODE BLOCK M00 Program stop End of Program CUT PROCESS OFF CUT PROCESS OFF CUT PROCESS ON CUT PROCESS ON HEIGHT SENSOR DISABLE HEIGHT SENSOR ENABLE MARKER OFFSET 1OFF
277. ith the machines optical tracing system to REMEMBER an existing template and then repeat it any number of times without the template Press the ENTER key The display changes to PGM 00000000 with the last used program displayed Enter program number to be used to store the taught data TEACH 1 TEACHING VALUES Once the teach mode is selected the prompt will change to YES STD VAL NO This prompt is used to bypass many of the variables used for teaching by allowing the operator to use a STANDARD set of values preset in the system The various teach setup parameters can be used to tailor the accuracy of the teaching process for different applications The STANDARD values result in a good compromise of teach resolution versus memory storage To choose the Standard Values press the key one time which will cause the YES on the left of the readout to begin flashing Then press the Enter key and continue at BEGINNING THE TEACHING PROCESS If some of the values are to be altered press the key twice so that the NO on the right of the readout is flashing Then press the ENTER button and go on to the individual parameter settings listed below If STANDARD VALUES ARE NOT SELECTED the prompting will ask for the 6 parameters which control the teaching process AO 73290 PART 3 TEACH 1 2 5RS OPERATION AND MAINTENANCE MANUAL DIGITIZING FACTOR MAXIMUM RADIUS MINIMUM RADI
278. ity A X gt X gt Y and all Aux Codes Forced to High Priority B X gt X Y gt Y and all Aux Codes Forced to High Priority C X gt Y Y gt X and all Aux Codes Forced to High Priority D X gt Y Y gt X and all Aux Codes Forced to High Priority E X gt Y Y gt X and all Aux Codes Forced to High Priority F X gt Y Y gt X and all Aux Codes Forced to High Priority PROGRAM FORMAT SD51 Digit D7 affects programs loaded under any of the WADR or ESSI program formats when they are programmed in ABSOLUTE Incremental programs are not affected For absolute programs this digit establishes how the I and J arc coordinates are defined Setting this digit to an even number causes the I J to be the same type as the X Y dimensions Therefore on absolute programs the I J also must be in absolute Setting this digit to a odd number forces the I J dimensions to be in incremental even if the program is in absolute For incremental programs the I J is always incremental PART 7 SETUP AND CONFIG 32 AO 73290 SETUP AND CONFIGURATION The third digit also selects whether or not the 2 5RS should used the SPECIAL END OF PROGRAM ASCII SEQUENCE set in SD52 This affects programs loaded under WADR3 and ESSII SD51 now has a bit defined which allows the end of program string function to be included on WADR3 ESSII or both types of special programs Setting the bit off ignores the special string and onl
279. ized for a particular machine This SERVICE DISPLA Y function accesses a second menu of all the adjustable parameters in the system These parameters are used to control the dynamic characteristics of the system and also to configure the 2 5RS to match the particular cutting machine and interface wiring PART 7 SETUP AND CONFIG 6 AO 73290 SETUP AND CONFIGURATION If this function is selected through the DISPLAY mode the system parameters may be displayed but not altered Only by using the SERVICE key can these values be displayed and entered Once this mode is selected the display changes to SD00 EXIT MODE which is the first parameter in the list Select the desired parameter by scrolling or by directly entering the 2 digit number of the particular parameter Once the correct entry is displayed press the ENTER key This causes the current value for that parameter to be displayed If the value is correct press the ENTER key to step to the next parameter in the menu Ifthe value needs to be changed enter the desired value using the numeric keypad decimal point and CLR OR keys Press the ENTER key when the value is correct Press the ENTER key a second time to step to the next parameter in the menu NOTE Some of the parameters do not show their effect on the machines performance until the ENTER key is pressed the second time and the menu has been stepped to the next paramet
280. just appear as another standard shape at this point Enter the dimensions for the custom shape as usual and then run the resulting part program as usual RUN 00000123 The normal LOAD FROM STD SHAPE prompt will not access any Custom Shapes If you run the Standard Shapes the usual way the Custom shape will not appear in the list you must go through the step of Running the BDF09892 program to get the GENERIC XFER OK message to make the Custom Shape active FUNCMENU 6 STORE FROM RS 232 The STORE FROM RS 232 function is used to upload a part from program memory out the serial port to a host storage device Once the function is selected the prompt PRGM 00000000 appears Enter the program number to be STORED to the remote device AO 73290 PART 2 FUNCTION MENU 3 2 5RS OPERATION AND MAINTENANCE MANUAL FUNCMENU 7 TEACH PROGRAM The TEACH function is used along with the machines optical tracing system to REMEMBER an existing template and then repeat it any number of times without the template See TEMPLATE TEACH section of this manual for detailed description FUNCMENU 8 DELETE PROGRAM DELETE is used to erase a part program Once the function is selected the prompt PRGM 00000000 appears At this point enter the number for the program to be deleted The scroll keys may also be used to select a part in program memory for deletion Press ENTER to DELETE the program All programs in program
281. l SD43 MARKER DELAY Not used No marker in this control SD45 DEFAULT Sett 5 DWELL SD47 X MARKER No4nsthon OFFSET 2 SD48 Y MARKER Nomak OFFSET 2 E SD49 START DELAY Ka Usually for plasma cutting Set to 0 for oxy fuel SD50 SERIAL See Pg 27 z DEFINITION Different BAUD range for 2 5RS and 2 5Plus SD51 PRGM See Pg 28 FORMAT this section SD52 SPECIAL ee EOP AO 73290 PART 7 SETUP AND CONFIG 77 Set to zero 2 5RS OPERATION AND MAINTENANCE MANUAL CNC is standard OSEE 434E4300 This is not really needed since downloading is not EXTEN 3 being used SD69 LANGUAGE SEL SD70 KNIFE DIA SD71 KNIFE BP ANGLE Set for English Not used for oxy fuel cutting Not used for oxy fuel cutting SD96 X HOME INDEX SWITCH SD97 Y HOME INDEX SWITCH SDA0 X LASH SDAI Y LASH SDA2 LASH RATE No home function specified on this machine Initially set to 0 Initially set to 0 Initially set to 0 After the values are preset the following procedures will help in adjusting the values TX MACHINE DIRECTIONS Y X l Turn up the operators speed dial and jog the machine in the X direction See jog instructions The machine should move in the rail axis away from the operator SD80 SD95 PROGRAM MABLE Set to 0 unless customer has specific use OFFSETS Ifthe machine moves toward the operator in the X Rail Axis reverse the setting of SD25 X DRIVE D
282. l formats allow various conversions to be performed on the program being loaded to comply with the standard programming Setting this digit to a 1 causes the CUSTOM AUX code tables described in the SER V70 section of this manual to be used when the program is loaded If the digit is set to 0 the normal aux codes as described in the programming section are used Implied Decimal Shift IDS in the table below Allows the 2 5RS to read tapes which are programmed with an implied decimal point in the X Y T J dimensions Example Some controls program a 2 dimension as X200 This would normally be interpreted as a 200 inch move The Decimal Shift Function allows a 2 digit shift to the left to be added to the number so it is correctly loaded as 2 00 inches Similarly some programs are loaded in 1 10 scale A decimal shift right of 1 causes these programs to be cut correctly PART 7 SETUP AND CONFIG 30 AO 73290 SETUP AND CONFIGURATION bi oa os es 95 os os OHO IDS left 2 places Auxiliary Code EL IDS left 3 places Translation Table NOT enabled IDS left 4 places IDS left 1 place IDS left 2 places Auxiliary Code IDS left 3 places Translation Table IDS left 4 places enabled IDS right 1 place BE IDS right 2 places IDS right 3 places IE PROGRAM FORMAT SDS1 LL B Bl E N B B B gt D 8 E E E E E
283. led Once a cut has finished and the machine has moved to a new pierce location this signal must go off for at least 1 second before a new cut will be allowed to start NOTE In the following descriptions the term OVERRIDE will be used to indicate that the operator has pressed the NC RUN button and has caused the LED in the button to go out This disconnects the 2 5RS outputs and returns to manual machine operation See GENERAL OPERATIONS SECTION MACH 1 4 OXY FUEL CUT INTERFACE DESCRIPTION Although the 2 5RS operates either OXY FUEL or PLASMA cutting systems the small size of the cabinet prevents the use of independent relays for each function Therefore the 3 relays are used for both plasma and oxy fuel cutting If a machine is to have only one of the cutting processes the connections can be made directly to the 2 5RS However if the machine is to have both plasma and oxy fuel it usually requires the addition of an external relay to switch the signals from the 2 5RS to the appropriate cutting circuitry This description shows the operation for both the plasma and oxy fuel cutting modes AO 73290 PART 7 INTERFACE 3 2 5RS OPERATION AND MAINTENANCE MANUAL As described in the 2 5RS INSTALLATION SECTION the selection of either the oxy fuel or plasma operation of the relays is determined in one of two ways A If the ON DELAY and ARC OFF DELAY setup parameter are set to 0 00 the 2 5RS will autom
284. ll keys are open and then allows normal operation to begin If a shorted key is found an error message is displayed showing which key is shorted from the following table KEY NAME KEY NAME KEY NAME 00 Number 0 40 DSP Y 85 NC RUN 01 Number 1 41 Service 86 START CYCLE 02 Number 2 46 87 STOP CYCLE 03 Number 3 88 BACKUP 04 Number 4 89 PART RET 05 Number 5 60 Jog 8A Scroll UP 06 Number 6 8B Scroll DOWN 07 Number 7 66 SHIFT 08 Number 8 8D Mesg Index 09 Number 9 8E RECYCLE 10 11 27 12 ENTER 13 CLR The following table applies to the New Style Panel and the Plus Panel KEY NAME KEY NAME KEY NAME 00 Number 0 84 Jog Latch 01 Number 1 41 Service 85 NC RUN 45 FEEDRATE 86 START CYCLE 02 Number 2 46 87 STOP CYCLE 03 Number 3 88 BACKUP 04 Number 4 89 PART 05 Number 5 8A Scroll UP 06 Number 6 8B Scroll DOWN 07 Number 7 66 SHIFT 8C DSP Y 08 Number 8 80 X 09 Number 9 81 X 8E RECYCLE 10 82 Y 11 83 Y 12 ENTER 13 CLR AO 73290 PART 7 SETUP AND CONFIG 3 2 5RS OPERATION AND MAINTENANCE MANUAL SETUP amp CONFIG
285. loading AO 73290 PART 5 SERIAL 17 2 5RS OPERATION AND MAINTENANCE MANUAL SERIAL 8 5 TYPICAL LOAD FROM RS232 USING XON XOFF SOFTWARE HANDSHAKING Download to the 2 5RS using SOFTWARE PROTOCOL requires that the remote device support lt XON gt lt XOFF gt software conventions Operator presses the SHF key and enters the program number to receive the data Then the various parameter selections are made 2 5RS turns on it s CONTROL LINE and waits for the status input line to indicate that the remote device is ready these can be tied together The 2 5RS indicates that transmission can start by sending lt XON gt lt RON gt lt 10 NULLS gt lt ROFF gt waits 1 second Then sends another lt gt If the COMMUNICATION ENHANCEMENT option is enabled the 2 5RS sends the following message to request the specific program RON DOWNLOAD PROGRAM 12345678 lt CR gt lt EOB gt The remote device can begin transmission any time after receiving the lt gt character If the 2 5RS needs to halt the transmission it sends an lt XOFF gt character which should cause the remote device to stop sending data The 2 5RS sends an lt XON gt character when the transmission can resume NOTE The STATUS INPUT LINE on the 2 5RS must be kept at a high level when software protocol is used When the END OF PROGRAM CODE is received the 2 5RS then sends a comlink termination message of lt BEL gt lt BEL gt lt BEL gt EOF lt
286. ls 0025 Setting this parameter smaller will cause more lines to be stored while making it larger will result in some loss of part definition This prompt appears as 1 2 RT X It is used to set the kerf direction command in the created program either to the left or right of the cut This value is used by the DIAL IN feature when the part is cut Most parts are done with the kerf to the left AO 73290 SYSTEM UTILITIES TEMPLATE TEACH TRACE NOTE When the Dial In Kerf option is used on a Taught program the program length will be increased 25 30 The extra space is used to store the kerf information without altering the original program dimensions This permits the kerfto be adjusted and changed as necessary since the original dimensions are available for the re calculation Ifthe Teach Kerf Direction is set either left or right the extra space required for the kerf data will be allocated during the teach process By allowing the space ahead of time the actual kerf calculation will run about 2096 faster However if the Dial In Kerf feature is not going to be used on a part program a value of 0 should be entered for the KRF 1 LF 2 RT X prompt This will remove the kerf codes and reduce the amount of memory required to store the part program However the Dial In Kerf will not work on the part TEACH 2 THE TEACHING PROCESS Once the teach setup parameters are entered either as the STANDARD or AL
287. lue is a trial and error procedure Too low a value causes some loss of accuracy in the part while too high a value causes unstable operation The units for LOOP GAIN are the same as those used for any of the other speed inputs either Inches per Minute or Millimeters per Minute However the value entered is the correction speed for a Path Error of approximately 00251n 0625mm If the Path Error is more than 0025in 0625mm the correction speed is the number of encoder counts of error multiplied by the Loop Gain Example Inch System If LOOP GAIN 2 00 and the Path error is 5 encoder counts 0125in the correction speed output to the drive is 2 00 x 5 10 0 ipm AO 73290 PART 7 SETUP AND CONFIG 15 2 5RS OPERATION AND MAINTENANCE MANUAL SETUP amp CONFIG 4 2 15 SD17 ARC OFF DELAY seconds This time value is only used during PLASMA CUTTING During a PLASMA CUT if the ON input signal is removed the 2 5RS automatically issues a CYCLE STOP command which halts motion and waits for the operator to press the CYCLE START key before continuing The ARC OFF DELAY time provides a delay before the ARC OFF condition is recognized This permits the machine to keep moving if a part falls out before the cut is completed or if a previous cut path is crossed If this timer were not provided the control would stop as soon as the ARC ON signal is removed and could not complete the cut path Typically set 1 2 seconds
288. mA GROUND PIN7 SIGNAL GND DO NOT CONNECT TO SHIELD GROUND PIN 8 A TRANSMITTED DATA OUTPUT TO 2 5RS PIN 9 A RECEIVED DATA INPUT TO 2 5RS PART 5 SERIAL 12 AO 73290 SERIAL SERIAL COMMUNICATIONS SIHL LY ANNOUO SISSVHO OL G 3IHS YANNI OL LOANNOO LON 5300 Q T3IHS TWNYALXA LNVLYOdWI 33s 13NI8VO 30 MOVE NO SM3YOS ONIGNNOYS OL dAVTO WLAN 096 SNISN 5842 OL ATSIHS TVNH3ILX3 dash 31 ovs YO 3NIHOVMW SLIX3 3 18V9 TILNN 13 08 WNWININ V 3303 3 18VO NOISSINSNVAL U3NO GIVH8 TVNH3LLX3 AlddV 0087 LY SNOT S31IN 338H L OL 38 NVO 318 2 LN3TVAIND3 6998 a Tag TVNY3LX3 LN3TIVAIQO3 9076 N30138 1434 06 3ONV LIOVdvO 318VO 318VO Alvd GALSIML G3q1T3IHS ATIVNGIAICNI 6 5 69655555 K M a X N N NUN NN NC N Ww WWW wA QOH RRR KR KKK KKK KY SSS Wau 404 318VO 30 QN3 LY 13 5 YANNI OL LOANNOO LON 30Q Q T3IHS TVNU3LX3 Wa3lndWOO LSOH Waldvav LNALNO vS690 0N Figure 121 TYPICAL RS 422 MODEM CONNECTION PART 5 SERIAL 13 AO 73290 2 5RS OPERATION AND MAINTENANCE MANUAL SERIAL 7 CHARACTER FORMATS The 2 5RS accepts several different character formats The most common are EVEN PARITY 7 DATA BITS OR 2 STOP BITS ODD PARITY 8 DATA BITS 1 OR 2 STOP BITS FLEXOWRITER EIA RS244 does not support some function
289. mber and re enter it ERROR 1 5 MEMORY DISABLED This error can occur when selecting any of the functions It indicates that a potential power loss was detected and that program memory has been set to a protected state This is done so that if a power loss does occur the programs in memory remain intact To correct press the RECYCLE key to re enable and test the memory ERROR 1 6 PROGRAM MEMORY FULL This error occurs when either LOAD or is selected and indicates program memory is full and cannot accept another program Use the DELETE function to erase any unneeded programs and re enter the desired function ERROR 1 7 END OF LIST This is not an error condition but merely a data display It occurs in any function mode when instead of entering a program number the scroll functions are used to index through the list of available programs When the last program in memory is reached an END OF LIST message is displayed followed by the number of bytes of memory currently used for program storage and the number remaining available for new programs ERROR 1 8 0 BYTES IN PROGRAM This indicates that a program which was selected to run has no program data in it and therefore cannot run This can occur if a program load is started but not completed The program space was created in memory but no data was ever stored The normal operation at this point would be to delete the program and either re load it or
290. me M79TI M79TI 79 1 Go to Table 2 home M79T2 M79T2 79 2 Go to Table 3 home M79T3 M79T3 7943 Go to Table 4 home M79T4 M79T4 79 4 These codes can be used at any point in a non cutting portion of a part program to re locate the machine to a different table s home position Also one ofthe home locations can be designated as PARK location to allow the operator to unload the cut parts and load new material The 2 5RS operator has the ability to override the programmed home command so that if the machine is sent to Table 2 but the material is on Table 1 the operator can override the command and return the machine to Table 1 This is done by pressing the Auxiliary function button blank area to the left of the DISPLAY button Normally there are several selections from this button however while a part is cutting it s only function is to allow the override of the home functions When the button is pressed while a part is being cut the display will show GO TO HOME X The operator can use the SCROLL ARROWS or enter the number directly of the desired table home Pressing ENTER will prompt for PUSH CYCLE START When CYCLE START is pressed the machine will proceed to the desired table home position If the program had already been started on the wrong table it will automatically restart after the home command so that the entire part is cut correctly at the new home position A variation due to this home capability occurs when th
291. me anyway The end of the loop is programmed by a data block containing only the G98 code This is the same code as is used for the overall program repeat but since there was a G97 Txxxx block already programmed the first G98 code following the G97 Txxxx block only acts as the end of the loop and not the overall program repeat Any number of loops can be programmed in a single part however they cannot be NESTED that is the G97 Txxxx must be followed by a G98 there cannot be a G97 Txxxx followed by another G97 Txxxx block The use of loop programming does not prevent the use of the overall program repeat function It is still allowed to have a G97 alone in a data block at the beginning of the program to set the repeat pointer location and a G98 at the end of the program to cause the program repeat G103 When LOAD RUN operation is selected G103 causes AUTO DELETE of current program and loads new program specified by Q word in same data block as G103 AO 73290 PART 4 WADR 11 2 5RS OPERATION AND MAINTENANCE MANUAL WADR 1 15 DESCRIPTIONS M00 PROGRAM STOP Causes machine operation to halt and all cutting functions to be turned off Pressing the START CYCLE key resumes program execution M02 PROGRAM END Either the M02 or the M30 must end a WORD NO REWIND ADDRESS PROGRAM If multiple programs are to be loaded all but the last one should end with the code since it does not cause a REWIND M30 PROGRAM
292. memory can be deleted by entering the program number 00000000 in response to the PRGM prompt When the ENTER key is pressed a verification prompt is issued to make sure the operator is aware that all programs will be erased YES ERASE ALL NO Pressing the key toggles between a flashing YES and NO To abort the function press the key so that the word NO is flashing and then press ENTER The control aborts the erase procedure and no programs lost To erase all the programs press the key so the word YES in the readout is flashing Then press ENTER Again since this procedure is irreversible a second verification is given as NO YOUSURE YES Notice that to erase all the programs the key must be pressed twice again This minimizes the chances of an accidental erasure Pressing the ENTER key with the NO flashing aborts the process If the Y ES response is selected the programs are erased and the readout displays PROGRAMS DELETED FUNCMENU 9 EDIT NEW PROGRAM The EDIT NEW function allows the EDIT of a part program that resides in program memory It may be altered in any way The EDIT NEW function also allows for the creation of a new part For a detailed description of the EDIT NEW PROGRAM function see section EDITOR PART 2 FUNCTION MENU 4 AO 73290 SYSTEM OPERATION SHAPES FUNCMENU 10 STORE
293. meter SD60 in mm PROGRAMMABLE FEEDRATE A FEEDRATE value may be inserted with this function VAL 1 Programmed feedrate in the same units as SD60 ipm mpm PLASMA HEIGHT SENSOR DISABLE PLASMA HEIGHT SENSOR ENABLE AUTO PROGRAM LOAD FOR LOAD RUN operation VAL 1 prompts for 8 digit number of next program to be loaded PART COUNTER INCREMENT Signals that a complete part has been cut This is used in programs where more thatn one part is programmed as part of a single program It allows each part to be counted individually AO 73290 SYSTEM UTILITIES PROGRAM TEXT EDITOR EDITOR CREATING A SAMPLE PROGRAM The following example shows the steps necessary to create a new program using the editor For simplicity many of the available entry options as described in the manual are not used This example shows a step by step approach to programming a part The display as shown on the CNC is in quotation marks and the necessary operator key entries are underlined Select EDIT NEW PROGRAM from the main menu and PRESS ENTER Assign a new part number and PRESS ENTER The control will provide the first and last blocks of the program and B 0001 INTERNAL C PROGRAM START is now displayed To add a new block PRESS SHF AND SCROLL DOWN The control will display INSERT LIN ARC To change this to INSERT FUNCTION PRESS To add a function PRESS ENTER The control will display FNC 00 PGMNOP PRE
294. mory is automatically allocated for each data block This causes the Kerf processing to run about 20 faster since the space is already available to store the results If the DIAL IN KERF option is not to be used or if the part program already has the kerf added to the dimensions the KERF LEFT or KERF RIGHT codes can be removed from the part program before it is loaded This uses less memory to store the part since no kerf space is added AO 73290 PART 4 WADR 9 2 5RS OPERATION AND MAINTENANCE MANUAL G45 G46 G70 G71 G90 G91 G92 G97 G98 The G45 function may be included along with the arc or line dimensions performing the leadin to the part Including a G45 in the data block allows the data to be altered to correctly lead into the kerf compensated part The G46 function selects which overlay parameter table is used for the part program This code followed by the table number ex G46 would load overlay parameter table 1 into the running parameters and uses those parameters for running the part Indicates that all subsequent part dimensions are in inch units Indicates that all subsequent part dimensions are in metric millimeter units Signals that all subsequent dimensions are in absolute programming format Note although the X Y dimensions are in absolute the I J dimensions can be either absolute or incremental depending on the setting of SD51 PRGM FORMAT Signals that all subsequent dimensions are
295. mums are the same as for pin 18 Maximums 30VDC 2 A or 60VDC 0 5 A 18 Input for Y Drive reference from Tracer 120VAC Q2 A MO 03435 POWER PIGTAIL DESCRIPTION RATING Dry contact 2 A 30VDC maximum Dry contact 2 30VDC maximum Cut sense return See pin 8 Return for Cut sense signal See pin 8 Y Drive reference output Cut sense input to signal the 2 5RS that cutting 115VAC 15 mA maximum oxygen is operating 2 5RS with MNJ 09045 PACKAGE using MO 07154 Interface Card MO 03538 Modified Enclosure MO 03435 Power Pigtail MO 17155 Interface Pigtail MO 17155 INTERFACE PIGTAIL DESCRIPTION RATING t end of differential Speed Reference Input 15VDC maximum 0 1 mA end of differential Speed Reference Input 15VDC maximum 0 1 mA Logic HI is 4 90V minimum 24V Black Drive enable maximum Logic LO is 1 35 V maximum 0 V minimum If Burny signal selected output is 1 ma 15V If signal selected is customer signal from pink wire then maximums are the same as for pink wire Maximums 30 VDC 2 A or 60VDC 0 5 A Input for Y Drive reference from Tracer 120VAC Q2 A AO 73290 PART 10 SPECIFICATIONS 5 Y Drive reference output 2 5RS OPERATION AND MAINTENANCE MANUAL Logic HI is 4 90V minimum 24V Yellow Red X Drive Enable maximum Logic LO is 1 35V maximum 0 V minimum If Burny signal selected output is 1 ma 15V If signal selected is customer Green Red X Drive r
296. n electrical problem with either the drive system electronics or the 2 5RS interface card Another possible reason for large errors while cutting a part is that the LOOP GAIN SD16 is set too low which prevents the error from being corrected SETUP amp CONFIG 4 4 6 V06 XERSCL Displays the speed percentage being commanded after the path error has been SCALED by the LOOP GAIN This display works for either lines or arcs Example Assume a part is being cut and the operators speed dial is set to 20 00 IPM The maximum speed at that point would be 20 ipm which would be 100 speed If this display showed 25 it indicates that a speed of 5 ipm 25 of 20 ipm is being commanded due to the error in the X axis PART 7 SETUP AND CONFIG 56 AO 73290 SETUP AND CONFIGURATION SETUP amp CONFIG 4 4 7 V07 X HOME Displays the distance from the HOME ALIGNMENT REFERENCE POSITION in the X axis SETUP amp CONFIG 4 4 8 V11 Y DRIVE Y AXIS DRIVE COMMAND SEE V01 X DRIVE for description SETUP amp CONFIG 4 4 9 V12 YDAOUT Y AXIS D A OUTPUT BITS SEE V02 XDAOUT for description SETUP amp CONFIG 4 4 10 V13 Y ABS Y AXIS ABSOLUTE POSITION DISPLAY SEE V03 X ABS for description SETUP amp CONFIG 4 4 11 V14 Y ENC Y AXIS INPUT ENCODER COUNTS SEE V04 X ENC for description SETUP amp CONFIG 4 4 12 V15 Y ERROR Y AXIS LINE ERROR DISPLAY SEE V05 XERROR for description SETUP amp CONFIG 4 4 13 V16 YERSCL Y AXIS SCALED ERR
297. nput voltage to this point as described below It is highly recommended that this input be connected to the machine s E STOP circuit to allow the 2 5RS to properly respond to an E STOP condition on the cutting machine For the E STOP monitor to initiate an E STOP the voltage at 6PL 9 and 6PL 7 must be removed Voltage must be applied to this input by the machine when the machine is ready to run This allows the 2 5RS to stop any jog or part programs that may be running If a jog is attempted while there is no voltage across 6PL 9 and 6PL 7 a message will appear warning that the machine is currently in an E STOP condition See the Electrical Specifications Section of this manual Note that the 2 5RS uses a common return for 6PL 9 E STOP sense and 6PL 8 CUT or ARC ON sense This common return is 6PL 7 The external circuitry must be able to accommodate a common return for both sense voltages PART 7 INTERFACE 2 AO 73290 SETUP AND CONFIGURATION INTERFACE MACH 1 3 OXY FUEL CUT SENSE INPUT 6PL 7 same return as for E 6PL 8 CUT SENSE INPUT STOP sensing circuit described above This input is used to sense that the cutting oxygen switch has been turned on and that motion along the cut path can begin Typically this signal is connected directly to the cutting oxygen switch or ot a signal line which operates at the same time The cut switch must be sensed in an OFF position before the logic will allow the cutting circuit to be enab
298. ns to the previous display To activate the jog function a sequence of two keys must be entered First press the key then immediately press and hold the numeric key 1 9 that has an arrow which indicates the correct jog direction The machine will jog in the selected direction at the cutting speed as long as the number key is held and will decel to a stop when it is released To jog again first press the key to re activate the jog function then press and hold the new jog direction numeric key NOTE The two key sequences described here and throughout the manual require that the second key be pressed within 2 seconds of the first Otherwise the double key sequence will not be done and only the second key will be read There is also a latched jog function which allows the machine to continue to move in the selected direction without any keys being pressed It is selected using a similar sequence First press the key to activate the jog function then press the 5 key to indicate that a latched jog is to be performed Finally press the numeric key to indicate the desired jog direction Each key must be pressed within 2 seconds of the previous one or the sequence is interrupted The machine begins moving in the selected direction at the speed set on the speed dial To stop the motion press the 0 key CYCLE STOP or RECYCLE may also be used to stop the latched jog operation NOTE The Latched Jo
299. nt X position value however it is displayed with 4 decimal places 0000 for inch systems and 3 decimal places 000 for metric systems AO 73290 PART 7 SETUP AND CONFIG 55 2 5RS OPERATION AND MAINTENANCE MANUAL SETUP amp CONFIG 4 4 4 V04 X ENC Shows the current X position value as actual input encoder counts The equation used to calculate the X position based on incoming encoder counts and the X encoder scaling value SD20 is ENCODER INPUT DIST REV SD20 ABSOLUTE ENCODER X POSITION COUNTS 4 X ENCODER V03 V04 LINE REV SD22 SETUP amp CONFIG 4 4 5 V05 X ERROR in mm When the 2 5RS is doing a line program block this display shows the X distance from the CORRECT PATH If inaccurate parts are being cut displays V05 V15 and V20 can be used to prove whether the problem is mechanical or is due to the 2 5RS position loop While a part is being cut or test run check the X ERROR and Y ERROR 15 at various points along the part while a line is being cut and V20 during ARCS If the error is very small or 0 it indicates that the 2 5RS is OK and that the problem is mechanical This could be caused by a loose encoder bracket or torch holder or backlash in the drive system If the display shows a large error it indicates that the 2 5RS knows that the path is incorrect but that it is unable to correct for it This can still be caused by a mechanical problem but is usually due to a
300. o convert a G31 to the Cut On function use the numeric keypad to enter 23106 Each digit appears as it is entered After all 5 digits are in the display appears as TVVFF 23106 Press the ENTER key to actually load the new table value and the display returns to the MODIFY ENTRY format and show 23106 G31 CUTON AO 73290 PART 7 SETUP AND CONFIG 71 2 5RS OPERATION AND MAINTENANCE MANUAL If the value is incorrect re enter the correct 5 digit code and press ENTER again Once the data is correct press the ENTER key a second time to return to the TABLE POSITION DISPLAY which now shows the next table position If the previous entry had loaded the AUX01 table location the display would now show AUX02 Although these descriptions may be confusing it should become clear after the procedure is actually performed To determine if this feature is needed at all consult the PROGRAMMING section of this manual to see ifthe AUXILIARY CODES defined as STANDARD for the 2 5RS are acceptable If they are there is no need for the CUSTOM AUX CODE CONVERSION feature However if special conversions are required setup this table to perform the needed reassignments Once the table is loaded press the RECYCLE key to exit SETUP amp CONFIG 4 5 11 SERV78 LOOP BACK This procedure aids in debugging the RS 232 link from the 2 5RS to a host computer When selected this procedure begins sending th
301. o stop before moving to the next part If the machine drives are well balanced there is no need to do the automatic speed calibration However if the speeds are not balanced the automatic speed calibration routine should be performed See 5 51 SPD CAL After all parameters are adjusted and the speed calibration done go to the SER V97 VAR STORE section of the manual and store the new values in the non volatile memory Backlash is any lost motion when the machine is moved in the and then in the direction Determine the backlash in each axis of the machine This is done by by jogging the machine and then subtracting the displayed dimensions from the measured movement in those axes Enter these dimension in SDAO and SDA1 Set SDA2 to about 1 10 of the maximum value entered for SDAO or SDAI SERV54 REF ADJUST for the Burny 2 5 PLUS The 2 5 PLUS software contains an enhanced version of the SERV54 REF ADJUST that can compensate for both the voltage at the speed dials maximum setting and also for any offset voltage at the speed dial s 0 speed setting This is useful for systems where a small amount of offset voltage in the reference circuit prevents the readout from actually reaching 0 00 when the speed dial is turned fully CW Alternately this 0 speed voltage setting can be bypassed so only the maximum pot setting is adjusted as would have occurred with the old SER V54 in previous software versions PART 7 SETUP AND CO
302. of connector of MO 034967 See below Enable X Drive Output AO 73290 PART 10 SPECIFICATIONS 7 2 5RS OPERATION AND MAINTENANCE MANUAL If Burny signal selected output is 1 ma 15V If selected signal is customer signal from pin E of male connector of Due Patpat MO 03497 then maximums are the same as for pin E male of connector of MO 034967 See below These signals do not connect to the 2 5RS but are passed through to the same pins on the male connector 230V 22A CCW Steer maximum MO 03497 CABLE CONNECTOR WITH MALE CONTACTS ECTOR MALE DESCRIPTION PIN LETTER Maximums 30VDC 2 A 60VDC 0 5 A 120VAC 2A Maximums 30VDC 2 2 A or 60VDC 0 5 A 120VAC 82 D H B F J Same as for female connector above Same as for female connector above TERMINAL BLOCK 1 1TB DESCRIPTION C X Drive reference Input Y Drive reference Input AC Supply input Return AC Supply Return See pins 2 and 3 1 2 Input pin for powering the 2 5RS from a 115VAC machine power source 3 Input pin for 230VAC machine power source 230VAC 0 110 A Input 4 System Ground 0V MO 03435 POWER PIGTAIL DESCRIPTION 115VAC 0 25 Alnput 2 A 220V AC maximum or 2 30VDC maximum Start cut relay contacts 2 A 230V AC maximum or Dry contact 2 30VDC maximum Enable cut output 2 A 230V AC maximum or Dry contact 2 30VDC maximum 7 Cut sense return See pin 8
303. of setup variables since many of them are common for all cutting tools encoder directions maximum drive speed etc IMPORTANT Data entered into the Multiple Setup Parameter Tables will return to previously saved data if the RECYCLE key is pressed the system is turned off or power is lost unless the SERV97 VARSTOR function is used Read the section of this manual entitled SERV97 VAR STOR AO 73290 PART 7 SETUP AND CONFIG 51 2 5RS OPERATION AND MAINTENANCE MANUAL The parameters which are contained in the overlay tables are SD03 ACCEL TIME SD07 CORNER SPEED SD10 RUN SPEED LIMIT SD14 GAIN BREAK SD16 LOOP GAIN SD18 SLOWDOWN DISTANCE SD19 HEIGHT SENSOR DISABLE SD29 SLOWDOWN RADIUS SD30 MIN RAD SPD SD32 MIN SLW ANG SD33 MAX SLW ANG SD45 DEFAULT DWELL TIME SD46 MINIMUM OFF TIME SD49 START DELAY TIME SD65 OVERLAY CFG When a part program is running the parameters from the selected table are copied into a running parameter area which is actually used to run the part program When a part program is started the system always defaults to the 0 table which is setup by the normal SERV 10 procedure If no table select codes are contained in the part program the system runs using the SERVIO parameters To switch to a different table the program must contain one of the following data blocks as a separate line in the program G46 TI Selects overlay table 1 G46 T2 Selects overlay table 2 G46
304. of this section are drawings of hardware that the 2 5RS uses and how it is mounted on a cutting machine It would be difficult to supply a drawing for every cutting machine The purpose of the hardware mounting drawings is to give a basic idea of how the hardware is actually mounted By using the drawings and following the specified rules for correct mounting procedure it should be possible to mount the necessary hardware on almost any cutting machine Keep in mind that this section gives the basic idea of the hardware mounting procedure The actual method implemented by the customer is determined by the personal preference and added input from personnel involved in the project AO 73290 PART 9 RETROFIT 1 2 5RS OPERATION AND MAINTENANCE MANUAL RETRO GEAR RACK MOUNTING l Always try to mount the gear rack teeth facing sideways or facing down Mounting the rack with the teeth facing up will cause the rack to accumulate cutting dirt and the teeth to become clogged creating dimensional errors 2 The gear rack should be mounted directly to the machine if possible If this method does not allow for proper clearance or encoder mesh into the gear rack another method must be used One such method is to mount the gear rack on a separate angle bracket By doing this the gear rack is away from the cutting machine surface to give extra clearance for proper mesh Washers or spacers can also be used to move the gear rack away from the cutting machine su
305. omer signal from pin 7 then maximums are the same as for pin 7 Input to rail relay Output to rail A If Burny signal selected output is 1 ma 15V If signal selected is customer signal from pin 9 then maximums are the 10 Output to rail B same as for pin 9 11 12 Speed refi NE Nominal 0 to 26VAC 400 Hz Exe ar Maximum 30V 150 mW 13 Commonned contacts of contact sets for wire See 14 and 15 below numbers 14 and 15 below Relay determines which NC is in control Maximums 30VDC 2 A or 60VDC 14 Dry contacts normally closed other half of u 1A 120VAC 2A contact set is pin 13 15 5 2 22 Maximums 30VDC 2 or 60VDC contacts normally open othe o 1 120VAC 2A contact set is pin 13 AO 73290 PART 10 SPECIFICATIONS 3 2 5RS OPERATION AND MAINTENANCE MANUAL Low speed relay input When 24V with respect to pin 17 is applied the speed range is set to low speed Return for low speed relay input See pin 16 I Sinks 500 mA 50V High impedance to 19 NCRun output low true Signals that Burny negative voltages 50V maximum Maximums 24VDC 0 6 A for relay coil 2 5RS is in control These pins are isolated from each other with common cathode diodes Dry contact 2 30VDC maximum Dry contact 2 30VDC maximum i Dry contact 2 30VDC maximum 115 VAC 15 mA Input See operator manual MACHINE oxygen is
306. on until it is ready to accept more data AO 73290 PART 5 SERIAL 15 2 5RS OPERATION AND MAINTENANCE MANUAL SERIAL 8 2 XON XOFF SOFTWARE PROTOCOOL SPECIAL HANDSHAKING PROTOCOL The 2 5RS also supports some special Handshaking protocols designed for specific devices They are as follows 3 BURNY IV Special protocol to communicate with BURNY IV controls 5 PTAPE Special protocol to communicate with Spooling Tape Readers These protocols should only be used when communicating with these devices SERIAL 8 3 COMMUNICATION ENHANCEMENT OPTION COMMUNICATION ENHANCEMENT is one of two optional communication protocols which can be used to provide a more automated link between the host computer and the 2 5RS When this option is installed the 2 5RS transmits a request to the host computer when the operator selects a LOAD FROM RS232 operation The remote computer can interpret this request and send back the corresponding program without operator assistance at the computer This allows for unattended operation of the computer and makes for a more automatic more efficient link For LOAD operations the 2 5RS sends the following header when a new program is requested program number 12345678 used for example DOWNLOAD PROGRAM 12345678 lt CR gt lt EOB gt SERIAL 8 4 LOAD FROM RS232 USING RTS CTS HARDWARE HANDSHAKING The operator selects the LOAD FROM RS232 function and enters the desired program number When the ENTER
307. only used to test the PLASMA START RELAY output Once selected use the CYCLE START and CYCLE STOP keys to toggle the relay output Pressing one of the SCROLL ARROW keys returns to the MANUAL CONTROL menu SPECFUNC 2 2 5 HEIGHT DISABLE This function is only used to test the PLASMA HEIGHT SENSOR DISABLE RELAY output Once selected use the CYCLE START and CYCLE STOP keys to toggle the relay output The relay is initially in the OFF condition which allows the Plasma Height sensor to operate Pressing the CYCLE START key sets the relay to the ON condition which should inhibit the Plasma Height Sensor raising or lowering the torch This relay is used when a part program is actually being cut to prevent the torch from diving into the plate when the machine slows to go around a corner The height sensor is disabled until the machine has re accelerated back to cutting speed Pressing one of the SCROLL ARROW keys returns to the MANUAL CONTROL menu PART 3 SPECIAL FUNCTIONS 6 AO 73290 SYSTEM UTILITIES SPECIAL FUNCTIONS SPECFUNC 3 FNC15 GO HOME The 2 5RS control has the ability to return to one of 4 different home positions somewhere in the operating area of the machine Table 1 0 0 home position must be defined by the operator using the FNC 16 SET HOME function after a power failure or after the 2 5RS has lost power for any reason Once it is defined it is remembered regardless of what other operation is perform
308. ontacts 2 30VDC maximum i contacts 2 30VDC maximum Sense return for pins 32 and 33 Input See pins 32 and 33 Use the specification with the number of the interface board with suffix MO 03502 2 use 24VAC 15 mA 30 32 Cut Sense input MO 03502 0 use 115VAC 2 15 mA MO 03502 1 use 230VAC 15 mA See the operator manual section MACHINE INTERFACE SENSING INPUT Use the specification with the number of the interface board with suffix MO 03502 2 use 24VAC 15 mA MO 03502 0 use 115VAC 15 mA gt 39 MO 03502 1 use 230VAC 15 mA See the operator manual section MACHINE INTERFACE SENSING INPUT and SD61 SYSTEM CONFIGURATION s Protective ground from machine power Chassis Ground source Neutral conductor of machine s power 0 25 A source Input Input pin for powering the 2 5RS from a Low 115V machine power source Input dica 229 PART 10 SPECIFICATIONS 20 AO 73290 PRODUCT SPECIFICATIONS Input pin for powering the 2 5RS from a 230V AC machine power source Input Cats 2 5RS MNJ 10380 using MO 04359 INTERFACE CARD MO 03561 CABLE 2 5RS BACK PANEL 37 PIN EXT DRIVE CONNECTOR DESCRIPTION NOMINAL RATINGS Signal Ground 0 Power Ground 0V Positive supply power output 24VDC 40 mA AO 73290 Negative supply power output Analog Ground Speed reference input Output to the Burny control relay coil on KS07 equ
309. ontrol the data flow instead of separate hardware lines only 3 wires are required TRANSMITTED DATA RECEIVED DATA and SIGNAL COMMON XON XOFF SOFTWARE PROTOCAL 25 PIN D SUB AT BURNY COMPUTER SERIAL I O PORT A TD 2 2 RD RD 3 3 TD RTS 4 D 9 STATUS IN 155 5 XN COM 7 F s n o YR DSR 6 CD 8 DTR 20 XON XOFF SOFTWARE PROTOCAL 9 PIN D SUB AT BURNY COMPUTER SERIAL I O PORT TD 3 O 2 RD RD 2 sC n a 9 TD RTS 7 9 STATUS IN CTS 8 re SC 5 XN COM 5 7 COM DSR 6 DTR 4 AO 73290 PART 5 SERIAL 11 2 5RS OPERATION AND MAINTENANCE MANUAL SERIAL 6 CONNECTION TO RS 422 DEVICES The serial port on the 2 5RS may be configured for either RS 232 or RS 422 operation RS 232 is more limited in distance and in some cases may be more susceptible to noise since it is a single ended ground referenced signal RS 422 is a differential signal type signal which permits longer transmission distances over 1 mile and better noise immunity If the remote computer is equipped with an RS 422 compatible port the 2 5RS could be connected directly to it However while the RS 422 port on the 2 5RS is electrically isolated from the internal circuitry the RS 422 port on the remote computer may not be Therefore even though a modem is not
310. operating INTERFACE SENSING INPUT Input pin for powering the 2 5RS from a 115VAC 0 25 115V machine power source Input pin for powering the 2 5RS from a 230V AC machine power source 2 568 MNJ 09045 PACKAGE using MO 03432 Interface Card MO 03435 Power Pigtail MO 03533 Internal Drive Pigtail MO 02460 Standard Drive Pigtail MO 02382 010 Standard Drive Pigtail 2 5RS BACK PANEL 37 PIN EXT DRIVE CONNECTOR DESCRIPTION RATING ignal common Ground for 5VDC regulator in Burny 2 5RS 0 V 20VDC input 24 V a 400 mA maximum 20VDC input 33 100 mA maximum Analog ground Analog Supply input 15 5 VDC 20 mA Analog Supply input 15 5 VDC 20 mA Nominal 0 to 12V peak Speed Re liput Limits 8 to 16 V peak 006 mA Logic high is 4 90V minimum 24V Enable Y Drive Input maximum Logic low is 1 35V maximum 0 V minimum Logic high is 4 90V minimum 24V Enable X Drive Input maximum Logic low is 1 35V maximum 0 V minimum PART 10 SPECIFICATIONS 4 AO 73290 PRODUCT SPECIFICATIONS If Burny reference is selected output is 1 14 ma 15V If signal selected is customer signal from pin 15 then maximums are the same as for pin 15 Maximums 30VDC 2 A or 60VDC 0 5 A 15 Input for X Drive reference from Tracer 120VAC Q2 A If Burny signal selected output is 1 ma 15V If signal selected is customer signal from pin 18 then maxi
311. or KERF RIGHT usually G41 or G42 in WORD ADDRESS or function 29 or 30 in ESSI See also the Shapes Dimensions Common to Most Shapes section of this manual especially for chain cutting kerf information PROGRAMMABLE KERF is a feature of part programs This feature allows the kerf of the WADR or ESSI program to be used instead requiring that it be entered by the user See the PART PROGRAMMING section of this manual for more information OVERRIDE KERF allows the operator to override the kerf that is programmed for a part with a new value PART 2 RUN 4 AO 73290 SYSTEM OPERATIONS RUNNING A PROGRAM RUN 4 CUTTING MODE SELECTION Once any optional parameters are entered the 2 5RS performs the necessary processing and then prompts the operator to select the desired CUTTING MODE from the following menu o MANUAL CUT o AUTO CUT o TEST RUN o SINGLE STEP RUN 4 1 MANUAL CUT The manual cut mode allows the part to be cut however the operator is required to preheat and manually start the cutting process using the machines cutting controls RUN 4 1 1 PIERCE RAMP OXY FUEL OR PLASMA The operator is prompted to enter the PIERCE RAMP time The display shows PIERCE XXX XX The Pierce Ramp time affects the acceleration of the machine when the cutting process is turned on to pierce the material If a time of 0 00 is entered the machine waits for the cutting process to be turned on and then accelerates quickly to the selecte
312. or RS 232 line SETUP amp CONFIG 4 5 11 PART 7 SETUP AND CONFIG 73 SERV78 LOOP BACK AO 73290 PART 6 SERVICE 5 2 5RS OPERATION AND MAINTENANCE MANUAL INSTALLATION 3 REPAIR OF THE BURNY 2 5RS WARNING When considering any type of disassembly please note HIGH VOLTAGES ARE PRESENT IN BURNY SYSTEMS THAT CAN INJURE AND KILL ONLY QUALIFIED PERSONS SHOULD OPEN OR DISASSEMBLE ANY PART OF THE BURNY SYSTEM TURN OFF AND RED TAG ALL POWER SOURCES DURING SERVICE BE CERTAIN THAT UNAWARE PERSONS DO NOT TURN ON THE POWER DURING SERVICE USE A VOLTMETER TO BE CERTAIN THAT ALL POWER SOURCES HAVE BEEN TURNED OFF IMPORTANT To avoid loss of programs read the section of this manual entitled Backup of Programs Stored in Burny Controls PART 6 SERVICE 6 AO 73290 SERVICE Generally components for the 2 5RS system are not repairable by the user In the case of malfunction of the system Burny service personnel shall be consulted to assist in isolating the component s causing the problem If acomponent has sustained damage the involved assembly is usually returned to the factory and a replacement assembly shipped to the user Service must be performed only by trained authorized personnel A special grounded wristband must be used when removing or installing EPROMS All circuit cards must be shipped in special static protective packaging Any card or part removed from a Burny product should be immediat
313. or Speed signal processing Nominal 0 to 6 6V peak 0 to 6 6V peak 0 2 mA Limits 5 79 to 7 4V peak 5 79 to 7 4V peak 035 mA Speed Reference Input Output low high impedance to 0 8V 10 Cut Start output Output high 15 kOhm resistor pull up to 11 35V max Logic low 0 to 1 35VDC Cubpepse tut Logic High 4 2 to SVDC Lamp Off hi true output 12V max 15 mA max If Burny signal selected output is 1 mA 14 15V If signal selected is customer signal from pin 15 then maximums are the same as for pin 15 Input to Y axis from alternate device ONAC maximum Strip Sense hi true input Input low 0 to 5VDC 2 mA maximum Output to Y axis Input high 12VDC If Burny signal selected output is 1 ma 15V If signal selected is customer signal from pin 15 then maximums are the same as for pin 15 Input to X axis from alternate device pov maximum n maximum 2 5RS with MNJ 09045 PACKAGE using MO 03467 Interface Card NC2 5 MO 03538 Modified Enclosure MO 03435 Power Pigtail MO 03497 Interface Cable NC2 5 MO 03497 CABLE CONNECTOR WITH FEMALE CONTACTS Output to X axis CONN ECTOR FEMALE DESCRIPTION PIN LETTER Speed Reference Input 3 9 to 4 4VDC maximum 0 032 mA Ground 0 If Burny signal selected output is 1 ma 15V If selected signal is customer signal from pin E of male connector of MO 03497 then maximums are the same as for pin E male
314. ordingly Changes in direction which are close to the MIN value run almost at full speed and as the angle increases toward the MAX value the machine slows down to a lower speed at the corner Typical Values SD32 MIN SLW ANG 10 DEGREES SD33 MAX SLW ANG 22 DEGREES SETUP amp CONFIG 4 2 31 SD33 MAX SLW ANG degrees multiple parameter This parameter sets the maximum boundary angle used by the corner slowdown routines See SD32 for description AO 73290 PART 7 SETUP AND CONFIG 21 2 5RS OPERATION AND MAINTENANCE MANUAL SETUP amp CONFIG 4 2 32 SD40 X MARKER OFFSET 71 in mm Parameters SD40 41 42 43 AND SD80 95 are used when the configuration of the 2 5RS supports a Plate Marking device Certain versions do not include a Plate Marking function in these cases these parameters can be ignored Parameters SD40 and SD41 should be set to the X Y offset distance between the cutting torch and the Marking device When a part requires marking a Marker Offset On command is first used to shift the marking device to the X Y position where the cutting torch was previously located This allows the marking portion of the program to be dimensioned the same as the cutting moves without having to compensate for the distance between the marker and cutting torch When the Marker ON command is issued the control turns ON the Marking device The control holds position for the time specified by the SD43 parameter and then begins moving along
315. otal size of the part to the original pierce point location the coordinates which were written down earlier and moving the machine to the resulting coordinates Once the machine is positioned at the repeat coordinates press the RECYCLE button to complete the teaching process AO 73290 PART 3 TEACH 5 2 5RS OPERATION AND MAINTENANCE MANUAL TEACH 4 TEACHING A CHAIN CUT PART First position the tracer at the location on the template that represents the corner of the plate then press the ENTER key Move the tracer to the location where the chain cut is to be started Note the X Y coordinates of the start position as they will be needed later Now turn the CUT ON gt gt lead into the template and trace the part When the tracer returns to the start position lead it out of the part and then move it up the plate to the start position for the next part This position may either be drawn on the template or may be calculated by adding the size of the part to the start position of the first part Remember since the cut has not been turned off the leadout and move to the next part are taught as a contour and not as a point to point move After reaching the start position for the next part press the RECYCLE RESET button to end the teach process Since the cut was never turned off the entire part including the move to the next part will be cut and will result in a continuous chain of parts being cut The process is complete and the
316. ows for Special End of Program codes and Forced Auxiliary Code Priority Unless there is a specific reason for using these special formats they should not be used since there are several parameters and data tables which must be setup for these to work correctly If these conversions are needed the specific setup steps are covered in the INSTALLATION section under the topic SD51 PRGM FORMAT and SD70 CUSTOM AUX AO 73290 PART 4 PROGRAMMING 1 2 5RS OPERATION AND MAINTENANCE MANUAL The following two sections describe the STANDARD WORD ADDRESS and ESSI PROGRAMMING Also for simplicity only incremental programming is described in these sections although the 2 5RS is capable of both INCREMENTAL and ABSOLUTE PROGRAMMING The following sections are meant as a reference for the programming formats used by the 2 5RS and not a training course in part programming Therefore it is assumed that the programmer is somewhat familiar with part programming techniques and procedures When the STANDARD WORD ADDRESS and ESSI FORMATS are used the following axis definitions apply The X axis is defined as the main rail axis with X as the direction away from the operator and X toward the operator The Y axis is defined as the cross axis with Y to the left and Y to the right PART 4 PROGRAMMING 2 AO 73290 PART PROGRAMMING WORD ADDRESS WORD ADDRESS PROGRAMMING LANGUAGE WADR 1 WORD ADDRESS PROGRAMMING Although ther
317. part is ready to cut PART 3 TEACH 6 AO 73290 SYSTEM UTILITIES DISPLAY MODES DISPLAY MODES The DISPLAY MODE is provided as a means of accessing various information without interrupting the actual machine operation The DSPY key may be pressed at any time during any operation It can be used while a part is being cut to check machine position cutting speed and other operating parameters or it can be used to access the various diagnostic displays to aid in troubleshooting a problem When the DSPY key is pressed the operator is prompted to select the desired display from the following list DSPY00 EXIT MODE DSPY20 EDIT PRGM DSPY01 X Y DISPLAY DSPY30 SHOW WORD DSPY02 PARTS CUT DSPY31 SHOW DBL DSPY03 FEEDRATE DSPY32 SHOW CRU DSPY05 SYS STAT DSPY33 SHOW BYTE DSPY10 SYS DATA DSPY34 SHOW CRUB DSPY11 DSPY VAR DSPY80 CONFIG DISPLAY 1 DPSY00 EXIT MODE Display 00 is used to cancel the DISPLAY MENU and return to the previous operation DISPLAY 2 DSPY01 X Y DISPLAY This display shows the current position for both the X and Y axis When a part is being run this display shows the distance from the original start point of the part When no part is being run the display may be used for direct X Y measuring The CLR or CE key clears both readouts to 0 Thus to measure a distance the operator should position the machine at the first location then clear the X Y positions by using the CLR or CE key As the ma
318. pressing the START CYCLE key again Machine is holding position Program is running cutting is selected Control has finished one cut moved to a new pierce location and is waiting for the CUT switch input to be turned off then back on to start the new cut Machine is holding position Motion is being delayed until timer reaches 0 Program is running plasma cut is in progress speed controlled by operators speed dial Program is running plasma arc on sense has been received Machine holds position until time reaches 0 and then begins moving along cut path Program is running plasma cutting is being done but the arc on sense has turned off probably indicating that the arc has gone out The machine continues along the cutting path as if the arc was still on until the timer reaches 0 00 Then the control stops the machine and perform a CYCLE STOP Program is running AUTO CUT was selected and the start signal received yet Program is running machine is cutting and the machine speed dial controls speed Program is running Oxy Fuel cutting is selected Torch has just pierced at a new location and is slowly accelerating up to the selected cutting speed based on the PIERCE RAMP TIME value entered by the operator AO 73290 SYSTEM OPERATIONS RUNNING A PROGRAM RUN RTN TO PATH Part program is running This display occurs for two reasons If the operator presses STOP CYCLE and jogs the machine away from the programm
319. programs with the PROGRAM END only code Each program is loaded based on the program number defined by the block in the program see individual Word address ESSI specifications If a program does not specifically define a program number the 2 5RS assigns a number with the first digit containing an A to indicate that it was Assigned Ifthe COMMUNICATION ENHANCEMENT OPTION is enabled when the END OF PROGRAM CODE is received the 2 5RS then sends a termination message of lt BEL gt lt BEL gt lt BEL gt EOF lt CR gt lt LF gt where represents 3 digit status code complete list of the status codes and there translations are located at the end of this section The 2 5RS then turns off it s control output line finishes loading the program and then either terminates the download with a PROGRAM LOADED message or re enables it s port for the next program as described in the section above The device sending the program can indicate an END OF FILE condition by sending an ASCII control D 04 This character indicates that the download link should be terminated This special END OF FILE character can be used by the host computer to indicate that the program requested does not exist by sending only the EOF code The 2 5RS detects that only the EOF was sent and displays PROGRAM FOUND message The character does not have to be used for normal down
320. r as SELECT PLASMA OR SELECT OXY FUEL Use the key to change the display to the correct type This does not actually switch the cutting function of the machine only the prompting and relay sequencing used during the part execution The operator must make sure that the correct cutting process is enabled on the machine Ifthis prompt does not appear It indicates that the setup parameters have been set to only use one of the cutting modes In these cases no operator response is required At this point the option codes are checked to see which of the optional software features are enabled the control If none are enabled continue at section CUTTING MODE SELECTION to select the desired cutting mode otherwise follow the directions below for each option RUN 2 GEOMETRY MODIFICATION OPTIONS There are several features which allow the geometric appearance of a part to be altered SCALING Allows part size to be magnified up to 65 times or reduced to 001 size ROTATION Allows part to be rotated from its programmed orientation to allow alignment with the plate or nesting among other parts MIRROR Allows the part to be mirror imaged in either the X Y or both axis AO 73290 PART 2 RUN 1 2 5RS OPERATION AND MAINYENANCE MANUAL These operations are enabled with the ENHANCED OPERATION option When this option is enabled a prompt will appear when the part is first run which appears as GEOMETRY NORM
321. ramming the appropriate field value In 2 5RS WORD ADDRESS programming language programmable offset values are defined using a field in a program block with an M71 MARKER OFFSET ON function code For example Word Address programming format M71 T4 ESSI programming format 11 4 defines MARKER 1 OFFSET and uses the values SD86 XOFST4 and SD87 YOFST4 for the offset move AO 73290 PART 7 SETUP AND CONFIG 49 2 5RS OPERATION AND MAINTENANCE MANUAL NOTE The 2 5RS sets the following parameters always equal to each other SD40 X MARKER OFFSET SD80 X OFFSET 1 SD41 Y MARKER OFFSET SDS 1 Y OFFSET 1 SD47 X MARKER OFFSET SDS82 X OFFSET 2 SD48 Y MARKER OFFSET SD83 Y OFFSET 2 See SD40 for additional information on markers and marker offsets OFFSETS USED VALUE 5 SD88 5 5 5098 5 Programmable offsets T OFFSETS USED VALUE SD80 XOFSTI 5081 YOFSTI SD83 YOFST2 SD85 YOFST3 SD87 YOFST4 SD90 XOFST6 _ Seo _ SD93 YOFST7 SD94 XOFSTS SD95 YOFSTS SETUP amp CONFIG 4 2 55 8096 HOME INDEX SWITCH in mm The value entered here is the X axis distance from the home index switch to the cutting table home position SETUP amp CONFIG 4 2 56 SD97 Y HOME INDEX SWITCH in mm The value entered here is the Y axis distance from the home index switch to the cutting table home position
322. re set to non zero values the operator is prompted to select the desired cutting sequence before the part can be run This does not switch the machine electronics only the prompting and relay sequencing performed by the control SD03 ACCEL 60 EST ESTIMATED ACCEL TIME 60 SEC may be TIME adjusted later SD04 MAX DRV Set to maximum speed of drive system on cutting 150 00 SPD machine given as 150 ipm Se PACKUP 40 0 EST NOMINAL BACKUP SPEED may be adjusted CORNER 10 0 EST NOMINAL CORNER SPEED adjusted later ns HOLD g0EST NOMINAL VALUE adjusted later ao E 20 0 EST This value is usually acceptable as is SD10 RUN SPD Allows machine to cut up to maximum speed capacity 150 00 i LMT of drive system SD11 TRV SPD Allows machine to traverse at maximum speed of 150 00 LMT drive system AO 73290 PART 7 SETUP AND CONFIG 75 2 5RS OPERATION AND MAINTENANCE MANUAL SD14 GAIN BREAK Normally set to 0 ERROR WARNING DISTANCE set so warnin SD15 ERR WRN Eo sounds if machine jams deviates from cut path by DST more than 25 in ADOS LOGE 1 50 EST Loop gain to be adjusted once actual test part is run GAIN SD17 ARC OFF Must be set to 0 00 to disable plasma prompts since TIME machine only has OXY FUEL SD18 SLWDWN Nominal SLOWDOWN distance to be adjusted later DIST when test part is run SD19 HEIGHT SENSOR DISABLE SD20 5 105 Given value for distanc
323. resides on the floppy disk Then press the ENTER key The 2 5RS control displays the prompt INSERT DISK PRESS ENTER TO CONTINUE Insert a formatted 3 5 floppy disk into the drive and close the door of the floppy drive Press the ENTER key to continue At this point the 2 5RS control does one of two things If D2 of SD50 SERIAL DEFINITION which is the programming language select digit is set to 0 prompting for the program type occurs If D2 of SD50 SERIAL DEFINITION is preset to some value the control begins the process of loading from the floppy disk A red LED indicator light on the disk drive begins to flash indicating there is some disk activity When the transfer is complete the 2 5RS control display changes to display LOADING COMPLETE If the selected program number exists on the disk the 2 5RS display changes to Loading 0 and begins to load the program If the selected program does not exist on the floppy disk the display changes to READ TIMEOUT indicating that the file does not exist NOTE Valid program numbers consist of up to 8 numeric digits with no leading 075 allowed All programs must reside in the root directory of the floppy disk The 2 5RS control loads and stores programs with a file extension that is preset by the SD53 FILE EXTEN variable See INSTALLATION section SD53 FILE EXTEN for setting this variable AO 73290 PART 3 FLOPPY 3 2 5RS OPERATION AN
324. ressing the START CYCLE key as the display is prompting press the 5 key and then the CYCLE STOP key This two key combination enters the alignment mode The display now prompts MOVE MACHINE TO FIRST CORNER THEN PRESS 1 OR 3 SAME ANGLE If the number 3 key is pressed the Plate angle calculated for the previous part is used This feature can be used for cutting several different parts on the same plate The control then displays the prompt ANGLE XXX XX then PRESS ENTER IF OK When ENTER is pressed the cut process prompting continues To align to a new plate the machine should be aligned with one corner of the material Normally this should be the starting corner for the program since the machine automatically returns to this location once the procedure is complete When positioned press the number 1 key The display now changes to MOVE MACHINE TO SECOND CORNER THEN PRESS 2 Jog the machine along the longer edge of the plate since this produces a more accurate indication of the angle of the plate If a large plate is being cut it is not necessary to go all the way to the next corner simply move down either edge at least 10 feet and align the machine to the edge of the plate Although the procedure works if the distance is less the results is more accurate if a longer distance is used After the machine is aligned to the second corner or along the edge press t
325. rface for added clearance 3 Be sure that the gear rack covers the entire travel distance of both rail and cross axis Allow enough rack at all travel limit ends that encoder does not go off of the end of the gear rack 4 When joining two sections of rack always use a short piece about 2 or 3 inches to obtain proper mesh between six foot rack sections Invert the short piece of rack into the two sections that are being joined together over the joint to obtain proper mesh DO NOT BUTT TWO SECTIONS AGAINST EACH OTHER This will cause an improper mesh and result in dimensional errors on parts being cut 5 Take the time to do a good job Improper mounting of rack will result in problems and the control will not work to expectations 6 Use whatever means is possible to insure that the gear rack is straight both horizontally and vertically A bowed rack will cause dimensional errors on parts being cut PART 9 RETROFIT 2 AO 73290 RETROFIT RETRO 3 ENCODER MOUNTING EXPLANATION The purpose for using digital encoders with the 2 5RS system is to provide a feedback pulse This tells the 2 5RS exactly where it is at all times Incorrect mounting of the encoders will cause the 2 5RS to get false distance readings causing the cut part to be the wrong size The following rules are provided so that encoders are mounted correctly insuring that accurate feedback is supplied to the 2 5RS This in turn will insure the parts being cut are correct dimen
326. rking device is turned ON This delay can be used to allow the marking head to be lowered into position Also it can be used to hold the machine in position for a center punching operation SETUP amp CONFIG 4 2 36 SD45 DEFAULT DWELL seconds multiple parameter This value sets the system default for the dwell time used when a dwell auxiliary code is included in a part program This value is used unless the part program establishes a new dwell time SETUP amp CONFIG 4 2 37 SD46 MIN OFF DELAY seconds multiple parameter This delay time causes a dwell after any control output is turned off It operates on all outputs Cutting oxygen etc and is in addition to any specific OFF delays for a particular operation such as the oxy fuel BLEEDOFF TIME Typically 0 to 1 SEC SETUP amp CONFIG 4 2 38 SD47 X MARKER OFFSET 2 in mm Marker offset 2 dimension in the X axis See SD40 for description SETUP amp CONFIG 4 2 39 SD48 Y MARKER OFFSET 2 in mm Marker offset 2 dimension in the Y axis See SD40 for description AO 73290 PART 7 SETUP AND CONFIG 23 2 5RS OPERATION AND MAINTENANCE MANUAL SETUP amp CONFIG 4 2 40 SD49 START DELAY seconds multiple parameter This timer is used to delay motion along the cut path when any of the tools on the machine are started or one of the stations lowered For example when the PLASMA TORCH IS ENABLED this delay prevents the plasma arc from firing for the specified time which allo
327. rmined by the LEAD IN DIMENSION LEAD IN DIMENSION must be less than SLOT WIDTH PART 2 SHAPES 38 AO 73290 SYSTEM OPERATION SHAPES SHAPES3 34 SHAPE 34 HORIZONAL HOLE REPEAT PATTERNS 3 MANUAL REPEAT ALL DIRECTIONS ALLOWED y me 1 o ka 8 9 1 X START INCHES OR MILLIMETERS 2 START I INCHES OR MILLIMETERS 3 SLOT WIDTH INCHES OR MILLIMETERS 4 SLOT HEIGHT I INCHES OR MILLIMETERS 5 X MOVE DISTANCE I RAIL DISTANCE TO NEXT HOLE 6 MOVE DISTANCE I CROSS DISTANCE TO NEXT HOLE 7 KERF DIMENSION WIDTH OF CUTTING TOOL PATH 8 LEAD IN DIMENSION INCHES OR MILLIMETERS 9 LEAD OUT DIMENSION INCHES OR MILLIMETERS 10 VERIFY YES NO YESOR NO NOTES The X and Y START values are used to define the center to center distance between holes From this center position the program moves the machine to the pierce point determined by the LEAD IN DIMENSION LEAD IN DIMENSION must be less than the SLOT HEIGHT AO 73290 PARTS 2 SHAPES 39 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 35 Q L 7 8 X START Y START DIAMETER DIMENSION X MOVE DISTANCE Y MOVE DISTANCE KERF DIMENSION LEAD IN DIMENSION LEAD OUT DIMENSION VERIFY YES NO SHAPE 35 CIRCULAR HOLE REPEAT PATTERNS MANUAL REPEAT ALL DIRECTIONS ALLOWED INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCH
328. rny Some users choose to keep various parts on site in case of a sudden need Spare parts for this purpose are not supplied with purchased equipment However replacement parts may be purchased from Burny for this purpose Burny service personnel can give advice as to which replacement parts are best to have on hand SERVICE 4 SPECIAL TOOLS Special tools are not required for installation and maintenance of the 2 5RS In the unusual event that a user is to construct or repair a Burny supplied cable proper crimping and extraction tools will be specified by Burny 5 BACKUP OF PROGRAMS AND TABLES STORED IN BURNY CONTROLS The 2 5RS has a battery system which maintains power to the memory even when the AC power to the unit is removed This keeps the programs stored in memory from being erased when the power is turned off While this battery system is very reliable there are still cases where something causes the stored programs to be lost Sometimes it can be a failure of a component or it can be an outside event such as a lightning strike or even dropping a plate on top of the control There are also cases where a new version of software requires the memory to be erased and all programs re loaded Regardless of the cause there are cases where all the programs stored in memory are lost FOR THIS REASON ANY IMPORTANT PROGRAMS SHOULD ALWAYS HAVE A BACKUP COPY STORED AWAY FROM THE 2 5RS CONTROL This way after the damag
329. rocess This allows multiple programs to be loaded by stopping the tape at the end of the first program then after the first program is stored it starts loading the next one on the tape If a rewind is desired the last program in the list should end with the 99 PROGRAM END REWIND code described below These two functions are used as a pair within a part program to perform the program repeat function The 97 acts as a pointer in the program When the 98 code is reached the program jumps back to the point in the program where the 97 occurred The program repeats to the beginning if the 97 code is not used Example 97 XX where XX is the loop count END OF PROGRAM REWIND either may be used When loading from paper tape this code stops the loading process and causes the tape to be rewound back to the start If the program is being downloaded from a remote RS 232 source this code stops the loading process and terminates the link If multiple programs are to be loaded the 90 code described above should be used on all but the last one AUTO LOAD RUN with optional XXXXXXXX specifies the next 8 digit program to be loaded PART 4 ESSI 24 AO 73290 PART PROGRAMMING ESSI ESSI 2 3 ESSI SAMPLE PROGRAM The following is an ESSI program for SAMPLE PART 1 see drawing at the end of this section The REF letters on the program listing refer to the circled reference points on the part drawing After the program is a detaile
330. rol functions are available OXY PRHT CUT High preheat then start Cutting Oxygen OXY ENABLE Turn on Cutting Oxygen Enable relay only OXY START Turn on Cutting Oxygen Start relay only PREHEAT Turn on High Preheat relay only SPECFUNC 2 1 1 OXY PRHT CUT This function is mainly used for cutting up scrap material or for stripping plates in a single axis It controls both the Preheat and Cutting Oxygen functions When selected the control prompts the operator to press the CYCLE START key to turn on the High Preheat gasses Once the High Preheat has been turned on the operator is prompted to press the CYCLE START key again to turn on the CUTTING OXYGEN High Preheat is turned off automatically Once the oxygen is turned on the JOG keys on the panel can be used to move the machine to cut in the desired direction The display now prompts the operator to press the CYCLE STOP key to turn off the cutting oxygen and re start the sequence Once the STOP key is pressed the START would again have to be pressed once for the Preheat and a second time for the Cutting Oxygen After all cutting is complete or to change to a different Manual control mode press either the SCROLL UP or SCROLL DOWN arrow key This returns to the menu of available MANUAL CONTROL functions and allows a different one to be selected SPECFUNC 2 1 2 OXY ENABLE This function only activates the CUTTING OXYGEN ENABLE RELAY It does not start the
331. rom ZERO HOME position to center of arc along the Y cross axis If 3rd digit of FORMAT is 1 dimension is incremental distance from start point to center of the arc along the Y axis thus dimension is incremental even though absolute programming is being used NOTE The following are the maximum values that can be used for the J value 99 999 9999 inches 999 999 999 millimeters IMPORTANT J values that exceed these limits produce a PGM SYNTAX ERR when loaded through the serial port WADR 1 8 SPECIAL NOTE ON PROGRAMMING ARCS The 2 5RS attempts to cut exactly what it is programmed to cut When programming arc blocks the distance from the starting point of the arc to the center should equal the distance from the end point to the center If the values are not equal the 2 5RS control uses the end point to center distance when cutting the part The difference is a PATH ERROR As this PATH ERROR increases an undesirable cut path and machine motion occurs The machine motion being a factor of setup parameters and machine speed If BACKUP is used to go in reverse through a cut path with improperly programmed arc blocks machine motion is affected The machine motion being a factor of setup parameters and backup speed IMPORTANT To prevent the possibility of a program containing an improperly programmed arc block from making unwanted cuts use the TEST RUN mode of operation f
332. ry yet Thus if power is lost before they are transferred the previous calibration values would be returned See SERV97 VAR STORE for details on permanently storing the values SETUP amp CONFIG 4 5 8 SERV52 MEMORY RESET This SERVICE MODE ONLY function causes the program memory to be erased and re initialized It is used when new software is updated and requires re structuring of the program storage memory It erases the existing program as well as the CUSTOM AUXILIARY CODE table described in section CUSTOM AUX of this manual When SERV52 MEM RESET is selected it displays YES RESET NO To reset the memory for the new card press key to cause the YES in the readout to flash Then press ENTER To abort the procedure without altering the memory press key to cause the NO to flash then press ENTER If YES was selected a second prompt makes sure that the operator is aware that the procedure erases any existing programs NO YOU SURE YES To RESET THE MEMORY press key to cause the YES in the readout to flash Then press ENTER To abort the procedure without altering the memory press key to cause the to flash and then press ENTER AO 73290 PART 7 SETUP AND CONFIG 65 2 5RS OPERATION AND MAINTENANCE MANUAL SETUP amp CONFIG 4 5 9 SERV 54 AUTOMATIC REFERENCE ADJUSTMENT This SERVICE MODE ONLY fun
333. s a system reset the same as if the unit has been unplugged and plugged in again If a new option code is entered into the 2 5RS the unit must perform a System Reset before the newly enabled option actually becomes available TYPICAL SETUP EXAMPLE The following description is provided as an example of the normal sequence used when setting up the control on a cutting machine It is not the only method and is not meant to be followed to the letter Rather it is a logical order which insures that all necessary parameters are set without unnecessary work For this example the imaginary cutting machine has the following characteristics only inch units are used however the METRIC setup would be the similar SYSTEM IS TO OPERATE IN INCH UNITS DRIVE SYSTEM CAPABLE OF 150 ipm OPERATION 500 LINE ENCODERS USED X AXIS TRAVELS 5 105 INCHES REV Y AXIS TRAVELS 4 990 INCHES REV PLATE TO BE CUT IS LOCATED TO THE RIGHT OF THE OPERATOR ONLY OXY FUEL CUTTING Armed with this information many of the system parameters can be setup immediately Before starting unplug both encoder cables from the back panel and also set the machine speed dial to 0 This should prevent the machine from moving until the parameters are initially set First select SERV51 SPD CAL and press the ENTER key The readout then prompts the operator to SET SPD DIAL THEN CYCLE START and then displays SET XXX XXXXX and the current setting of the spee
334. s and codes and cannot be used if SOFTWARE PROTOCOL is used since there are no control codes defined in the RS 244 Spec ASCII RS 358 RS 244 The character format is selected either during installation and setup or by the operator when the serial I O operation is selected For the remainder of this description the lt gt symbols are used to indicate specific characters as follows lt CR gt lt EOB gt lt XON gt lt RON gt lt XOFF gt lt ROFF gt lt EOF gt lt NULL gt HEX 0D HEX 0A HEX 11 HEX 12 HEX 13 HEX 14 HEX 04 HEX 00 ASCII CARRIAGE RETURN ASCII END OF BLOCK ALSO LINE FEED ASCII TRANSMITTER ON ASCII DC2 RECEIVER ON ASCII DC3 TRANSMITTER OFF ASCII RECEIVER OFF ASCII EOF END OF FILE BLANK TAPE HEX CODE SHOWN MUST HAVE APPROPRIATE PARITY BIT ADDED TO THE CODE The actual program format can be one of several types as listed in the programming section of this manual PART 5 SERIAL 14 AO 73290 SERIAL COMMUNICATIONS SERIAL SERIAL 8 HANDSHAKING PROTOCOL SPECIFICATIONS HANDSHAKING is the way in which the data flow between the 2 5RS and the host storage device is regulated and controlled There are basically two types used by the 2 5RS The first type is HARDWARE HANDSHAKING which uses the STATUS IN and CONTROL OUT signal lines RTS and CTS to control the data that flows through the transmit and receive lines The second type is
335. se the FEEDRATE at a smooth rate or the desired FEEDRATE can be entered directly on the keyboard When the ENTER key is pressed the new feedrate takes effect NOTE If the feedrate is lowered the displayed value ramps down to the new value Wait until the display has reached the entered feedrate value before exiting the DSPY03 mode the feedrate does not continue to ramp down if the display is canceled NOTE If the unit is equipped with a HI LO OFF speed selector switch it should be set to the closest range for the desired cutting speed The digital displayed feedrate cannot be set above the value set by the HI LO OFF selector switch Therefore if the switch is set to OFF the displayed feedrate shows 0 00 and cannot be raised If the selector is set on LO the displayed feedrate can only be raised as high as the maximum of the LO range Setting the switch to HI allows control over the entire speed range however better performance is achieved at slower cutting speeds if the selector is first set to LO and then the digital feedrate set to the desired value SETUP amp CONFIG A 1 5 SERV05 SYS STATUS This function gives the status of the system If a program is running the display will show the program number of the part being cut SETUP amp CONFIG 4 1 6 SERV10 DSPY10 SYS DATA This function is the most important service mode It allows the various operating parameters to be changed and thus allows the control operation to optim
336. sed to select 1 of 8 offsets See SD80 SD96 in INSTALLATION amp SETUP OFFSET 1 ON Turns on the 1 marker offset and moves the machine to the offset position The prompt VAL 1 0000 is used to select 1 of 8 offsets See SD80 SD96 in INSTALLATION amp SETUP INCH DIMENSIONS EFFECTS PROGRAM DURING LOAD PROCESS ONLY Indicates that all following dimensions are programmed in INCH units While this code effects the program dimensions as they are being loaded into memory once the program is loaded it serves no purpose Therefore editing or deleting this code does not effect the operation ofthe machine However ifthe program is STORED via the RS232 port the edited code effects the resulting Word Address or ESSI program If the program is re loaded the changed codes effect the data being loaded into memory MILLIMETER DIMENSIONS AFFECTS PROGRAM DURING LOADING PROCESS ONLY Indicates that all following dimensions are programmed in MILLIMETER units See comments for INCH code 14 above ABSOLUTE DIMENSIONS AFFECTS PROGRAM DURING LOADING PROCESS ONLY Indicates that all following dimensions are in absolute format When a program is being loaded all dimensions are saved as Incremental movements even if the input program uses Absolute dimensions Therefore once the program is loaded this code serves no purpose Editing or deleting this code does not affect the operation of
337. set this variable to 00000000 Press SHF then 0 to enter a value of A Press SHF then 1 to enter a value of Press SHF then 2 to enter a value of Press SHF then 3 to enter a value of D Press SHF then 4 to enter a value of E Press SHF then 5 to enter a value of F PROGRAM FORMAT SD51 NOTE For SD51 D1 D2 are not used and should be set to 0 1 2 3 4 s 6 7 o maem SERM C ECC Bs DURING CLINK PROGRAM REQUEST SEND FILE SPECIFIED X X X X BY SD53 DISABLE COMMUNICATION Here 0 is the normal setting for most machines PART 7 SETUP AND CONFIG 28 AO 73290 SETUP AND CONFIGURATION PROGRAM FORMAT SD51 The fourth digit D4 affects all programs loaded by any WADR3 or ESSI1 format It sets the default for a decimal shift of the value for programmable kerf and or programmable feedrate oi oa os oa vs v oe 0089 Not shifted Shifted left 1 PROGRAMMABLE KERF Shifted left 2 Shifted left 3 Shifted left 1 place PROGRAMMABLE FEEDRATE Shifted left 2 places Shifted left 3 places AO 73290 PART 7 SETUP AND CONFIG 29 2 5RS OPERATION AND MAINTENANCE MANUAL PROGRAM FORMAT SD51 The fifth digit DS only affects programs loaded using either the WADR3 or 55 special program formats These specia
338. sion to hold them for proper mesh with the gear rack Just enough tension to keep the encoder firmly meshed and to keep it from popping out of the rack will do Too much tension will damage the encoder A conventional tension or compression spring can be used to spring load the encoder into the gear rack After the encoders are mounted be sure to run the cutting machine to all maximum travel limits Verify that nothing interferes with either encoder Avoid any sharp impacts to the encoder Sharp impacts will damage the encoder AO 73290 PART 9 RETROFIT 3 2 5RS OPERATION AND MAINTENANCE MANUAL RETRO 4 CABLE LENGTH DETERMINATION 10 In general the cable lengths that are needed depend on the application and what additional options are ordered with the 2 5RS The determination of cable lengths is very important In general always allow more At least an extra 18 to 24 inches It is important to make sure all cables are long enough but extremely long cables can act as an antenna for electrical noise For plasma cutting applications it is a MUST that all 2 5RS cables be routed to keep them separated from any plasma cables by a minimum of two feet This is done to minimize the possible damage caused by high frequency spikes produced by a plasma system Always determine the location of the 2 5RS and encoders before measuring for cable lengths Encoder cables are always needed for the 2 5RS application To determine the length of the
339. sionally l 10 Always have the encoder parallel to the gear rack see drawing B0 19621 The distance from the center of the encoder shaft and distance from the center of the shoulder screw pivot should be the same distance to the gear rack Choose a suitable location for encoder mounting Try to stay away from mounting the encoder in a vulnerable location such as the end of a rail truck or next to the torches On a bridge type machine with a dual rail axis always mount the rail encoder on the tracing table side away from the cutting torch side On a cantilever machine always mount the rail encoder on the center support beam If possible mount the rail axis encoder on the tracing table side away from the cutting torch side If possible mount the cross axis encoder to the cross axis drive gearbox Mounting the encoder to the tracing eye is acceptable but use this method as a second choice Encoders come with a universal mounting bracket See Drawing BO 19618 The mounting bracket configuration can be re arranged to meet mounting requirements Always leave enough clearance from the top of the encoder housing to any part of the cutting machine An encoder cable is plugged into the connector on top of the encoder housing This calls for a 3 clearance from the top of the housing to any part of the cutting machine Encoders are spring loaded with minimum tension into the gear rack Encoders do not require a great amount of ten
340. sions set to 0 If a function block was inserted the prompting switches to the function editing prompts listed in FUNCTION BLOCK EDITING with the function code set to PGMNOP 00 Go to the indicated section to enter the desired values EDITOR 1 5 TERMINATING THE EDITOR Once the necessary corrections have been made to the program and the BLOCK DISPLAY is showing press the RECYCLE key to terminate the editor and return to the main SELECT FUNCTION prompt If there were no data changes in the program no delete s insertions or any editing of data values the program can be run immediately with no additional processing However If any data had been changed or any blocks inserted or deleted the DIAL IN KERF and ACCEL DECEFL processing must be re done on the program Thus if a program is edited and then run the delays associated with the kerf and decel programs will occur the first time After that the program can be re run with no delay AO 73290 PART 3 EDIT 7 2 5RS OPERATION AND MAINTENANCE MANUAL EDITOR 1 6 INTERNAL FUNCTION NAMES CODES PGMNOP 00 PROGRAM NOP Normally NOT used during program edit UNUSED 01 UNUSED INDEX Ignore UNUSED 02 UNUSED INDEX Ignore CHNTOP 03 CHAIN TOP This code sets a repeat pointer which is used when the CHAIN BOTTOM 04 code is executed If the 03 code is not included in a program program returns to the beginning of the program If this code is include
341. software version and the amount of memory installed in the unit Pressing the ENTER key jumps to a list of all the available options for the system with an or OFF displayed next to the option name indicating whether it has been enabled in the unit or not When first selected the display continuously scrolls through the following SERIAL xxxxxxxxx Serial Number VERSION mm yy dd SoftwareVersion HDW TYPE 10 Hardwareversion number _ KINSTALLED Amount ofMEMORY Pressing the ENTER key first shows OPTIONS ON OFF and then switches to a list of all the available options for the system along with an ON OFF indication next to the name showing whether the option is enabled turned ON or not OFF Use the ENTER or the Scroll keys to sequence through the list IMPORTANT Before calling regarding a service or operation problem use DSPY 80 and write down the SOFTWARE SERIAL NUMBER and SOFTWARE VERSION NUMBER displayed on the readout This will aid the service personnel in determining the type of system and the software installed NOTE The serial number must be the one displayed on the readout not one found on a sticker somewhere on the enclosure AO 73290 PART 3 DISPLAY MODES 3 2 5RS OPERATION AND MAINTENANCE MANUAL BLANK PART 3 DISPLAY MODES 4 AO 73290 SYSTEM UTILITIES SPECIAL FUNCTIONS SPECIAL FUNCTIONS The key on the 2 5RS front panel is used to select the
342. sometimes needs to be inverted so that the motion of the machine is correct Use the jog keys to move the machine in the X axis and check that it moves in the correct direction If not use the key to toggle the NORM REV values This reverses the polarity of the X drive output signal SETUP amp CONFIG 4 2 24 SD26 Y DRIVE DIRECTION This parameter is used to reverse the polarity of Y axis drive output signal See SD25 for detailed description PART 7 SETUP AND CONFIG 18 AO 73290 SETUP AND CONFIGURATION SETUP amp CONFIG 4 2 25 SD27 PLATE SIDE This parameter should be set to the position of the plate being cut with respect to the operators console LEFT RIGHT This value is used by the STANDARD SHAPE routines and others to determine repeat movements and initial moves from the corner of the plate All programs should start at THE CORNER OF THE PLATE NEAREST TO THE OPERATORS CONSOLE SINCE THIS GIVE THE BEST VIEW OF THE PLATE FOR ALIGNING THE TORCHES To change the value press the key to toggle the LEFT RIGHT indication o lo R R T o R R SETUP amp CONFIG 4 2 26 SD28 HEIGHT RELAY Norm Rev Some systems have one of their output relays used as aPLASMA HEIGHT SENSOR disable relay This relay s contacts are normally connected to the plasma system s HEIGHT CONTROL When the 2 5RS slows for a corner this relay energizes and causes the PLASMA HEIGHT SENSOR to
343. stallations and should be in accordance with all local statutes The 2 5RS cabinet must be grounded to the machine frame earth ground connection by a braided ground strap at least 12 mm in width A wide flat ground strap provides a better RF ground path than a wire The strap can be terminated with standard crimp terminals at both ends The strap should connect to one of the chassis ground screws on the back of the 2 5RS cabinet See the instructive ground strap installation drawing Cables must be obtained from designed or approved by Burny Cables and leads shall be insulated The insulation must be rated for the maximum voltage of insulated or uninsulated conductors that the cable does or could contact If after installation there are unused connectors on the rear panel of the unit the unused connectors must be covered with a plastic protective cap Metal ground clamps are used at each end of every cable to connect the cable shield to equipment casings In cases where the shield is not snug within a clamp the clamp should be gently crimped Over crimping can cause internal damage to the cable The clamp must make snug contact with the shield around the full circumference of the cable Cable ends connected to the 2 5RS should have shield clamps connected directly to the 2 5RS cabinet See the cable ground to back of cabinet drawing Cables ends connected to rack mounted encoders H20 or H25 type must have the shield clamp connected to
344. standards used by the 2 5RS IMPORTANT Values will return to the previously saved values if the RECYCLE key is pressed the system is turned off or power is lost unless the SERV97 VARSTOR function is used Read the section of this manual entitled SERV97 VAR STOR The 2 5RS includes several features which allow the format of the programs loaded into the system to be altered so that they match the programming standards of the system These programs must be loaded through the RS 232 PORT They may be programmed in either ESSI or WORD ADDRESS Examples of the conversion utilities of the 2 5RS are ABSOLUTE INCREMENTAL PROGRAMMING SEE SD51 PRGM FORMAT Allows programming in either Incremental or Absolute dimensions with selectable definition of arc I and J dimensions AXIS REVERSAL AND EXCHANGE SEE SD51 PRGM FORMAT Allows definition of X and Y axis to be reversed and permits sign definitions for each axis to be configured to match the incoming program Along with these features the CUSTOM AUXILIARY CODE function described in this section of the manual allows the auxiliary codes within a part program to be converted to the standard function codes used by the 2 5RS For example most systems use G02 for a clockwise arc and a G03 for counter clockwise However if the programming standard used for other machines at the users site would happen to use a G27 and G33 or even a pair of M codes they co
345. supply power output 24 VDC 40 mA Output Analog Ground 0 Nominal 0 to 5V peak or 0 to 5V peak Limits 1 3V peak to 3 8V peak or 1 3V peak to 3 8V peak 0 16 mA 10 Enable Drive input 1 These inputs are isolated from each other AO 73290 PART 10 SPECIFICATIONS 11 Speed reference input from customer s speed potentiometer 2 5RS OPERATION AND MAINTENANCE MANUAL Enable Drive input 2 Enable Drive input 3 NC Run Low output low true This is the Y drive reference output This is the Y drive reference input Enable X and Y Drives Input This is the X drive reference output This is the X drive reference input Preheat Gas solenoid power contacts These are normally open dry contacts Start Cut contacts These are dry contacts Enable Cut contacts These are dry contacts Sense return for pin 32 Cut On Sense from the customer s machine Signals 2 5RS that the cutting oxygen is operating Stop input from the customer s machine Signalis supplied by the machine Lack of voltage on this pin causes the BURNY to stop moving and shut off the cutting process with common anode diodes Logic low 0 to 1 35V Logic High 4 2 to 5V Sinks 500 mA 50V High impedance to negative voltages 50V maximum If Burny signal selected output is 1 ma 15V If signal selected is customer signal from pin 15 then maximums are the same as for pin 15 Maximums 30VDC 2 A or 60VDC a
346. t boards and chassis should be reassembled in reverse order of the disassembly process The front panel screws should all be installed and tightened for good electromagnetic compatibility Reconnect the 2 5RS to the cables and wires external to the 2 5RS Programs and files should be reloaded into the machine The system should be tested to ascertain that performance limits important to the user are achievable The List Of Diagnostics and Tests Of The 2 5RS section of this manual contains information for diagnostics as well as table and file checking PART 6 SERVICE 10 AO 73290 SERVICE SERVICE 7 BEFORE CALLING BURNY Before a telephone call is made to BURNY for any type of assistance it is important that the SOFTWARE SERIAL NUMBER and SOFTWARE VERSION DATE CODE is known DISPLAY MODE 80 displays this information DSPY 80 CONFIGURE is a display mode which displays the system Serial Number Software Version and the amount of memory installed in the unit Pressing the ENTER key jumps to a list of all the available options for the system with an ON or OFF displayed next to the option name indicating whether it has been enabled in the unit or not When first selected the display continuously scrolls through the following SERIAL Serial Number VERSION mm yy dd Software Version HDW TYPE 10 Hardware version number _ KINSTALLED Amount of memory Pressing the ENTER
347. t written permission of Cleveland Motion inc violation of our exclusive rights px ae CUSTOMER INSTRUCTION TRACER CONNECTOR SHIELD IZE DRAWING NUMBER REV 0 72108 1 Nor 1 1 1 i2 es i2 es SHEET 1 OF 1 BLANK HOUSING X43 09107 CONN CLAMP X43 09108 FEMALE PINS X43 26274 1 QTY 9 38 SHRINK TUBING X26 04263 3 LONG EXTERNAL BRAID X26 01762 24 LONG FOAM TAPE X09 08344 3 LONG COMMON MARKER CHANNEL MODULAR ENCODER X28 25312 CHASSIS CHANNEL B MARKER CHANNEL CHANNEL 1 2 3 4 5 6 7 B 9 en piii X26 01762 24 airy MK 909 90 90 4 9 X XQ NOTE c 12 CONNECTOR CLAMP MUST TIGHTENED 8 ATERATE coLoas 1 377 KAP 02 96 SECURELY ONTO THE THREADED CONNECTOR sme o em BLANK 1 5 P D PINION SD20 AND SD21 CURRENT previous PREVIOUS ORNE SPEED GB GB MOTOR FINAL pes pem ARM 125 1 5 P D 1 625 P D 1 6667 2 0 Pp 52022 MOPED P N CMC P N CMC P N PM IMPM MODEL RATIO PULLEY PULLEY SPEED Rano PINON PINION PINION PINION PNON Lines SP 150 W ENCODER FOLDED MO 11783 12F MO 11344 12F MO 08935 0 150 3 8 MT 2630 141AF 33 9 20 30 1619 50 85000 0 092672 2 354 3 0891 3 7069 40158 41189 8000 SP 150 W ENCODER FOLDED 0 11783 22 MO 11344 22F MO 08795 0 250 6 4 2
348. tance the machine is moved at the MIN HOLD SPD toward the correct position If the distance is greater than 021 a normal linear proportional gain is used to move the machine back until it is again within this HOLD boundary This fixed gain method actually provides a higher gain and therefore better position hold than could be achieved with a normal proportional gain loop The following graph illustrates position hold loop SLOWDOWN DISTANCE 9 MIN HOLD SPEED 02 POSITION ERROR NOTE At 0 error the speed would also be 0 PART 7 SETUP AND CONFIG 12 AO 73290 SETUP AND CONFIGURATION SETUP amp CONFIG 4 2 3 SD09 ERROR SPEED MAXIMUM ipm MPM This parameter is used to limit the MAXIMUM ERROR SPEED which can be developed due to large position errors This helps to prevent oscillation by limiting the VIOLENCE of the shaking that occurs in unstable systems minimum speed 20 ipm 500 MPM A good starting point for this value is to set it to one half of the maximum speed set in SD04A MAXIMUM DRIVE SPEED Consult the drive and machine operation manual for the drive and machine maximum run speeds SETUP amp CONFIG 4 2 9 SD10 RUN SPD LIMIT ipm MPM multiple parameter This parameter and the next are used to limit the speed of the machine to something less than the maximum drive capability Normally it is not necessary to limit the speeds since the machine was designed to work with the drive system However some ol
349. tection By setting the 2 5RS for RS 422 communication and using one of these RS 422 to 232 modems the proper isolation and transient protection is achieved along with increasing the maximum transmission distance See the RS 422 section of this chapter for further details SERIAL 4 RS 232 FOR HARDWARE HANDSHAKING These drawings show the typical connection from a 2 5RS control to the standard 25 Pin and 9 Pin RS 232 connectors found on most IBM compatible computers and peripherals For HARDWARE HANDSHAKING 5 wires are required TRANSMIT DATA RECEIVE DATA REQUEST TO SEND CLEAR TO SEND and SIGNAL COMMON AO 73290 PART 5 SERIAL 9 2 5RS OPERATION AND MAINTENANCE MANUAL RTS CTS HARDWARE PROTOCAL 25 PIN D SUB AT BURNY COMPUTER SERIAL I O PORT TD 2 0002 RD RD 3 n RTS 4 9 STATUS IN CTS 5 T 8 CONTROL OUT COM 7 7 COM DSR 6 CD 1 DTR 20 RTS CTS HARDWARE PROTOCAL 9 PIN D SUB AT BURNY COMPUTER SERIAL I O PORT A TD 3 I 2 RD RD 2 T983 TD RTS 7 nn 99 STATUS IN CTS 8 O 6 CONTROL OUT 5 O 7 DSR 6 DTR 4 PART 5 SERIAL 10 AO 73290 SERIAL COMMUNICATIONS SERIAL SERIAL S RS 232 FOR SOFTWARE HANDSHAKING These drawings show the typical connection from a 2 5RS control to the standard 25 Pin and 9 Pin RS 232 connectors found on most IBM compatible computers and peripherals Since SOFTWARE HANDSHAKING uses transmitted characters to c
350. tem Serial Number Software Version and the amount of memory installed in the unit Pressing the Enter button jumps to a list of all the available options for the system with an or OFF displayed next to the option name indicating whether it has been enabled in the unit or not Press ENTER or use the scroll keys to step through the options to check if they are enabled For more information on DISPLAY 80 see SECTION DISPLAY MODES IF A PARTICULAR OPTION IS REQUIRED BUT IS NOT ENABLED CONSULT THE FACTORY SERIAL COMMUNICATIONS is the transferring of data between two devices over a communication link For a communications link to operate properly the characteristics of the transmitting and receiving devices must match If they do not the program will either not load at all or will be interpreted incorrectly The 2 5RS can adjust the following characteristics to match the external device PROTOCOL RTS CTS XON XOFF AND SPECIAL DEVICES PROGRAM TYPE WORD ADDRESS ESSI AND SPECIALS CHARACTER TYPE NUMBER OF DATA BITS PARITY BAUDRATE 2 5RS 110 300 9600 BAUD RATE 2 5 Plus 110 300 230 The same factors affect both the receiving and transmitting characteristics of the system therefore once set they should function in either direction AO 73290 PART 5 SERIAL 1 2 5RS OPERATION AND MAINTENANCE MANUAL These characteristics can be set for the system one of two ways Any or all of the chara
351. the machine However if the program is stored via the RS232 port this code is used to re construct the program so that it appears the same as when it was loaded Thus changing affects the program data as it is being re loaded into memory PART 3 EDIT 9 2 5RS OPERATION AND MAINTENANCE MANUAL INTERNAL FUNCTION NAMES CODES CONT ABSRPL 17 ABSOLUTE REGISTER PRELOAD EFFECTS PROGRAM DURING LOADING PROCESS ONLY This code occurs only in Absolute dimension programs and is used to reset the absolute zero point to a new location Since dimensions are not stored in absolute format this code has no affect on the machine after the program is loaded It is only saved so that the program can be re constructed when a STORE via the RS232 15 done INCDIM 18 INCREMENTAL DIMENSIONS AFFECTS PROGRAMS DURING LOADING PROCESS ONLY Indicates that all following program dimensions were in INCREMENTAL format See comments for ABSDIM code 16 DWELL 19 PROGRAM DWELL As a part is being run this code causes the machine to execute a programmed dwell function The motion stops and all relays are maintained in their current state After the specified dwell time the program continues execution The dwell function can also contain a data word which sets the dwell time to be used for this and all following dwell commands until a new time is set If the time is included in the function block it is displayed as VAL 1 XXX XX
352. the machine is operating in This parameter allows the range of speed displays to be shifted to match the requirements for different types of machines For example water jet machines usually run very slow so the range can be shifted down to allow for better resolution High speed plasma glass cutters and other applications may require speeds above the 1310 ipm value with a reduced resolution w IMPORTANT This parameter like SD60 INCH MM must be set before any other parameters are entered Setting SD68 to 4 selects the normal Burny range The following selections are available SD68 MAX SPEED ipm mm min RESOLUTION ipm mm min 0 81 9175 2047 0025 0625 1 163 835 4095 005 125 2 327 67 8191 01 25 3 655 34 16383 02 5 4 NORMAL 1310 68 32767 04 1 5 2621 36 65535 08 2 6 5242 16 131068 16 4 7 10485 44 262136 32 8 73290 PART 7 SETUP AND CONFIG 47 2 5RS OPERATION AND MAINTENANCE MANUAL SETUP amp CONFIG 4 2 51 SD69 LANGUAGE SEL SD69 LANGUAGE SELECT allows the one alternate language to be selected The language option option 11 must first be enabled and EPROM 73 replaced with an having the appropriate language Set SD69 LANGUAGE SELECT to the following value to select the alternate language 0 ENGLISH 1 GERMAN 2 FRENCH 3 FINNISH 4 ITALIAN 5 SPANISH 6 SWEDISH 7 DUTCH 8 PORTUGUESE 9 NORWEGIAN A ROMANIAN B CZECH 2 5 PLUS ONLY FOR NOW
353. the numeric keypad Direction arrows are provided for quick reference The actual LEAD OUT position is determined by the direction of the cut The figure above shows the LEAD OUT position assuming a clockwise cutting direction has been selected When running the resulting NC part program position the torches at the corner of the plate regardless of the REPEAT MODE selected From this position the program moves out to the actual pierce point When performing AUTO REPEAT mode operations parts are shifted to the left and right at a 60 degree angle to minimize the amount of scrap between parts LEAD OUT TYPE 0 is 10 degrees to tangent LEAD OUT TYPE 1 follows LEAD IN path AO 73290 PARTS 2 SHAPES 57 2 5RS OPERATION AND MAINTENANCE MANUAL SHAPES3 53 CUT DIRECTION STARTING POSITION INNER DIAMETER SIZE OUTER DIAMETER SIZE LEAD IN DIMENSION LEAD OUT DIMENSION LEAD OUT TYPE SCRAP DIMENSION 9 KERF DIMENSION 10 REPEAT MODE IF AUTO REPEAT MODE II VERIFY YES NO SHAPE 53 RING REPEAT PATTERNS AUTO MANUAL PLATE SIDE LEFT RIGHT 8 CLOCKWISE OR COUNTER CLOCKWISE 1 OF 8 POINTS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS INCHES OR MILLIMETERS 0 OR 1 DISTANCE BETWEEN PARTS IN MM WIDTH OF CUTTING TOOL PATH AUTOMATIC OR MANUAL POSITIONING IF MANUAL REPEAT MODE 11 REPEAT DIRECTION 1 OF 4 POINTS
354. the torch to crash into the plate In the other case when the cut path either crosses or even just touches a previous cut path the torch can again dive into the plate By setting this distance value to some nominal value keep the value as small as possible it can prevent these problems In the case of the leadout by establishing a standard leadout length for example 25 inches and setting SD19 to 40 inches it would guarantee that the plasma height sensor would be disabled at least 15 inches before the leadout started and so it can t follow the part falling out In the case of the cross or intersect of a previous cut the part program must contain the appropriate Height Sensor Disable code see programming section at the point of intersection SD19 would then disable the height sensor at the specified distance BEFORE the intersect point and prevent the torch from diving into the plate SETUP amp CONFIG 4 2 18 SD20 X ENC DIST REV SETUP amp CONFIG 4 2 19 SD21 Y ENC DIST REV SETUP amp CONFIG 4 2 20 SD22 ENC COUNTS REV The X amp encoder distance per one revolution and the number of encoder counts per one revolution allow for various encoder rack pinion combinations to be used with the 2 5RS control The 2 5RS has the ability to use a wide range of encoders The value entered in SD20 X ENC DIST REV is the length of travel in mm along the X axis per one revolution of the X axis encoder The value entered in SD
355. tice the acceleration out of the corner back to full speed If it appears too long reduce the 5003 ACCEL TIME value Similarly if the acceleration appears too fast increase the accel time AO 73290 PART 7 SETUP AND CONFIG 79 2 5RS OPERATION AND MAINTENANCE MANUAL 10 Now Select SHAPE 23 SQUARE RADIN and enter the appropriate dimensions to give a 5 rectangular part Enter a corner radius of 0 10 in order to check the SD30 MIN RAD SPD parameter Run the part at full speed and notice the speed during the small radii in the corners If it appears that the radius runs to slow increase the SD30 MIN RAD SPD parameter If the machine overshoots the radius or seems to be running the small corner radii too fast lower the SD30 MIN RAD SPD value The objective of all these adjustments is to provide the smoothest most accurate operation with a minimum of time spent in the corners Try various combinations of adjustments to get the optimum performance Setup the control and run a series of RINGS After the cut is turned off watch that the cutting oxygen has completely stopped before the machine begins to move to the pierce point on the outside If the machine begins to move before the cutting oxygen has stopped increase the SD02 BLEEDOFF time value If the Bleedoff time value seems excessive reduce the setting of SD02 BLEEDOFF Make sure the new value still provides enough delay to allow the cutting oxygen t
356. to SET SPD DIAL MAX THEN PRESS ENTER The operator should turn the machine s speed dial fully CW to it s maximum setting Also if there are any speed range switches set them to the HIGH SPEED setting so that the speed dial is at it s maximum setting Press the ENTER button to calculate the adjustment factor for the MAX position of the speed pot The readout temporarily changes to show the data and calibration values and then changes to the normal feedrate display FEEDRATE Test the speed dial by slowly backing away from the full CW position and verify that the displayed FEEDRATE value beings to drop as the pot is turned AO 73290 PART 7 SETUP AND CONFIG 81 2 5RS OPERATION AND MAINTENANCE MANUAL Continue turning the speed dial all the way to it s 0 speed setting and verify that the display shows FEEDRATE 0 _ If it does not quite reach 0 it could indicate that noise on the signal was measured during the 0 calibration ofthe pot If this occurs repeat the SERV54 procedure If the pot operation is correct the calibration values must be stored permanently To do this press the hidden SERVICE button and perform the SERV97 procedure This will permanently store the results of the SERV54 procedure PART 7 SETUP AND CONFIG 82 AO 73290 SETUP AND CONFIGURATION INTERFACE INTERFACE MACH 1 MACHINE INTERFACE This section describes the relays and sensing inputs of interface cards based on the 2 5RS
357. to 500 feet away with special RS232 extended distance cable To use RS 232 communication over 500 feet would require the addition of short haul direct wire or fiber optic modems to boost the range The RS 422 setting of the 2 5RS serial port allows for direct connection to RS 422 devices over mile away and may be the better choice for long distance links See the section on RS 422 communications later in this chapter for further details w IMPORTANT The MO 06354 RS 232 422 OUTPUT ADAPTER ASSEMBLY provides total electrical isolation between the 2 5RS internal electronics and the transmission wire to the remote computer or serial device As long as the distance between the two devices is within the RS 232 or 422 specifications no additional isolation is needed to protect againstground loops or power system problems However there can be considerable electrical noise PART 5 SERIAL 8 AO 73290 SERIAL COMMUNICATIONS SERIAL generated on the wires leading from the 2 5RS to the remote computer While this will not harm the 2 5RS due to it s built in isolation the noise could damage the input circuitry at the remote computer For this reason we recommend that all installations include some sort of transient protection and isolation at the serial port of the remote computer to protect it against line induced noise damage There are also RS 422 to RS 232 conversion modems available which also provide this type of isolation and transient pro
358. to check and correct the position of the part on the material to be cut RUN 4 3 SINGLE STEP Single Step mode is similar to TEST RUN however only one program move is executed each time the START CYCLE key is pressed Thus the dimensions at the end of each data block can be checked RUN 5 START CYCLE After the desired cutting mode is selected and the required data Preheat Pierce Ramp etc have been entered press ENTER to proceed to cut the part The display now shows the prompt PRESS CYCLE START At this point if the PLATE ALIGNMENT OPTION is not enabled in the control simply locate the machine at the starting position on the plate usually the lower corner and press the green START CYCLE key This starts program execution continue at RUNNING THE PART AO 73290 PART 2 RUN 7 2 5RS OPERATION AND MAINYENANCE MANUAL RUN 6 PLATE ALIGNMENT OPTION The optional PLATE ALIGNMENT feature compensates for plates which are not aligned not squared with the cutting machine Without this option the plate must be carefully aligned to be parallel with the main rail or else the parts may run off the edge as the cutting progresses down the rail The alignment option rotates the part program so it follows the angle of the plate This not only insures that the parts cut correctly but also reduces the setup time since the plate no longer has to be squared to the machine To perform this alignment instead of p
359. to see if the specific code is listed in the conversion table If it is not the code remains unchanged and is loaded normally However if the table contains a conversion definition for the particular auxiliary code the input code is replaced with the new value from the table It is then processed and stored in memory The table may contain up to 50 conversions made up of any combination of WORD ADDRESS codes or ESST function codes Each entry in the table contains information which defines which type of input it is LOOKING for and what the conversion should be To access the table for display and possible modification of the conversion values Select SERV70 CUSTOM AUX When the ENTER key is pressed the memory is checked to see if the aux table has been initialized If so the prompting continues by displaying the first table location Since the AUXILIARY CODE TRANSLATION TABLE is stored in the battery backed program memory the room for the table data must be allocated in the memory space This is performed automatically when the SERV52 MEMORY RESET function is done However if the 2 5RS had been updated from an earlier software version it is possible that the room for this table is not available in memory If this occurs an error message AUX TABLE ERROR is displayed which indicates that the table is not present in memory To correct the error and allow the table to be loaded p
360. to store the data A LOADED message is displayed when a LOAD operation is successfully completed Pressing the RECYCLE key returns to the main prompting menu If the serial device being used disables it s STATUS LINE during the communication the display changes to WAITING until the port comes back ON LINE Any errors that occur during a SERIAL I O OPERATION are listed in the section ERROR MESSAGES of this manual SERIAL 1 CONFIGURING THE COMMUNICATION PORT The 2 5RS is equipped with an isolated RS 232 RS 422 Serial Communication Port which is used to connect to host computers and other serial devices The communication port is housed in a separate enclosure usually attached to the back of the 2 5RS cabinet in place of audio beeper The enclosure MO 06354 contains isolated RS232 422 electronics status LEDs audio beeper 9 pin output connector and an internal RS232 422 selector switch PART 5 SERIAL 4 AO 73290 SERIAL COMMUNICATIONS SERIAL There are 4 sets of LEDs which show the state of the input output signals The top LED shows the signal as being LOW or OFF while the bottom LED shows the signal being HIGH or ON When the unit is sending or receiving data the LED s will be blinking showing the passage of the serial data stream RS 232 O EEE Company zom RX CTS er TX RTS O _ AS 232 422 O OUTPUT ADAPTER 06354 O The 2 5
361. to the start of the next will only store 1 point to point PT TO PT move When the lt lt CUT ON gt gt mode is selected the beeper will again indicate the change and the readout will show CUT ON CONTOUR for about 1 5 seconds before returning to the X Y position display There will now be a flashing sign in the center of the readout to indicate that the lt lt CUT ON gt gt mode is active IMPORTANT Due to the software processing time the speed during the teaching process must not exceed 25ipm 635 mmpm or the resulting part will appear choppy due to the loss of some data PART 3 TEACH 4 AO 73290 SYSTEM UTILITIES TEMPLATE TEACH TRACE The template tracing system must be set so the taught path compensates for the cutting kerf of the torch This can either be accomplished by having the template drawn with the correct kerf modified dimensions or by using the kerf offset feature of most tracing systems to offset the path In either case ifthe template tracing eye combination produces a correct size part when cut optically The resulting taught program will be the correct size also NOTE Although the Dial In Kerf feature on the 2 5RS allows either a positive or negative kerf to be added to the program after it is taught the best results are still obtained by teaching the program with the kerf included in the template or tracing eye and then using the Dial In Kerf to Fine Tune the resulting program The TEA
362. tors speed dial to the FULL SPEED maximum position Also ifthere are any speed range switches set them to the high speed setting so that the speed dial is now set for the maximum drive speed Press the ENTER key The readout temporarily shows the DATA AND CALIBRATION VALUES and then changes to the normal FEEDRATE 150 00 At this point the value displayed on the readout should be the same as the value entered for the MAXIMUM DRIVE SPEED AS SD04 MAX SPD or 150 for this example 6 Set the control to test run a 5 00 inch diameter CHAIN CIRCLE part Start the test run and turn the speed dial to full speed While the machine is going around the circle if the path oscillates or is wavy reduce the setting of SD16 LOOP GAIN until the oscillation stops If no oscillation is noted try raising the SD16 LOOP GAIN value until the shaking starts and then reduce it till it just stops Now check the performance of the machine as it slows for each corner of the part If it appears to be banging into the corners rather than smoothly decelerating either increase the SD18 SLOWDOWN DIST or decrease the SD07 CORNER SPD values Since this is a trial and error type of adjustment it is impossible to predict which adjustment gives the best results Similarly if the corners appear Mushy reduce the SD18 SLOWDOWN DIST or increase the SD07 CORNER SPD After the machine slows for a corner no
363. tting circuit in such a way that opening it will stop the cutting oxygen and reset any automatic relay sequencing When running a part this contact will not close until the OXY sense input is first sensed to be off PART 7 INTERFACE 4 AO 73290 SETUP AND CONFIGURATION INTERFACE This prevents the enable contact from re starting the cut This contact 1s only supposed to enable the cutting circuit so the oxygen can be started either by the manual cut switch or by the 2 5RS OXYGEN START CONTACT If the 2 5RS is set to OVERRIDE this contact will be maintained in a closed position to enable the existing machine cutting circuitry MACH 2 6 OXY START CONTACT PINS 3 AND 4 OF 6PL 6PL 3 L This contact is connected to the cutting circuit so that it can initiate the cutting oxygen but only if the OXY ENABLE CONTACT is closed It may either directly connect the cutting oxygen circuit or may provide a signal to the machines existing AUTO CUT circuitry This contact will only operate when AUTO oxy fuel cutting is selected The contact will close after the PREHEAT time reaches zero 0 and will remain closed until the part is complete If MANUAL cutting is selected this contact will remain open and the cutting oxygen must be started with the machines existing manual cutting controls If the 2 5RS is in OVERRIDE this contact stays open 2 7 CONTACT PINS
364. tting functions suspended Program steps which would be cut are run at the speed set on the machine speed dial while traverse moves are done at the high traverse speed If SINGLE STEP is selected the program executes one program step each time the START CYCLE key is pressed In either the TEST RUN or SINGLE STEP modes the part may be repositioned on the plate as follows Allow the machine to run through the program to a point where it is apparent that the part needs to be moved to keep it on the available plate Then press STOP CYCLE to stop the machine at that point Now use the jog function to move the torch to the desired position on the plate Once it is in the correct position press the START CYCLE key again to continue the test run This process of stopping the test jogging the torch and then continuing may be repeated as many times as needed to position the part correctly Once the part is positioned press the STOP CYCLE key and then the PART RET key 3 times to return to the home position of the part Press the STOP CYCLE key again to return to the main cutting prompts and select the desired cutting mode PART 2 RUN 12 AO 73290 SYSTEM OPERATIONS RUNNING A PROGRAM The PART RET key actually allows returning to one of three different positions on the part being cut Pressing the PART key the first time returns to the most recent pierce point on the part The display now shows RETURN
365. uctor of machine s power source Input Input pin for powering the 2 5RS from a 115V machine power source Input Input pin for powering the 2 5RS from a 230V AC machine power source Input PRODUCT SPECIFICATIONS Nominal 0 to 5V peak Limits 2 4 to 7 7V peak 0 06 mA Maximums 30VDC 2 A or 60VDC a 0 5 A 120VAC 2 7 2VDC 15 mA if Burny reference is used If customer signal is selected see pin 10 for specifications Sinks 500 mA 50 V High impedance to negative voltages 50V maximum These pins are isolated from each other with common cathode diodes If Burny signal selected output is 1 ma 15V If signal selected is customer signal from pin 15 then maximums are the same as for pin 15 Maximums 30VDC 2 2 A or 60VDC a 0 5 A 120VAC 2 Logic is 4 90V minimum 24V maximum Logic LO is 1 35V maximum 0 V minimum 1 mA maximum If Burny signal selected output is 1 ma 15V If signal selected is customer signal from pin 18 then maximums are the same as for pin 15 Maximums 30VDC 2 2 A or 60VDC a 0 5 A 120VAC 2 2 230V AC maximum or 2 30VDC maximum 2 230V AC maximum or 2 30VDC maximum 2 230V AC maximum or 2 A 30VDC maximum 115VAC 30 mA 115VAC 15 mA See operator manual section MACHINE INTERFACE SENSING INPUT 115VAC 15 mA maximum See operator manual section SD61 SYSTEM CONFIGURATION and
366. uld be reassigned by the CUSTOM AUX CODE feature so that they would cause the correct CW and CCW arcs to be cut This feature also allows ESST auxiliary codes to be re assigned in the same way AO 73290 PART 7 SETUP AND CONFIG 67 2 5RS OPERATION AND MAINTENANCE MANUAL The CUSTOM AUX CODE CONVERSION feature only works if programs are loaded using the WADR3 or ESSI1 special program formats The standard programming instructions in the operation manual do not mention these formats since they are not required by the majority of the users The special conversions and axis definitions as described in SD51 PRGM FORMAT and the AUXILIARY CODE conversions do not affect programs if they are loaded using any of the other programming formats WADR WADRI WADROQ ESSI This allows standard programming to be less confusing and simpler To use the CUSTOM AUX CODE CONVERSION feature first the left most digit of SD51 PRGM FORMAT must be set to a 1 as described in that section of the manual If it is a 0 the standard or 551 program formats for the 2 5RS are used regardless of the setting of this table Assuming that the SD51 PRGM FORMAT digits are properly set the conversion table must be loaded for the necessary code changes The table works by checking each incoming word address or code and all ESSI auxiliary functions It scans through the table
367. uld be set to a low enough speed that the machine can backup around a corner without excessive stress bumping in the gearbox or drive system Consult the drive and machine operation manuals for the maximum drive and machine speeds SETUP amp CONFIG 4 2 6 SD07 CORNER SPEED ipm MPM multiple parameter This value along with parameter SD18 control the deceleration ramp used to SLOWDOWN before a corner The slope of this ramp is constant regardless of the travel speed as illustrated MAX SPEED CORNER SPEED lt 5007 0 DISTANCE SLOWDOWN TO CORNER DISTANCE SD18 all UC SCC C P vi the CORNER SPEED affect the DECELERATION RAMP Both these values should be set to the minimum required to achieve acceptable corners on parts This minimizes the time required to do the corner and therefore reduces the variation in the cut quality due to the change in cutting speed NOTE TO PREVENT STALLING IN CORNERS DO NOT SET THE CORNER SPEED TO 0 00 Typical Values CORNER SPEED 10 ipm 250mpm SLOWDOWN DIST 75in 19mm AO 73290 PART 7 SETUP AND CONFIG 11 2 5RS OPERATION AND MAINTENANCE MANUAL SETUP amp CONFIG 4 2 7 SD08 MINIMUM HOLD SPEED ipm MPM This speed value is used when the control is holding the machine in position The speed entered for this parameter is used as a fixed GAIN value during the time the machine is within 02in 5mm of the correct position Within this dis
368. ur written permission Any use of this print without written permission of Controls inc is a violation of our exclusive rights CABLE GROUND NOMAS EICH BACK UF CABINET t Company CAD DWG NO 00020000 SIZE DRAWING NUMBER REV 8 L A 0272105 BLANK USE 360 METAL CLAMP TO GROUND EXTERNAL BRAID ON RER MOTOR TACH CABLE TO ONE OF METAL CLAMPS PROVIDED WITH THE SCREWS ON THE MOTOR MOUNTING PLATE AS SHOWN ALL BURNY CABLE ASSEMBLIES This print is the property of Cleveland Motion Controls Inc and is furnished as confidential information only It must purpose without our written permission Any use of this print without written permission of Cleveland Motion Controls Inc a violation of our exclusive rights Cleveland MOTOR CABLE GROUND CLAMP INSTALLATION 2630 ice T REV not be copied traced or reproduced in any manner nor submitted to any outside parties for any SHEET 1 OF 1 A BLANK WITH CABLES DISCONNECTED SLIDE METAL BRAID COMPLETLY ONTO THE ENCODER CABLE he AL4 CLAMP PLUG THE CONNECTORS TOGETHER AND SLIDE A THE BRAID OVER THE CONNECTORS AS SHOWN APPLY METAL CLAMPS AND USE SUPPLIED CN HARDWARE TO GROUND BRAID TO 5 SOK EXTERNAL CABLE SHIELD Z SELECT AL4 OR LARGER ALS CLAMP TO FIT TIGHTLY ON ENCODER CABLE METAL BRAID BRAID CLAMPS AND WITHOUT DAMAGING HARDWARE SUPPL
369. w equipped with the optional Dial in Kerf feature described in the RUN PROGRAM section of this manual the value of 0 00 should be entered for the KERF prompt during the dimension entry See exceptions below By entering 0 00 at this point the Dial in Kerf feature can be used when the part is actually cut to enter and adjust the kerf dimension as needed If a KERF value other than 0 00 is entered during the dimension prompting of a standard shape it is permanently added to the part dimensions and the Dial in Kerf feature is bypassed when the part is cut thus the kerf cannot be adjusted and the entire part must be re entered to change it NOTE On any Chain Cut parts such as the WEDGE PAIR or CHAIN RECTANGLE the kerf must be entered along with the part dimensions during the program creation This is due to the common side cutting and nesting which is done on these parts Regardless of the kerf entered the DIAL IN KERF will not function on these parts See also the Dial In Kerf section of this manual Most of the standard shapes also prompt for a SCRAP dimension see below This is the space left between successive rows of parts Since the Dial in Kerf feature does not increase the part to part spacing the value for SCRAP must allow for enough material to accommodate the anticipated KERF plus the desired amount of actual material to be left between the rows of parts AO 73290 PARTS 2 SHAPES 3
370. ws the station to reach its cutting position SETUP amp CONFIG 4 2 41 SD50 SERIAL DEFINITION This parameter selects the various program and COMMUNICATION CHARACTERISTICS of the serial RS 232 port The value is a 4 digit number where each digit controls a specific function If any digit is set to zero 0 the operator is prompted to make the selection when a serial operation is performed sets up the communication protocol pi 2 os m D1 of SD50 gt DHBB romped orrowcot Bi RTS CTS HARDWARE PROTOCOL x XON XOFF SOFTWARE X PROTOCOL PTAPE 1 Special SPOOLING TAPE X READER PROTOCOL CLINK 1 Special Cad Comm Link NOTE Any number not listed should not be used See Section SERIAL COMMUNICATIONS for more information PART 7 SETUP AND CONFIG 24 AO 73290 SETUP AND CONFIGURATION PROGRAMMING LANGUAGE SD50 D2ofSD50 H The Operator is prompted for program type WADR Standard 2 5RS WORD ADDRESS X ESSI Standard 2 5RS ESSI Sessa NOTE Any number not listed should not be used See Section PROGRAMMING for more information Hl RTL Oniy nor roman N E AO 73290 PART 7 SETUP AND CONFIG 25 2 5RS OPERATION AND MAINTENANCE MANUAL CHARACTER FORMAT SPECIFICATION SD50 NP7D ASCII NO PARITY 7 DATA BITS NP8D ASCII NO PARITY 8 DATA BITS EP7D ASCII EVEN PARITY
371. ximum values that can be used for the Y values 99 999 9999 inches 999 999 999 millimeters IMPORTANT values that exceed these limits produce a SYNTAX ERR when loaded through the serial port AO 73290 PART 4 WADR 3 2 5RS OPERATION AND MAINTENANCE MANUAL WADR 1 6 I DIMENSION FOR ARCS Not used on lines Incremental programming distance in the X rail axis from the start point to the center of an arc Absolute programming dependent on SD51 PRGM FORMAT If 3 digit of PRGM FORMAT is a 0 the dimension is the distance from ZERO HOME position to center of arc along the X RAIL axis If 3 digit of PRGM FORMAT is 1 dimension is incremental distance from start point to center of the arc along the X axis thus dimension is incremental even though absolute programming is being used NOTE The following are the maximum values that can be used for the value 99 999 9999 inches 999 999 999 millimeters IMPORTANT values that exceed these limits produce SYNTAX ERR when loaded through the serial port PART 4 WADR 4 AO 73290 PART PROGRAMMING WORD ADDRESS WADR 1 7 J DIMENSION FOR ARCS Incremental programming distance in the Y cross axis from the start point to the center of an Absolute programming dependent on SD51 PRGM FORMAT If 3rd digit of PRGM FORMAT is 0 dimension is distance f
372. y again This stops the address flashing and starts flashing the data value Now any value entered on the keypad changes the data field Once the new data value is entered press the ENTER key This places the data value back at the address location The data field continues to flash and the value can be changed again Once the flashing value is correct press the ENTER key again to return to the address entry mode address flashing To enter either the Address or Data value use the NUMERIC keypad and the CLR OR CE keys PART 7 SETUP AND CONFIG 60 AO 73290 SETUP AND CONFIGURATION Ifa HEXADECIMAL value is being entered 0 1 2 3 4 5 6 7 8 9 A B C D E F be used To enter a number just press the value on the keypad To enter an F use a 2 key combination of the SHIFT key and then one of the numbers on the keypad Press SHF then 0 to enter a value of A Press SHF then 1 to enter a value of Press SHF then 2 to enter a value of Press SHF then 3 to enter a value of D Press SHF then 4 to enter a value of E Press SHF then 5 to enter a value of F SETUP amp CONFIG 4 5 1 SERV30 SINGLE WORD MEMORY DISPLAY SINGLE WORD 16 bit hexadecimal display entry of any memory location in the system The display for the SERV30 DSPY30 utility appears as follows MW XXXX AA HHHH The Address of th
373. y looks for the normal end of program codes bi oa os es vs s 57 vs IF D7 IS EQUAL TO 0 Default conditions 4 Special End of Program on WADR3 loads only 8 Special End of Program on ESSII loads only C Special End of Program on WADR3 amp ESSII loads 1 Sets I J dimensions for incremental even if program is in absolute 5 Special EOP on WADR3 loads only enabled and I J dim for incremental 9 Special EOP on ESSII loads only enabled 1 dim for incremental D Special EOP WADR3 amp ESSII loads enabled and I J dim for incremental NOTE Any number not listed should not be used AO 73290 PART 7 SETUP AND CONFIG 33 2 5RS OPERATION AND MAINTENANCE MANUAL PROGRAM FORMAT SDS1 Digit D8 also affects all programs loaded by any WADR or ESSI format It sets the default for program dimensions as either absolute or incremental This causes any program which does not have a code declaring it as either absolute or incremental to be assumed as the type set by this digit Programs which contain the correct auxiliary code for ABSOLUTE INCREMENTAL are loaded according to that code regardless of this digit 5 ws os vs os os Por 98 IF D8 IS EQUAL TO 0 INCREMENTAL DIMENSIONS USED AS DEFAULT 1 ABSOLUTE DIMENSIONS USED AS DEFAULT SETUP amp CONFIG 4 2 43 SD52 SPECIAL EOP This parameter allows up to 4 characters to be entered in ASCII as 8 digits which specify a 4 character string which can
374. yed Use the key to toggle between the YES NO response and press ENTER The YES response causes the X Y VJ prompting to restart so the dimensions can be verified and changed again if necessary The NO response ends the editing of the data block and stores the results in memory NOTE If only the ENTER key is pressed for each prompt and none of the data values changed the original block is not replaced in memory However if any of the dimensions or arc direction values are changed a new data block is created and the entire original block is replaced After all the prompts are entered and the VERIFY NO response entered the readout returns to the MAIN DATA BLOCK DISPLAY EDITOR 1 2 3 FUNCTION BLOCK EDITING If the block being edited is a function CUTON KRFLFT ETC the following prompt is displayed FNC NAME The digits contain the function number from list at the end of this section The function name is displayed on the right side Some examples are FNC 03 CHNTOP FUNCTION 03 CHAIN TOP FNC 05 CUTOFF FUNCTION 05 CUTTING OFF To change the function the scroll keys may be used to move up or down the list of functions given in the list end of this section Each time an UPIDOWN SCROLL key is pressed the next function number and name from the list is displayed Thus there is no need to memorize the function codes since the scrolling can be
375. yed PRESS VERIFY NO is displayed PRESS ENTER B 0005 ARC CW is displayed and also B 0005 X I is displayed PART 2 RUN 14 AO 73290 SYSTEM UTILITIES PROGRAM TEXT EDITOR To add a new block The control will now display INSERT LIN ARC X DIM 0000 is displayed Y DIM 0000 is displayed Use the numeric keypad to enter the dimension 20 and T DIM 0000 is displayed J DIM 0000 is displayed VERIFY YES is displayed VERIFY NO is displayed B 0006 LINE Y is displayed To add a new block INSERT LIN ARC is displayed Change to Insert Function by INSERT FUNCTION is displayed FNC 00 PGMNOP is displayed FNC 05 CUTOFF is displayed PRESS SHF AND SCROLL DOWN PRESS ENTER PRESS ENTER PRESS ENTER PRESS ENTER PRESS ENTER PRESS PRESS ENTER PRESS SHF AND SCROLL DOWN PRESS PRESS ENTER PRESS SCROLL DOWN UNTIL THEN PRESS ENTER B 0007 CUTOFF F05 is displayed The program is finished AO 73290 PRESS RECYCLE PART 3 EDIT 15 2 5RS OPERATION AND MAINTENANCE MANUAL B 0004 LINE X B 0006 LINE Y B 0005 ARD CW X I X B 0007 CUTOFF F05 B 0008 PGMRWD F23 B 0001 PGM START INTERNAL CO B 0002 CUT ON F06 B 0003 KRFLT F08 EDIT NEW SAMPLE FRORAM PART 2 RUN 16 AO 73290 SYSTEM UTILITIES TEMPLATE TEACH TRACE TEMPLATE TEACH TRACE The TEMPLATE TEACH function allows the 2 5RS used along w

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