Home

INOVA 115V Users Manual

1. I TI 9 9 OE or B2 P31 m Oa EE mE OQ o P33 VE TEV pe TOR ETE CS CR Fos cV ue vet veal uw 5 oe E IRE Vs 5 ERIS sm By 3 E i OC FLOTO mw g de om ee NB amp ais s 8g OQ o o F9 ae Li WEIL GE E RR eo E s ge H le D a 8 FE i Oo 1 n ae d 20 E t BE 233 R R 3 XHEF ESL OW tat Dr d ce ERU LE 80 pee SP ar d 6 d ESO m 5 o ut Hk W T Cr E glt r VE h ERa R30 us gl Ewlo Hear O a an Bs A C5 amp l w beet amp ee Te OR HH C370 jov YN D ur tas Oo Oo o Oo 1 auro FER SETARCVOLTACE 120 0 MI Manual ACTUAL ARC VOLTAGE 000 0 ARC TRANSFER HEIGHT 0 100 5 PIERCE HEIGHT 0 150 1 puw h PIERCE TIME t S CUTTING HEIGHT MODE AUTO RAISE PARTIAL IHS RUN INOVA PRECISION ARC VOLTAGE CONTROL a PLASMA LIBURN 1X2 Th
2. uu tora 0072 Zid EKRA O Q pe ye ed a ead yaa zaa 662 MS m mua ej reas O i Hfz T E 3 2 aes M 4 aads z WAd T z reer BR S ease gl SS a a EEGSQ SRR HER FAST ens j EN T Ej aT IAS AST VASI NOW ASt IAY Diny N3NHDO Daa Aze Zear T E zd T TT Y enxny 469 5 aom s F V 29N3 g8 9N3 960 F a ZAS man 863 erta Wo OpT31 66037 8ET31 eqs 96037 setal yET31 ET31 amp yT31 sum eri Lf te 4j S6 O OJ aa n resp i ND ean Wid fu 4 E6 I O O O ome j a 06l F ES r620 pa EXA 269 a a ea y Jee 7 RIA wen 0T 14 LT T 882 3 4 H sea F 620 er Ds Cs CO m Yeo sa d 982 a z vem eer 4 L 689 y83 oga 4 F JN3XANI N3AD E seu 7 Sad Jz d rea d esa isa 4 H Tesr i yso edd 4 ian ec L 649 28a ear 4 z cai 614 Tog Pii 83 9850 Y 280 C 318 lszaL Eum 8228 LLA d Lot ev LA 3 X re M B9VLI0A amoy 929 lt um o o NGA 94A 843 yaa S23 ESTE P an R 2zounnu OTdL za F gt na 82031 814 Ld E Cb ele CENE CoOw3 san sen edi p 928 E E iw Oo o Jol NI 172 a v IR IR 18 NAM J i 2 aava wiad gt L cou WEN 2 p o IN za 43 zan
3. O OJ 2 eI Y S 152 3174 O D Qv 5 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 2 Parts List Inova User s Manual Rev K Remote Control Imperial Assembly 110020 Metric Assembly 110120 Item Number Part Number Quantity Description 1 110001 1 Remote base 2 110002 1 Remote cover 3 110026 2 Switch assembly 4 110000 1 Touch Screen 5 110009 1 LCD display 6 110300 1 Remote microprocessor p c board Imperial 110305 Remote microprocessor p c board Metric 7 110012 1 Remote RF shield top 8 110013 1 Remote RF shield bottom 9 110400 1 Remote communication p c board 10 709003 1 Receptacle 9 position 1 709002 1 Receptacle 14 position
4. ca 00601 Nd ATEWASSY AOE AQE 4 l 009017 Nd ATAWASSY ASI CND Y i a O 6031 SS p25 1 AJA 66S0IT Nd dod NYE zaa O O29 d ONI OIDITTS3NNT dn WAd E10 etAOW NADG 278 G d DU S N nose Su Ade Sn 02 A02 O O cae 8 S samo i BIA BAG iu JOTAUDA H i CO F a 2 Lana 6n T23 S xD ing 8AUN F Ne A M A J O 23 xb cs EIS Did i r a zo zo zu IS 70 70 zu B BAd se alg Ba pee sees COR Ou a N i N AZI Se 2 i Se rH arr TH 4ZAOW H 00 i L adi Tro NADG SUR on 8fl on Lsea O10 Ida B Zea fi C2 i ee foe pod saon TA QS Deae NI Trea g A 3r OFS oleoa LR Jat a T TT fora hs a paon zn E 8 Talaan SD a ozah WX J I Er LI ERR NS EAE S 1 p ear NARS oer A A AA 00 0 00 7U 70 0 00 700000 o an Y PR IRE GER las SFIS eia an ADK an T T Eae Cabe PREL E TET a S 1937 tyro SO si ano Ns PM 2 119 yn en en In TAON qp NMOG WAd 80 ys az 19 dn Zo ex luz 2a d sy gp T ved Q ol Q zi 83 vo si 0 o 3 O S K ni 1033 C3 D 99 1X3 Agi O sn 9 23 23 9 EIS 2a TO Ta va CO CO mc vati Jag 1X3 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR Inova User s Manual Rev K Parts List Power
5. COLOR POSITION NO TERMINAL REDA um 2 709017 PIN BLACK 4 WHITE 12 BLACK 14 GREEN 10 BLACK 11 709017 PIN STRAIN RELIEF 709025 PLUG 709024 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 8 Parts List Inova User s Manual Rev K D Cable Assembly 711720 X CONSOLE VOLTAGE DIVIDER P2 9 POS STRAIN RELIEF 709015 PLUG 709016 CABLE 711031 TERMINAL POSITION NO COLOR POSITION NO TERMINAL 709018 SOCKET BLACK SG 709028 FAST ON 1 J RED Sl SIG 709028 FAST ON 5 9 GREEN LOGIC 709028 FAST ON 709018 SOCKET 7 z WHITE LOGIC 709028 FAST ON 709019 KEY 2 TOTAL SOCKET COUNT 5 TOTAL FAST ON COUNT 4 THE D CABLE PART NUMBER IS 711720 X WHERE X IS THE LENGTH OF THE CABLE IN FEET E Cable Assembly 711725 X CONSOLE GROUND LUG STAR GRO Doo o O CABLE 711029 THE E CABLE PART NUMBER IS 711725 X WHERE X IS THE LENGTH OF THE CABLE IN This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any
6. sess 5 1 Transmitting Parameters to the Inova Control Console eee 5 Communication Error Checking on ede elo rr ceret d ae ec ae dae eco e x Rada 5 2 Programming the Cutting Arc Voltage tiet ded vase nda iie re eoo ed beh toe eund 5 2 ks 472 Sen08l Commands 6 utei oet ea en oa eu ctn usine cae E 5 3 Status Bis Description s nonum to a ey ean e o ede Pt pte at a eyes 5 6 ESB Node Representation satria ea er a tea edt AA M X ER ERAN IR GRUT Iced Rat 5 6 Fault Status iioi cardiaco iaaa ibcdiau e ER qva a Vase intei iid te da 5 7 Synchronous Mode oet eoa bo a Decr tente bete booa bate E E a ete 5 7 Section 6 Troubleshooting 27 1s 6 1 Section 7 Parts LISt oe ntt n HP RA AN RR ERE 7 1 Control Consoles oeste eds e e E aids sures oak cory E E Gases Eass 7 1 Remote COO sso ood isa nied onmi r a oa t Rotam aa aeeai 7 3 POSIBIOBEE ass cas tes E A a E S E T T ETE 7 4 CA E I E EAE EE E EE E EAT EEE m TEC 7 6 Be CADIS T arao e Aaaa aiara 7 7 SES Cable bestens tones tesi e dv ER e diva E qu c divides 7 8 Do er TTE 7 9 TESAC ODIO ecoute Rett a ere E AE ee Tem DTS Co ice Ee ac AE 7 9 ps M tn 7 10 uou oco sep I 7 1 posco m 7 12 SARS AN sa dons cusa nec E d EE AM uU EAE 7 13 ge oci e Cc 7 14 K Cable p 7 15 Control Console Microprocessor P C Board sssssssssssseeeeeeeen enne 7 16 H Br
7. 3 9 Interface Cable Installation xc de eye iste oe e e EO LR EN Te RU RE 3 10 Section 4 Operation oo oi ot en ete iban ooa 4 1 Operating Controls nossa ssa re ase E in n A SA AA AEE AERE AAA eee ids 4 1 Remote Control Rud Screen iussit ie a e i a ed ie i an e aec dave a nia 4 2 Remote Control Menu Screen e oo e ptam oso ce ede dona pesa etna bles depre ARI pep sa ANDE Nes ebUud 4 3 Remote Control Edit Screen eed abdidit oae itu asas 4 4 Remote Control Maintenance Sereen 2 aie cadere e S TVNTO seti ho ep noe i Te eee 4 5 Remote Control Crossover Height Screen iie adeste ended ba e Esp EAUI REUS ING E Sd ds 4 6 Remote Control Contrast Screen eese n otia ie esti ee of MER Seen 4 7 Remote Control Status LED s Screen 00 0 0 ccee cc ccccssccceessececeeesscececeesseeeceeseeeceesssseeeesesaeeeenes 4 8 SEQUENCE OF ODET ALON 2o oeste ond de hos eet pe tbt a roni dete ees ea lula asad a d bap ertoneae 4 9 Initial Sepe e eto tp tole ee a ee rem e qs se es Seale Poe ada Aa dE 4 10 Pre UD Sebup oe tias eec aaa uv baci audi s utet base nn sa ous E 4 12 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR Inova User s Manual Rev K Section 5 Serial Communication lec cece cece sss 5 1 Initializing The Inova Control Console
8. The system returns a Low Motor 1 6A fuse blown Voltage error 2 Bad Microprocessor p c board check the Motor Voltage LED on the Microprocessor p c board If it is illuminated replace the Microprocessor p c board If it is not illuminated check the 12V LED on the H Bridge p c board If it is illuminated check the continuity from P24 pins 8 and 9 on the H Bridge p c board to P18 pins 16 and on the Microprocessor p c board If the wires are good replace the H Bridge 3 Improper H bridge voltage if the 30V and 12V LED s are not illuminated on the H Bridge check for 20VAC between P25 pins 3 and 4 on the H Bridge p c board If there is 20VAC between P25 pins 3 and 4 and the 30V and or the 12V LED s are not illuminated replace the H Bridge If the 20VAC voltage is missing check for 120VAC and 20V AC on the motor transformer TR1 If 20VAC is present on the secondary of TRI check for continuity between TR1 and P25 on the H Bridge The system returns an Over Current 1 Faulty Microprocessor p c board check the error Over Current LED on the Microprocessor p c board and the OC LED on the H Bridge If neither LED is illuminated replace the Microprocessor p c board 2 Positioner is binding clean and adjust the positioner 3 Brake is not turning off check the Brake Off LED on the Microprocessor p c board It should illuminate while the positioner is This information is subject to the cont
9. e Electrically both the X and Y drive axes should be adjusted to specifications to reduce any overshoot or vibration when the machine is being moved e The Inova is a high gain electrical system that requires specific grounding procedures This is necessary to ensure that stray electrical noise or high frequency noise does not interfere with its normal operation The ground stud located on the side of the control console should be connected directly to the point known as star ground This is generally referred to as the common ground point on the cutting table where all subsystems of the machine are grounded This point is then connected to a driven earth ground which should be near the star ground The ground rod should be at least 3 4 inch in diameter and should be driven into the earth s permanent moisture layer The length of this ground rod varies from installation to installation This ground rod should have been installed during the installation of the machine Please refer to the National Electrical Code Article 250 Section H Ground Electrode System or other appropriate codes e Please see page 2 10 for cnc machine interface signals This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 2 Overview Inova User s Man
10. orANGE 15 16 K BLACK 16 1 f X RED 1 2 XJ BLACK 709018 SOCKET 22 1 709098 SOCKET 23 f 4 RED NC WHITE NC 709098 SOCKET 24 f 4 RED NC 709018 SOCKET J GREEN NC 709019 KEY 7 TOTAL SOCKET COUNT 35 THE B CABLE PART NUMBER IS 711710 X WHERE X IS THE LENGTH OF THE CABLE IN FEET This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 7 Parts List Inova User s Manual Rev K C Cable 711715 X CONSOLE POWER SUPPLY P3 9 POS 3 O STRAIN RELIEF 709015 PLUG 709016 CABLE 711001 TERMINAL POSITION NO COLOR POSITION NO TERMINAL 709018 SOCKET 1 RED Xxx ONE 2 a BACK XX 7 3 WIET xX 4 T BLACK XX B sem i 5 CREEN lt XX 709018 SOCKET 6 JJ BLACK XX NONE e 709019 KEY TOTAL SOCKET COUNT 8 THE C CABLE PART NUMBER IS 711715 X WHERE X IS THE LENGTH OF THE CABLE IN FEET INSTALL THE FOLLOWING PLUG WHEN USING A KALIBURN POWER SUPPLY
11. 2 Remove the limit switch p c board item 7 by removing the upper and lower 4 40 X 1 2 socket head screws from the p c board The middle screw should not be removed Use a 3 32 hex wrench to remove the screws Note If the screws need to be replaced do not use screws longer than 1 2 Longer screws will hit the internal carriage assembly Encoder Replacement 1 Remove the strain relief from the positioner plug P10 Using an extraction tool push out pins 8 through 14 on P10 2 Remove the 2 encoder shaft coupling set screws using a 1 5mm hex wrench Note If one or both of the set screws are not accessible and the positioner cannot be moved electrically it will be necessary to rotate the shaft manually until the screws are accessible This is done by removing the bottom plate of the positioner item 15 and rotating the inner bearing nut item 14 3 Remove the 2 4 40 X 5 16 hex head encoder mounting screws using a 3 16 open end wrench and slide the encoder off of the motor shaft Motor Removal 1 Remove the strain relief from the positioner plug P10 Using an extraction tool push out pins 1 and 2 on P10 2 Using a 3 16 hex wrench remove the 3 8 16 set screw from the front part of the top housing item 25 This will expose the motor ball screw flexible coupling item 4 3 Using a 7 64 hex wrench remove the 4 6 32 X 1 3 4 screws that hold the bottom plate item 15 to the main extrusion Remove the bottom plate an
12. Beyond this remedy KALIBURN will not be responsible for any special incidental or consequential damages or injury to the person or property of anyone by reason of any defect in any equipment sold hereunder Returned Goods Procedure KALIBURN utilizes a returned goods procedure which must be followed before returning any items for repair replacement or restocking This means that a returned goods authorization number must be obtained prior to shipment to KALIBURN It will be necessary for the customer to provide a description along with the stock number and serial number if applicable of the item to be returned In no case will a returned shipment be accepted by KALIBURN without the proper returned goods authorization number This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR Inova User s Manual Rev K TABLE OF CONTENTS Section 1 Specifications sse 1 1 System DESCHDLUOP S sono docte neta tacite pepe c gd o d ete ortas te Diu e ad RT a 1 1 Safety dau cc stad e SN coe M certe o Ettore su os ees rede 1 1 System Components 1958 Rees eso e ot eie eiie e SE e m 1 1 Specifications soo onai ran iod e Uva Hat etna iiec aUa deti E a b etna uda hype deas da Eua baa 1 2 Section 2 Overview 4 eene tentent ttent
13. Remote or Power Dual Console Network Divider Supply RS 422 Quick Connect RS 422 ld p D Cable K Cable This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 4 Overview Inova User s Manual Rev K Quick Connect Dual System Configuration The dual system configuration is two systems using the basic configuration with the addition of a dual quick connect cable The dual quick connect cable provides an easy way of interfacing two Inova systems for synchronous cutting B Cable Precision Plasma C Cable Power Supply CNC Controller Electrode RS 422 F Cable Power Supply Machine Motor Drive Interface Interface Cable Inova Control Console Voltage Remote or Power Dual Console Network Divider Supply RS 422 Quick Connect RS 422 D Cable A Cable Cable 3 RS 422 RS 422 Inova J Cable Remote BE Cable Precision Plasma C Cable Power Supply Electrode RS 422 Plate Contact Power Supply Machine Motor Drive Interface Interface Cable Inova Control Console E Cable Remote or Power Dual Console Network Divider Supply RS 422 Quick Connect RS 422 L LJ D Cable A Cable Cable 3 RS
14. check the continuity of the D cable Logic and Logic wires If the cable is good check the continuity from P2 to P13 on the Microprocessor p c board If the voltage divider LED is off check for 120VAC to the voltage divider If the 120VAC is good disconnect the wire connected to the Pilot Arc terminal on the voltage divider If the LED now illuminates check the Pilot Arc wire for shorts to ground If the LED still does not illuminate when the Pilot Arc wire is removed and the 120VAC is good replace the voltage divider No plasma torch arc initiation 1 The system is in IHS Test mode switch to THS Run 2 Faulty plasma start relay on the Microprocessor p c board check for contact This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 5 Troubleshooting Inova User s Manual Rev K closure between P19 pins 1 and 2 on the Microprocessor p c board upon completion of IHS sequence 3 Faulty wiring between P19 pins 1 and 2 on Microprocessor p c board and P3 pins 1 and 2 4 Faulty arc hold relay on Microprocessor p c board check for contact opening between P19 pins 5 and 6 on the Microprocessor p c board upon completion of IHS sequence 5 Faulty C cable check continuity between P3 and power su
15. supply These voltages can be in excess of 300 volts Fatal shock hazard does exist Exercise extreme caution while working in these areas Please refer to the plasma power supply manufacturer s operating manual for additional information Various other safety hazards exist while operating a plasma arc cutting system Please see the plasma power supply manufacturer s operating manual for information on eye skin and hearing protection as well as other information required to safely operate the equipment System Components The Inova System consists of the following components Required Components Inova Control Console Inova Positioner Inova Voltage Divider Torch Clamp Interface Cables Insulating Washers System Manual Optional Components Inova Operator s Remote Control Torch Collision Sensor This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 1 1 Specifications Inova User s Manual Rev K Specifications Control Console Stock NUMBER 26 ol tee cot Pas Pec n 110025 Inp t PO WET e dte tdet de datant qais ad 115VAC 50 60Hz Input C rrent cierren nran no iuba bos 3 Amps oru PE 6 35 in 161 mm ANTO se e s E 15 5 in 394 mm Depth scent Pre Sen Eben Fas Ge adt 12 in 305 mm WISN ee 30 Ib 13 6 kg A
16. udpe P C Board es cst e poe e Ras aeq ted te eos et ena 7 17 Power Distribution P C Board iiuis odeur tene rio recur en ere ie ope e ee aed 7 18 Voltage Divider Filter P C BG ard rose iieri e RR quebec peer encanta ure quse de DIM OG 7 19 Emit Switch Pe Boi dnte eet an ed Moser opt uiae St acc ea 7 19 Remote Microprocessor P C Board eiie eee nsae into euet neto enn Enea nan aoa nd 7 20 Remote Communication P C Board suis tut ien feci e aces Reg Ae FUR QUMERR ON Dea FU SRMU EAE 7 21 Appendix A Error Codes 2 7 sse A 1 Appendix B Dip Switch Settings sss B 1 Control Console Settings dust patrie eda rca a etse dia mu ee Gute dra Med B 1 Remote SeLUBBS curo Su Echo ture cen eed Destaca RU D eL e E ud cid s B 2 Illustrations Figure 1 1 Control Console Mounting Dimensions serere 1 2 Figure 1 2 Remote Mounting Dimensions sssssesseeeeereneeen eene enne 1 3 Figure 1 3 Positioner Mounting Dimensions essere 1 4 Figure 1 4 Voltage Divider Mounting Dimensions sese 1 5 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR Specifications Inova User s Manual Rev K Section 1 Specifications System Description The Inova torch height contr
17. 0096 msb 00 Isb 96 If we were sending the parameter to a console operating on node 5 the following string would be transmitted AA 05 E3 00 96 0D For multiple torch configurations commands may be sent to all torches at the same time This is referred to as a global command For any global command the net node is C8 200 decimal In the example above to send a pierce height of 150 inches to all the consoles in a network the following string would be transmitted AA C8 E3 00 96 0D Sample Windows software is available from KALIBURN for controlling multiple Inova systems from a PC Please contact KALIBURN for further information Communication Error Checking All commands and parameters transmitted to the Inova console will be back transmitted in exactly the same form for error checking Global commands will not be back transmitted Only the console with node focus will back transmit a command in a multiple torch configuration The purpose of node focus is to only allow one console to use the transmission lines at a time If no node focus is set on initialization the first console node to receive a command will receive node focus automatically Commands and parameters may be given to consoles without node focus but there will be no back transmit since that console s transmission lines are disabled The Set Crossover Height command and the Send Status Bits command do not back transmit since they cause another parameter to be back tran
18. 422 RS 422 Inova Remote This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 5 Overview Inova User s Manual Rev K Simplified Dual System Configuration In the simplified dual system configuration a CNC or PC Host initializes and edits parameters of the two consoles and power supplies The dual console quick connect cable relieves the CNC or PC Host Controller from the task of torch synchronization See Appendix B for net node settings CNC G Cable Controller Precision Plasma C Cable F Cable B Cable Power Supply Power Supply Machine Motor Drive Interface Interface Cable Inova Control Console Electrode RS 422 Plate Contact Voltage Remote or Power Dual Console Network Divider Supply RS 422 Quick Connect RS 422 lj D Cable K Cable J Cable Precision Plasma C Cable Power Supply Q Lond Lal Power Supply Machine Motor Drive Interface Interface Cable Electrode RS 422 Plate Contact E Cable Inova Control Console Voltage Remote or Power Dual Console Network Divider Supply RS 422 Quick Connect RS 422 PO Gm D Cable K Cable This information is subject to the controls of th
19. AA nn F3 0D Sets programmed arc voltage to actual Present Operating Voltage feedback value Stores previous arc voltage so it can be retrieved with 244 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 4 Serial Communication Command Set IHS Touch Speed Set Arc Voltage to Present Operating Voltage Set Arc Voltage to Previous Value Synchronous Mode Multiple Systems Only Request Parameter Parameter Value Power Supply Command Cycle Start Corner Height Freeze Partial Raise Enable 244 247 248 249 250 251 252 253 Hex String AA nn F2 0D AA nn F3 0D AA nn F4 0D AA C8 F7 0D AA nn F8 0D AA nn F9 0D AA nn FA 0D AA C8 FB 0D AA C8 FC 0D AA C8 FD 0D Inova User s Manual Rev K Additional Information Speed in inches per minute Valid Range 0 to 99 default 40 Sets programmed arc voltage to actual feedback value Stores previous arc voltage so it can be retrieved with 244 Sets programmed arc voltage to value stored with parameter 243 Valid nodes in LSB See LSB Node Representation Number holds which parameter to send via parameter 249 according to the following 1 Se
20. COLOR POSITION NO TERMINAL 709018 SOCKET 1 X RED 8 709018 SOCKET 2 L BLACK 3 2 3 f t WE 9 4 K BLACK 2 5 f X GREEN 7 709018 SOCKET 709018 SOCKET 7 pue BLACK NC 709019 KEY 8 TOTAL SOCKET COUNT 12 THE G CABLE PART NUMBER IS 711735 X WHERE X IS THE LENGTH OF THE CABLE IN FEET This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 11 Parts List Inova User s Manual Rev K H Cable Assembly 711740 X NETWORK CONSOLE 2 NETWORK CONSOLE 1 P6 9 POS Pu 7 POS STRAIN RELIEF 709015 STRAIN RELIEF 709015 PLUG 709016 CABLE 711001 PLUG 709208 TERMINAL POSITION NO COLOR POSITION NO TERMINAL 709018 SOCKET 1 X RED 1 709018 SOCKET 2 BLACK 2 9 3 6 WHITE 3 4 BLACK 4 5 GREEN 5 709018 SOCKET 7 Tae BLACK NC 709018 SOCKET 709019 KEY 8 TOTAL SOCKET COUNT 12 THE H CABLE PART NUMBER IS 711740 X WHERE X IS THE LENGTH OF THE CABLE IN FEET This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or tra
21. If this cable is used the G cable is not required G Cable This cable connects the control console to the CNC controller provided that the CNC controller is communicating with the Inova system via RS 422 serial communication link If this cable is used the F cable is not required H Cable This RS 422 serial communication cable connects one control console in a multiple system network to another control console This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 10 Installation and Maintenance Inova User s Manual Rev K I Cable This RS 422 serial communication cable connects the power supply to the remote provided that the power supply is capable of transmitting and receiving serial data via RS 422 communication link J Cable This dual console quick connect cable is used to connect two consoles in a multi torch installation It is used as an easy way of connecting two systems for synchronous cutting K Cable This RS 422 communication cable connects the power supply to the control console provided that the power supply is capable of transmitting and receiving serial data via RS 422 communication link and the Inova system is being operated without a remote control unit Power Cabl
22. Pwm LED s should illuminate when the down button is pressed If the LED s don t illuminate check the Up and Down LED s on the Remote Microprocessor p c board If they are working properly check the receive and transmit LED s on the Remote Microprocessor p c board Remote Comm p c board and Console Microprocessor p c board Ifthe receive transmit LED s work inside the remote but not in the console check the A cable and internal wiring from P5 to P15 on the Microprocessor p c board 7 Ifthe Up Up Pwm Down and Down Pwm LED s work correctly on the Microprocessor p c board check the same LED s on the H Bridge p c board If the LED s illuminate This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 1 Troubleshooting Inova User s Manual Rev K correctly on the Microprocessor p c board but not on the H Bridge p c board check for open connections on these 4 wires between the Microprocessor p c board and H Bridge p c board If the LED s don t work correctly on the H Bridge p c board check the 12V Ext LED on the H Bridge p c board If it is not illuminated check the 12V LED on the Microprocessor p c board If the 12V LED is illuminated on the Microprocessor p c board and the 12V Ext LED is not illuminat
23. Tra ae je Or T T T Is 8en S J 09N H NI YOM MS zx o azai Ten S l S99 ANa 799 amp sex TTTTT dia Lod was wall OL memes 3 e 199 93 amp 099 28 smn EAE E sa p A 4883 Fr asas een Lat 9c3 a Iyd ecco O s saco oen Z85 al ei eB 1 a osu 4 H nO La La En sn oa TI 4 L ssa LIT vse Bat TS Has LIKIT w34an 849 E Tn sid 2 amp 5 o Isr Ly2 2 ese Q sro D Yra Ed van pu it s amp ES 2v3 n aaa esa J im Oo 4 Tea ip a407 OF 2 asm i23 EC Lod ein 0S F X 24 8 9 P B 1 3 ezan j Tq qo A 6r8 2 Lerat amp wl gt O Noro seo Tt s ll 7 ig on oa a vin zza 21 jme eea ees 1 Sra H Aavis ink lNVIS 319429 OED B 3142 a r S Ce 29 t gn rar Du T d 9N a m7 T A Cre AUR ep eia 35VL7IDA IAY 4 L c29 Eg gg 82 Coral pe ein eu Oosa C3 an P en SA gn LII o Ce 7 929 ul A m ia Lut E AR cou 775 a SA poor geest era 1 ing aval Lee eea t n an en 8 pip ej TT TT resh iea FH 25 ry sy eee Es on F9 cn yn 029 6n LT Du 813 Qa ee q F 1ND dno SHE i aS sleep EI oO A 4 H ano 4 mo S S S DS BRIRIBISI aS EJ via 4 H sina Nit aa ana ane La La La La T T TTTTTTTTT O gb 2 g i 4 F SH d k 23037 m PD v8 gm si Wa Ta or 69 She O amp m 82 yori O C O CH day ora TM SII ZA vid etd 98 eld TIT EN OTI SY 6c 8d 8 39 S2 WA 3x WAd dn NADI HA NO 43 Svea unoxny LnDXnv oan x E en a CO Scu UAE C z 2 L E 4 E eu 7 es eB ino dWO9 31949 va Ann dn3 EE L yi eat aaa Mami ost bast sam Zo
24. cable supplies power to the Inova remote as well as an RS 422 serial communications link between the remote and the console B Cable This cable connects the control console to the torch positioner C Cable This cable connects the control console to the power supply D Cable This cable connects the control console to the voltage divider printed circuit board located in the power supply E Cable This cable connects the ground stud located on the side of the control console to star ground on the cutting table The star ground point is where all subsystems are connected to the cutting table including the work ground lead of the plasma power supply There should be one cable connected from the star ground point to the driven ground rod It is extremely important that the E cable and the plasma power supply work ground lead are both connected to the star ground point The E cable is not a safety ground It is part of the voltage feedback circuit used for arc voltage control Also before installing the E cable make sure that the control console is isolated from the cutting machine using the insulation washers provided See the Control Console Installation instructions in this section F Cable This cable connects the control console to the CNC controller provided that the CNC controller is not communicating with the Inova system via RS 422 serial communication link The keyed plug connects to the console
25. p c board No positioner movement when initial 1 The system is in Manual mode switch to pierce height should be set Auto 2 The system has not received a cycle start command check the Cycle Start LED on the Microprocessor p c board and or the remote control unit 3 The plasma power supply motion contacts are continuously closed check the Motion In LED on the Microprocessor p c board Incorrect pierce height setting 1 The pierce height setting on the remote is incorrect 2 Faulty plate sensing circuit check the Plate Sense LED on the Microprocessor p c board and or remote control unit It should be illuminated until the torch touches the plate at which time it should go out If the plasma torch has no plate sensing member switch to the remote control Maint screen and disable the CTP feature If the torch has a plate sensing member check the LED on the voltage divider It should also be illuminated until the torch touches the plate at which time it should go out If it is illuminated check the This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 4 Troubleshooting Inova User s Manual Rev K continuity of the D cable Logic and Logic wires If the cable is good check the continuity from P2 to P13
26. the chassis ground stud is free from any corrosion Remove power to the Inova system and remove the cover of the remote control unit Verify that all components are securely mounted and verify that all connectors are seated properly Verify that all AMP connectors are tight and secure and check all AMP cable clamps for any exposed wire Collision Sensor Installation The Inova system uses an optional pneumatic collision sensor to protect the torch in the event of a crash The collision sensor is installed between the positioner carriage plate and the torch The collision sensor allows the torch to deflect to the side in the event of a crash A normally closed switch opens upon impact The switch is usually wired to an emergency stop input on the x y machine The following procedure describes the parts and installation steps for the collision sensor 1 Mount the collision sensor to the positioner carriage plate using 6 M3 x 22mm socket head cap screws Use a 2 5mm hex wrench to tighten the screws 2 Mount the torch clamp to the collision sensor using 3 10 32 x 3 4 socket head cap screws Use a 5 32 hex wrench to tighten the screws Be sure the torch clamp is square to the cutting table before tightening the mounting screws 3 The collision sensor is supplied with a 1 8 NPT female pipe thread fitting for the air supply input An adjustable regulated air supply should be used for the input The input air should be supplied at 40 87 ps
27. the main extrusion item 19 Use a 7 64 hex wrench for the 6 32 screws and a 3 32 hex wrench for the 4 40 screws 4 Using a 3 32 hex wrench remove the 2 4 40 X 1 1 4 screws that hold the positioner cover item 27 to the bottom housing item 18 Do not remove the 2 6 32 X 1 1 4 screws that hold the bottom housing to the main extrusion 5 Using a 3 32 hex wrench remove the 4 4 40 X 1 4 screws and washers that hold the belts item 17 to the carriage item 26 6 Remove the belts from the top end of the positioner Note that the outside and inside of the belts are different The steel cable is visible on the inside of the belt 7 Remove the positioner cover item 27 and clean the belt slots in the cover and the main extrusion item 19 8 At this time the ball screw should be wiped off with a clean rag and the ball nut should be re oiled with 3 In One oil To re oil the ball nut remove the 4 8 32 X 1 2 screws that hold the ball nut to the carriage Use a 9 64 hex wrench to remove the screws Rotate the ball nut to one side to find the oiling hole and apply a small amount of oil Reattach the ball nut to the carriage 9 Wipe off the guide rails with a clean rag and apply a light coat of 3 In One oil on the rails 10 Lightly coat both sides of the new belts with 3 In One oil 11 Insert the belts in the slots of the main extrusion body item 19 from the top end Note that the outside and inside of the
28. the torch begins to retract When the torch breaks contact with the workpiece on its way up the Inova positioner quickly positions the torch at the specified pierce height from where contact with the workpiece was lost If the torch plate sensing member is in contact with the workpiece during retraction the torch will continue to retract until the contact is broken or the upper limit switch is reached The CTP circuit ensures that the torch is never in contact with the workpiece when initiating the arc This eliminates dragging the torch along the workpiece and damaging the consumables Secondly it assures the proper starting height above the workpiece for piercing which results in longer consumable life If the torch used does not have a plate sensing member such as a ceramic front end the pierce height can vary and is dependent on the spring back of the material being cut If the torch does not have a plate sensing member pierce height positioning begins when an adjustable force level is sensed between the torch and the workpiece The power supply positive P S and power supply negative P S connections on the voltage divider should be connected to the proper output points of the plasma power supply In general if the power supply used has a chopper control the connections will be made at the output of the power supply If the power supply used is a drooping type power supply and only has a diode bridge then the connection
29. 018 Cut off the four fast on connectors and wire the plug as follows Signal Pin 1 Signal Pin 4 Logic Pin 3 Logic Pin 2 Now connect the cable to the outside of the SR 45i at the P7 plug This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 7 Installation and Maintenance Inova User s Manual Rev K KALIBURN SR 100i Voltage Divider Installation 11 WARNING 1 TURN OFF ALL POWER BEFORE WORKING ON EQUIPMENT 1 Remove the back panel of the SR 100i Four holes are provided in the upper left corner of the inside back panel for voltage divider installation 2 Remove the paint around the lower left hand voltage divider mounting hole This will provide a chassis ground point for the white ground wire on the voltage divider 3 Install the voltage divider with the 4 6 32 X 3 8 screws provided Orient the board so the transformer is in the upper right hand corner of the board Mount the white ground wire under the stand off leg where the paint was removed 4 The SR 1001 has a built in wiring harness for a voltage divider Each of the wires has a label indicating where it is to be connected Connect the wires to their respective terminals on the voltage divider 5 If the D cable supplied with the Inova has fast on term
30. 4 O OO LEE e e oo ar 2 Ca o 5 2 1 wm o6 q M jx iz l 2 r OOOO ha Hu ae o2 AZ oO 1 2a ur Ge Ge QF D In v to E a 3S o NL OS 5 o gt IEI 5 e Ore Ma y 7 B x LH JO I gt DB1 C37 2e Tibet xnv 919 WAd RA U4 C 2ce0 6VAC 12VAC ZMS 1 O DB2 P31 C6 RA3 RA7 RA8 Eie C38C35 C36 W am J E eR 05 9 G29 822 A u gt a Orb s13 e jol Ix L NIE Os ee e 2H T T 4 L 3098 ip d mr 1NI4 E a 0 O Qi T u in jo o9 s BL DEDE Ll We e 22 qe O8 g x ein oo o o j biti N coy 5 tery amp Er T Os amp S PTT d C Co veo 223 9 n muc o Rey Dispersija u 5 Te3 a gt IR cucu e3 c9 amp 9 co 9 313 C E 9 c ov cv vd aed f ad aS i o 1 O EE E a S E Ea Sa aal 3C ESS p Inc o Olmon o O d Maja ja AG ora AgI WAd ZEN xnv O Prete fart CONO dat CHO PLF m es m EN 4 This information is subject to the controls of the Exp
31. A m E5 0D Height in mils inches 1000 Valid Range 0 to 999 Set IHS Touch Force 230 AA nn E6 0D Relative number Valid Range 0 to 200 default 20 Set Crossover Height 231 AA nn E7 0D Height in mils inches 1000 to Absolute Value Valid Range 0 to 9999 Actual Crossover 232 AA m E8 0D Height in mils inches 1000 Height Valid Range 0 to 9999 This value is returned when command 209 is issued Set Retract Delay 233 AA nmn E9 0D Time in ms seconds 1000 Valid Range 0 to 9999 default 9999 9999 Automatic mode Set AVC Delay 235 AA nn EB 0D Time in ms seconds 1000 Valid Range 0 to 9999 9999 AVC Disable Status Bits 236 AA nn EC 0D See Status Bits Description in the following section This value is returned when command 214 is issued Arc Voltage Confirm 237 AA mn ED 0D Arc voltage in volts 100 Used in conjunction Valid Range 5000 to 25000 with 226 Set Proportional 238 AA nn FE 0D Relative number Gain Valid Range 50 to 750 default 250 Release Arc Hold 239 AA C8 EF 0D Valid nodes in LSB Synchronous Mode See LSB Node Representation Proceed 240 AA C8 FO 0D Valid nodes in LSB Synchronous Mode See LSB Node Representation Set Manual Speed 241 AAnn FI 0D Speed in inches per minute Valid Range 0 to 999 default 100 Set IHS Touch 242 AA nn F2 0D Speed in inches per minute Speed Valid Range 0 to 99 default 40 Set Arc Voltage to 243
32. Distribution P C Board Assembly 110700 8L 9L O O O T3 z9 63 94 8 8a M 64 Cay 8d F 8T31 NOW Act WWD 9 SOZOTT Nd ATHW3SSV ADE 00 011 Nd ATEWSSSV ASTI T Ad l 669011 Nd 82d JANVIE ONI SIBI T43NNI S131 JjJregcr ca 8 Za Ca Za 031 84 q291 3IUWN33 Act O S3IDONd Ag raa Ca 8 G va C yd DOWNY Apt eag j ed E A 8 8 93 COE 9031 JAVA Arve NOW 3l1DW33 A9 eag Jrag r TAE WADO 3LDW3N A9 yaa JI tab on a 8 C 2a 8 Ta 8 AOEZ Sn AOE 7ST EL ds Ave JpiVal Ave 121 Waa Ael 021 Waa AT NOW c NOW ei 09 WAR 09 M WOO Waa A9 WAND Waa 9 NOW Waa A9 nal Waa 3 DITWNV Avy aNd DI WNV AYT S3TD2N3 9 SIDON 9 SL el Eed 22d This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 18 Parts List Inova User s M
33. EAR 4 3 Operation Inova User s Manual Rev K 8 Set Man Speed Button Touch this button to edit the Manual Speed on the Edit Screen Manual Speed is the travel speed of the positioner when the up or down push buttons are pressed The Manual Speed can be adjusted from 20 to 999 inches per minute 508 to 25374 mm min but is limited by the travel speed of the positioner The factory default setting is 100 inches per minute 2540 mm min 9 Set Touch Speed Button Touch this button to edit the IHS Touch Speed on the Edit Screen The IHS Touch Speed is the travel speed of the positioner during the IHS portion of the cutting sequence The IHS Touch Speed can be adjusted from 10 to 99 inches per minute 254 to 2514 mm min The factory default setting is 40 inches per minute 1015 mm min 10 Set Touch Force Button Touch this button to edit the Touch Force on the Edit Screen The Touch Force is the amount of torch touch force required to generate a torch retract during the IHS sequence It is used as a backup to the soft touch plate sensing technique and can be adjusted from 0 to 200 Higher numbers cause the torch to press harder on the plate before retracting The factory default setting is 20 11 Maint Button Touch this button to go to the Maintenance Screen Remote Control Edit Screen SET ARC VOLTS 120 0 V 1 Numerical Button Touching a numerical button will place the number in the parameter value at the cursor loca
34. Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 2 Operation Inova User s Manual Rev K Remote Control Menu Screen SE PIERCE HEIGHT 7 8 9 10 11 1 Set Arc Volts Button Touch this button to edit the Arc Voltage on the Edit Screen The Inova system maintains the Set Arc Voltage during a cut in the Auto mode Raising the Arc Voltage will increase the torch height during a cut while lowering it will decrease the cutting height of the torch The Arc Voltage can be adjusted from 50 to 250 volts in 1 volt increments The Inova can also be set to Auto Voltage mode by programming the Arc Voltage to 0 000 volts In Auto Voltage mode the system maintains the actual feedback arc voltage that corresponds to the Cut Height at the time the corner height freeze signal is removed at the start of a cut and the AVC Delay time has expired 2 Set Transfr Height Button Touch this button to edit the Arc Transfer Height on the Edit Screen The Arc Transfer Height is set during the IHS initial height setting sequence and is the height that the plasma torch initiates an arc The Arc Transfer Height can be adjusted from 0 to 999 inches 25 3 mm 3 Set Pierce Height Button Touch this button to edit the Pierce Height on the Edit Screen The torch moves from the Arc Transfer Height to the
35. Node Settings When multiple systems are connected together whether through the quick connect J cable or through the RS 422 H cable each system must have a unique node identification number system 1 system 2 etc Use the following procedure to properly set the net nodes 1 Subtract one from the desired net node 1 to 8 2 Note that each position of SW3 dip switch 3 has a binary value as shown below OFF ON 1 Hi mg SW3 1 binary value 1 SW3 2 binary value 2 SW3 3 binary value 4 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR B 1 Appendix B Inova User s Manual Rev K 3 Turn on the SW3 switch positions whose values add to the net node number minus one For example the above figure shows a console with SW3 2 enabled SW3 2 has a binary value of 2 Therefore the console has a net node value of 3 since 2 1 3 f the desired net node was 4 SW3 should be set so the switch positions totaled 3 since 3 1 4 In this case SW3 1 and SW3 2 would be switched on since SW3 has a binary value of 1 and SW3 2 has a binary value of 2 Dip Switch 4 Options SW4 1 is used for OEM purposes only SWA 2 is used to switch the Inova Remote from Com2 to Coml default Com2 If SW4 2 i
36. OSITION NO TERMINAL 709017 PIN 1 RED 1 709017 PIN 2 XJ BLACK 12 3 O amp WE 3 4 BLACK 4 5 GREEN 5 13 2 BLACK NC 6 BLUE 6 7 k BLACK 7 8 YELLOW 8 9 Lj BLACK 9 14 10 BROWN 10 709017 PIN 11 k BLACK 11 709017 PIN 12 709019 KEY TOTAL PIN COUNT 25 THE A CABLE PART NUMBER IS 711705 X WHERE X IS THE LENGTH OF THE CABLE IN FEET This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 6 Parts List Inova User s Manual Rev K B Cable Assembly 711710 X CONSOLE POSITIONER P104 P069 P10 16 POS STRAIN RELIEF 709230 STRAIN RELIEF 709021 PLUG 709020 CABLE 711206 PLUG 709112 TERMINAL POSITION NO COLOR POSITION NO TERMINAL 709018 SOCKET 3 f X WE 3 709018 SOCKET 4 kK BLACK 4 17 5 fX GREEN 5 6 b BLACK 6 8 BUE 8 9 7 BLACK 9 14 SHIELD i1 14 10 YELLOW 10 11 BLACK tt 12 BROWN 12 15 k BLACK 13 21 15
37. Pierce Height after the Inova receives a motion arc transfer signal from the power supply The Pierce Height can be adjusted from 0 to 999 inches 25 3 mm 4 Set Pierce Time Touch this button to edit the Pierce Time on the Edit Screen The Pierce Time is the time that the torch is held at the Pierce Height When the Pierce Time elapses the torch is moved from the Pierce Height to the Cut Height The Pierce Time can be adjusted from 0 to 9999 mS 9 999 seconds 5 Set Cut Height Button Touch this button to edit the Cut Height on the Edit Screen The torch is moved from the Pierce Height to the Cut Height after the Pierce Time has elapsed but before the AVC arc voltage control mode 1s activated at which time the cutting height of the torch is governed by the Arc Voltage parameter The Cut Height can be adjusted from 0 to 999 inches 25 3 mm Run Button Touch this button to go to the Run Screen 7 Set Raise Height Button Touch this button to edit the Raise Height on the Edit Screen The torch will retract to the Raise Height position at the end of a cut provided that the system is in the Partial Raise mode The Raise Height can be adjusted from 0 to 9 999 inches 253 9 mm D This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the
38. Plate feature If the plasma torch has a plate sensing member this feature should be enabled Otherwise the CTP feature should be disabled 4 ACA On Off Button Touch this button to enable and disable the Automatic Collision Avoidance feature The ACA feature helps prevent torch crashes during a cut 5 PStart Button Touch this button to enable and disable the Power Supply Start feature When enabled the Inova applies a start signal to the plasma power supply Run Button Touch this button to go to the Run Screen 7 Set Cross Height Touch this button to go to the Crossover Height Screen The Crossover Height is the height at which the positioner changes from high speed to slow inch down SID speed during the IHS sequence 8 Set AVC Delay Touch this button to edit the Arc Voltage Delay time on the Edit Screen The AVC delay time is the delay between the removal of a corner freeze signal and the resumption of arc voltage control The AVC delay time can be adjusted from 0 to 9999 milliseconds mS When a value of 9999 mS is entered the AVC mode is disabled D This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 5 Operation Inova User s Manual Rev K 9 Set Retract Delay Touch this button to edit the Retract Delay time
39. R This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 9 Overview Inova User s Manual Rev K Pierce Time The pierce time is the delay between the reception of an arc transfer signal motion signal from the plasma power supply and the transition of the torch from the pierce height to the cutting height Retract Delay The retract delay is the time between a stop command and torch retraction It should be adjusted so the arc is extinguished before the torch retracts at the end of a cut Touch Force The touch force is the force required to initiate torch retract during initial height sensing in the event that the soft touch feature is not triggered The parameter is represented by a relative number between 0 and 200 Larger numbers represent higher touch forces This setting should be set to the lowest value that reliably sets the initial pierce height of the torch If the value is too low the torch will not travel all the way to the plate and the arc will be initiated in the air CNC Machine Interface Signals The following cnc machine signals should be present for any machine that does not use an RS 422 communications link to control the Inova console s Cycle Start Input The Inova requires a relay contact closure on this input to start the cutting sequence Opening the contacts will terminate the cutting cycl
40. T 0 100 uu PIERCE HEIGHT 0 150 PIERCE TIME Q7 00 AWC CUTTING HEIGHT 0 130 O MODE AUTO RAISE PARTIAL IHS RUN The two exterior push buttons are multi functional and perform the following tasks e In Manual mode the push buttons move the positioner up and down When the buttons are initially pressed the positioner travels at 15 inches per minute As the buttons are held down the positioner speed increases to the programmed Manual Speed which is set from the Menu Screen e In Auto mode the push buttons move the positioner up and down until a start signal is applied to the Inova at which time automatic operation takes control After an arc transfer signal has been received from the power supply the push buttons can be used to alter the programmed arc voltage Activating the upper push button increases the arc voltage thus increasing the cutting height of the torch Activating the lower push button decreases the arc voltage thus decreasing the cutting height of the torch e When the Contrast Screen is being viewed the push buttons are used to adjust the contrast of the LCD screen e When the Crossover Height Screen is being viewed the push buttons are used to set the crossover height of the system This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary
41. TON CANCEL CROSSOVER HEIGHT 4 400 Instructions for setting the Crossover Height 2 Set Button Touch this button to set the Crossover Height when the torch is at the desired position 3 Cancel Button Touch this button to cancel the procedure and retain the current Crossover Height setting This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 6 Operation Inova User s Manual Rev K Remote Control Contrast Screen 1 USE THE EXTERIOR BUTTONS TO ADJUST THE LCD SCREEN CONTRAST 2 WHEN AT THE DESIRED CONTRAST MON PRESS THE SET BUTTON CANCEL Instructions for Adjusting the LCD Screen Contrast Set Button Touch this button to set the new desired Screen Contrast 3 Cancel Button Touch this button to cancel the procedure and retain the current Screen Contrast setting Ne Note If the contrast cannot be adjusted or the screen cannot be read dip switch SW2 2 on the remote microprocessor p c board can be switched to the on position to restore the factory default contrast setting This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contr
42. The OD character is the end of command character In the above example if the console receiving the command to switch to manual were on node 1 the following hex string would need to be transmitted AA 01 CA 0D To send a parameter the parameter value needs to be sent as part of the command For example to send a desired pierce height of 150 inches to the console look up the pierce height command in the table You will see the following table entry This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 1 Serial Communication Inova User s Manual Rev K Command Hex String Additional Information Set Pierce Height 227 AA m E3 0D Height in mils inches 1000 Valid Range 0 to 999 Once again AA signifies the start of the command The nn is the appropriate net node to receive the command The E3 227 decimal signifies the pierce height command and the OD is the end of the command The in the hex string is the MSB followed by the LSB of a type int The integer is the value used in the additional information column Thus the is sometimes referred to as the additional information value In the example we wanted to transmit a pierce height of 150 inches 150 mils This value in hexadecimal would be
43. W KALIBURN INOVA Torch Height Control System 115 VAC 50 60Hz Revision K 03 07 2012 Manual Part Number 718057 REVISION This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR Inova User s Manual Rev K Revision History Rev ECO Author Date Description of Change 0 As released 2 E e Changed serial communication protocol e Changed description for avc delay and retract delay 4 e Parts list update Section updates e Section 1 5 g g e Section 7 e Section 3 e Section 5 e Appendix B 6 i 08 04 06 e Section 5 RS 422 Serial Command update Section updates 7 gage f Becton e Section 5 Changed company name to KALIBURN 8 02 25 08 e Added Export Administration Regulations EAR statement 39 i Mere a Added revision History section e Updated Company contact information e Added plug to F Cable G Cable e Updated positioner installation K _ 03 07 2012 page 3 1 only insert bolt head into t slot figure 1 3 too e Positioner stroke adjusted from 9 2 in 234mm to 8 6 in 219mm This documentation may not be copied photocopied reproduced translated or reduced to any electronic medium or machine readable format without ex
44. YELLOW 7 8 L BLACK 8 24 9 4 BLUE 9 10 K BLACK 10 3 ORN 3 4 BLACK 4 709018 SOCKET 19 20 RED XX 20 L WHT XX 20 I 21 RED XX 21 CRN XX 709018 SOCKET 21 T 709019 KEY 11 17 TOTAL SOCKET COUNT 34 THE J CABLE PART NUMBER IS 711750 X WHERE X IS THE LENGTH OF THE CABLE IN FEET This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 14 Parts List Inova User s Manual Rev K K Cable Assembly 711755 X CONSOLE POWER SUPPLY RS 422 PORT P5 14 POS STRAIN RELIEF 709015 STRAIN RELIEF 709025 PLUG 709024 CABLE 711001 PLUG 709016 TERMINAL POSITION NO COLOR POSITION NO TERMINAL 709017 PIN 3 RD 3 709018 SOCKET 4 BLACK 2 12 1 1 X WE 5 2 K BLACK 4 5 GREEN 1 709017 PIN 13 MM BLACK NC 709018 SOCKET TOTAL PIN COUNT 7 TOTAL SOCKET COUNT 5 THE K CABLE PART NUMBER IS 711755 X WHERE X IS THE LENGTH OF THE CABLE IN FEET This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United Sta
45. age is automatically increased any time contact is sensed between the torch and the plate provided that the CTP function is enabled If the torch contacts the plate while a Corner signal is applied the torch retracts to the programmed Cut Height provided that the CTP function is enabled This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 9 Operation Inova User s Manual Rev K 19 When the Cycle Start signal is removed from the Inova the Retract Delay timer is initiated 20 When the Retract Delay timer elapses the torch retracts to the Full Raise or Partial Raise Height depending on the Partial Full switch setting Note that if the power supply Motion signal is controlled by transferred arc current the Retract Delay timer should be set to 9999 mS In this case the torch retracts at the end of the cut as soon as the arc is extinguished 21 When the torch reaches the correct Retract Height the Cycle Complete signal is issued to the x y machine Manual Mode 1 The Cycle Complete signal is continuously issued to the x y machine in Manual mode The torch must be manually positioned to the desired pierce height The CNC control issues a Cycle Start signal to the Inova A Plasma Start signal is issued to the power supply W
46. alization is simple Apply power to the console wait at least two seconds then transmit the desired pierce height cutting height arc voltage and arc voltage confirmation and the console will be ready for operation All other parameters have default values on startup and may be changed at any time Transmitting Parameters to the Inova Control Console To transmit parameters to the Inova control console convert the following hex strings to 8 bit binary arrays AA 10101010 and transmit them using a 9600 baud RS 422 serial communication port The port settings should have a start bit one stop bit and no parity RS 422 commands and descriptions are given in a table in this section This table contains the necessary hex strings for sending different commands and parameters to the console For example to switch from AUTO mode to MANUAL mode look up the command for switching to MANUAL You will see the following table entry Command Hex String Additional Information Switch to Manual 202 AA nn CA 0D None Note that spaces in the command string are shown for clarity only and should not be sent as part of the command A command string always begins with the value AA hex 170 decimal The nn is the value of the net node to receive the command The net node value of a console is set by console dip switches See Appendix B for net node dip switch settings The value CA 202 decimal is the value that signifies the switch to MANUAL mode command
47. amp 2 3 16 Torch clamp 2 1 4 Free bearing block Bearing Brake bracket Top housing Carriage assembly Cover Receptacle 16 position Strain relief This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 4 Parts List Inova User s Manual Rev K ra d ii a 00 T o Ej le e Ei e LJ BR 07 CA 6 ITE o0 Ca 9 i E 11 ET O9 el EHO OQ ESTE E 4 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 5 Parts List Inova User s Manual Rev K A Cable Assembly 711705 X CONSOLE REMOTE P5 14 POS P20 14 POS STRAIN RELIEF 709025 STRAIN RELIEF 709025 PLUG 709024 CABLE 711002 PLUG 709024 TERMINAL POSITION NO COLOR P
48. and 214 Send Status Bits is transmitted to the Inova console parameter 236 Status Bits is returned The status of the system is returned in the following format MSB LSB 00110110 01110101 Sync Reset 7 L Motion In IHS Complete e Motion Out Limit Enabled End Travel CTP Enabled In AYC AGI Enabled In Limit IHS Run In Comer Partial Raise Cycle Complete AUTO Start Applied LSB Node Representation Use the following LSB node representation to control which console nodes respond to a given command A set bit indicates that the node will activate the command A cleared bit indicates that the node will deactivate the command LSB 01110101 L Node 1 Node 2 Node 3 Node 4 Node 5 Node 5 Node 7 Node 8 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 6 Serial Communication Inova User s Manual Rev K Fault Status When Fault Status parameter 18 is requested under command 248 the following faults are returned with command 249 A 1 indicates that the fault has occurred Bit 0 0x0001 Start signal received before control initialized Bit 1 0x0002 Low motor voltage Bit 2 0x0004 Over current Bit 3 0x0008 Motion signal when start applied B
49. anual Rev K Voltage Divider Filter P C Board Assembly 110800 INNERLOGIC INC dj DO OR DiD OOO Oo o N eo wd S o Zz n Y Zz lt 1 m ASS Y PN 110800 Limit Switch P C Board Assembly 110500 INNERLEGIC Sv CEDI RED assy 110500 D1i r SEE R F isco GRN BLANK 110499 LIMIT amp O BLK WHT ae E L1 LI pee n su gt ce ca c4 sya Ap lwr RED CS 4 Le I 4 L3 De rm EN COMPONENT C6 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 19 Parts List Inova User s Manual Rev K Remote Microprocessor P C Board Imperial Assembly 110300 Metric Assembly 110305 OOEOTT Nd A 8W3SSV u TAJA 66201 Nd 43d ANV1E 258S ve ONT QIDUTM3NNI LHST OWE os 2 15 o 8 i OQ s S in H ToT ae y Z elJ WOO S dN NAOC EH ei g EIA 92A E 4 L 4 L E eki S2
50. ary to the requirements of the EAR 4 7 Operation Inova User s Manual Rev K Remote Control Status LED s Screen MOTION IN PLATE SENSE START O O O MOTION OUT LIMIT MOTOR VOLTAGE O O END TRAVEL CORNER OVER CURRENT e O O VIEW LEDS ERROR CODE 0 1 Status LED s e Motion In Indicates that the Inova has received an arc transfer signal from the plasma power supply e Motion Out Indicates that the Inova has transferred a motion signal to the x y machine e End Travel Indicates that the positioner has reached the upper or lower limit switch e Plate Sense Illuminates when the torch clears the plate Extinguishes when the torch touches the plate e Limit Indicates that the Inova is in the Limit mode AVC mode is disabled while the Limit mode is active e Corner Indicates that the Inova has received a corner signal from the x y machine AVC mode is disabled while the Corner is active e Start Indicates that a cycle start is applied to the Inova e Motor Voltage Indicates that the Inova console motor voltage is satisfactory e Over Current Indicates that the motor is drawing excessive current 2 Error Code If more than one error exists each error code will be displayed for a brief period of time See Appendix A for a list of error codes Run Button Touch this button to go to the Run Screen 4 Maint Button Touch this button to go to the Maintenance Screen 0S This information is subject to the
51. ations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 8 Overview Inova User s Manual Rev K Corner This feature allows the arc voltage control to be disabled while cutting It is used to prevent the torch from diving into the workpiece during corners when initially piercing a heavy plate or any other time the x y machine speed decreases below the programmed cutting speed Crossover Height The transition from high to low speed during initial height sensing takes place at the crossover height This height should always be at least two inches above the plate to avoid damaging the torch Cutting Height The cutting height is the height the torch is moved to after the pierce time has elapsed and before the AVC mode is activated in which case the cutting height will be governed by the arc voltage setting Cycle Complete In Auto a cycle complete contact closure indicates that the torch has reached the correct retract height at the end of a cut In Manual the cycle complete contacts are always closed Full Partial Raise The torch can be programmed to retract to the top of the travel or to a programmable partial raise height at the end of a cut The partial raise height is adjustable in increments of 001 inches IHS Test Run IHS run is the normal cutting mode of the system IHS test allows the initial pierc
52. belts are different The steel cable is visible on the inside of the belts 12 Place the positioner cover item 27 in position and loop the belts around the top and bottom belt guides item 16 13 Feed the belts into the slots formed between the positioner cover and main extrusion and re attach both ends to the carriage using 4 40 X 1 4 socket head screws and washers Apply thread locking compound to the 4 40 screws and lightly tighten them so as not to deform the belts Be sure to use the washers between the belts and the 4 40 X 1 4 socket head screws Use a 3 32 hex wrench to tighten the screws 14 Reassemble the positioner in the reverse order Remote Installation The remote should be mounted securely to the operator s workstation Refer to Figure 1 2 for the remote mounting dimensions Ensure that the chassis ground stud on the back of the remote box is connected to work ground See Section 4 for more information on the remote control unit This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 3 Installation and Maintenance Inova User s Manual Rev K Remote Maintenance Keep the remote touch screen free from any smears or debris by wiping it with a damp cloth A mild window cleaner can be also be used Verify that
53. bject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 1 3 Specifications Positioner Stock Number S model Stock Number HD model Height eee deret Width iacens Depth cete tese Weight o eic ds STOKE scies nid Capacity HD model Capacity S model E 7 82 199 19 59 498 i 12 69 322 UPPER LIMIT SWITCH 4 06 103 LOWER LIMIT SWITCH Inova User s Manual Rev K ORTE EEEE 110030 EEE 110031 O AEE EE EE 27 5 in 699 mm E E EEE 4 4 in 112 mm tides E E 2 6 in 66 mm RT NE E 15 Ib 6 8 kg E E DRM 8 6 in 219 mm E E ve I EA 50 lb 23 kg AAE AE ERA ARE EE E 25 lb 11 kg TOP VIEW NOTE T SLOTS ACCEPT 1 4 HARDWARE ONLY INSERT BOLT HEAD INTO T SLOT 3 76 96 64 16 2 68 68 2 58 66 4 53 115 TOOL f COLLISION SENSOR TORCH CLAMP Torch Clamp Size Dimension A 1 3 8 5 72 145 mm 1 195 5 81 148 mm 1 3 4 5 93 151 mm 1 15 16 6 03 153 mm 97 6 03 153 mm 2 3 16 6 13 156 mm 2 145 6 16 156 mm Figure 1 3 Positioner Mounting Dimensions This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States
54. contrary to the requirements of the EAR 1 4 Specifications Inova User s Manual Rev K Voltage Divider SIOCICINUITDEE e iue defeat nesies 301200 LSS it ac uec eei ois ae ess ebbe deett sd 2 00 51 mm ME 5 ahi cadences cage odd M OA 4 65 118 mm CLT S cete Lei deat saegtace 3 75 95 mm A SIDI fe socer d RUNG d REN dens 6 oz 2 kg Division Ratio sean URN ra eir dy aee Rd 1 40 NEED ERR e PILOT ARC Bog PS RETAINING CAP CHASSIS GROUND WIRE 3 35 85 3 75 95 SIGNAL 120VAC 4 25 108 Note Overall height is 2 00 51 mm including standoffs and components Figure 1 4 Voltage Divider Mounting Dimensions This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 1 5 Overview Inova User s Manual Rev K Section 2 Overview Features The Inova System comes standard with the following features e Fully programmable via RS 422 serial communication or from the optional operator s remote control with touch screen interface Position control precision of 0001 inches Arc voltage control resolution of 1 volts Maximum fixed position arc voltage control error of 4 volts Software DSP digital signal processing servo control loop Maximum torch retract speed of 600 inches per minute Init
55. controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 8 Operation Inova User s Manual Rev K Sequence of Operation Automatic Mode 1 The CNC control issues a Cycle Start signal to the Inova 2 The Cycle Complete signal is removed from the x y machine 3 If AGI automatic gas initiator is enabled a Plasma Start signal and an Arc Hold signal are issued to the plasma power supply to start the gas preflow sequence 4 The torch travels towards the plate at rapid speed and switches to the IHS Touch Speed when the Crossover Height is reached The torch touches the plate at the IHS Touch Speed 5 If CTP clear the plate is enabled the torch immediately retracts to the Arc Transfer Height when ohmic contact is sensed between the torch and the plate If CTP is disabled the torch presses down on the plate until the Touch Force value is reached at which time the torch retracts to the Arc Transfer Height Note that if CTP is disabled the Arc Transfer Height cannot be reliably set because the exact position of the plate is unknown 6 If AGI is enabled the Arc Hold signal is removed from the power supply and if AGI is disabled a Plasma Start signal is issued to the power supply 7 The power supply initiates an arc and the Inova receives a Motion signal arc transfer si
56. ct voltage divider ratio verify that the output on the Signal and Signal terminals is 1 40 the voltage on the P S and P S terminals Plasma torch dives into workpiece when machine motion occurs mous This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 6 Troubleshooting Plasma torch dives into workpiece when the x y machine traverses a corner or slows down Upon arc transfer plasma torch goes out and the torch retracts Plasma gas flows as soon as the Inova begins the IHS sequence and the arc fires before sequence is complete Torch oscillates up and down while cutting in AVC mode Torch will not follow warped plate while cutting any Inova User s Manual Rev K Faulty E cable connection verify that the E cable is connected from the control console ground stud to the star ground on the cutting table No corner height freeze signal from x y machine to the Inova check the Corner Freeze In LED on the Microprocessor p c board and or the remote control unit The system lost the cycle start signal switch to the remote Maint screen and depress the PStart button If the plasma arc transfers correctly the problem is with the x y machine cycle start signal If the arc still does not transf
57. d rotate the inner bearing nut item 14 until the motor ball screw coupling screw is aligned with the 3 8 16 screw hole 4 Loosen the motor ball screw coupling set screw with a 3 32 hex wrench 5 Using a 3 32 hex wrench remove the 2 4 40 X 1 4 screws that hold the limit switch cover item 10 to the top plate item 3 6 Using a 7 64 hex wrench remove the 4 6 32 X 1 3 4 screws that hold the top plate item 3 to the top housing item 25 7 Remove the motor and top plate item 3 from the top housing item 25 8 Using a 7 64 hex wrench remove the 4 6 32 X 3 8 screws that hold the top plate item 3 to the motor Note Use thread locking compound when reinstalling the motor mounting screws This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 2 Installation and Maintenance Inova User s Manual Rev K Belt Removal and Replacement 1 Remove the motor from the positioner See Motor Removal in this section 2 Using a 5 32 hex wrench remove the 6 10 32 X 1 2 screws that hold the carriage plate item 6 to the carriage item 26 3 Remove the top housing item 25 by removing the 2 4 40 X 1 1 4 screws and the 2 6 32 X 1 1 4 screws that hold the top housing to the positioner cover item 27 and
58. e Corner Freeze Input The Inova requires a relay contact closure on this input to disable arc voltage control during automatic operation The corner relay contacts should close any time the x y machine speed decreases below the programmed speed Partial Raise Enable Input The Inova requires a relay contact closure on this input to enable the torch to retract to the programmed partial raise height Opening the contacts disables the partial raise feature and causes the torch to retract to the full raise position Disabling the partial raise feature is useful when the x y machine traverses across large distances If this signal is not used switch SW4 3 x y raise disable should be switched to the on position Motion Output With control console microprocessor p c board switch SW2 3 in the OFF position the Inova provides a relay contact closure on this output as soon as it receives a motion signal from the power supply With SW2 3 in the ON position the Inova provides a relay contact closure on this output after it completes the pierce delay time and moves the torch from the pierce height to the cutting height See Appendix B Cycle Complete Output In Auto the Inova provides a relay contact closure on this output when the torch has retracted to the programmed raise height at the end ofa cut The contacts are always closed in the Manual mode This information is subject to the controls of the Export Administration Regulations EAR Th
59. e The power cable supplied with the Inova system must be connected to a 115VAC source Connect the brown wire of the power cable to 115VAC hot the blue wire to 115VAC neutral and the green yellow wire to ground This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 11 Operation Inova User s Manual Rev K Section 4 Operation The Inova must be operated from the optional remote control unit or from an x y machine via RS 422 serial interface See Section 5 for information on transmitting parameters to the Inova via RS 422 serial communication The following sections describe operation of the Inova system when using the optional remote control unit If the remote control is not used see the x y machine manufacturer s documentation for operating instructions The remote control unit is available in metric and imperial formats Switch SW2 on the control console microprocessor p c board must be set according to which remote control is being used See Appendix B for further information on setting switch SW2 Operating Controls The Inova remote control is equipped with a touch screen user interface item 1 and two exterior push button switches items 2 and 3 ACTUAL ARC VOLTAGE 000 0 SET ARC VOLTAGE 120 0 vac ARC TRANSFER HEIGH
60. e Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 6 Overview Inova User s Manual Rev K Network Configuration In the network configuration a CNC or PC Host initializes and commands single or multiple consoles and power supplies See Appendix B for net node settings G Cable Controller H Precision Plasma C Cable B Cable Power Supply Power Supply Machine Motor Drive Electrode Interface Interface Cable RS 422 Plate Contact Inova Control Console Remote or Power Dual Console Network Divider Supply RS 422 Quick Connect RS 422 E H Cable K Cable i Precision Plasma C Cable B Cable Power Supply 1 Power Supply Machine Motor Drive Electrode Interface Interface Cable RS 422 Plate Contact Inova Control Console Remote or Power Dual Console Network Supply RS 422 Quick Connect RS 422 H Cable K Cable Precision Plasma Cable E Cable Power Supply Power Supply Machine Motor Drive its Electrode Interface Interface Cable RS 422 Plate Contact Inova Control Console s Remote or Power Dual Console Network Supply RS 422 Quick Connect RS 422 D Cable T K Cable This information is subject to the controls of the Export Administration Regulations EAR Thi
61. e and replace if necessary Verify the integrity of the supply air connections and tighten if leaks are found This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 4 Installation and Maintenance Inova User s Manual Rev K Voltage Divider Installation General 1 WARNING 1 TURN OFF ALL POWER BEFORE WORKING ON EQUIPMENT The voltage divider provides a feedback signal which is derived from the actual cutting arc voltage of the plasma power supply The Inova control uses this feedback signal to control the cutting height of the torch The voltage divider used in the Inova supplies a 40 1 signal This simply means that a cutting voltage of 100 volts results in a signal of 2 5 volts provided to the control The clear the plate CTP feature is incorporated in the voltage divider p c board and is automatically activated any time the torch plate sensing member exposed nozzle metallic nozzle shield etc 1s in direct contact with the workpiece The CTP sequence of operation is as follows 1 The torch descends toward the workpiece after a start command is given to the Inova 2 When a certain amount of force is developed between the torch end and workpiece or the CTP feature senses contact between the torch plate sensing member
62. e height of the torch to be checked for proper standoff without starting an arc Switching from IHS test to IHS run will enable arc starting and proceed normally through a cutting sequence IHS Touch Speed IHS touch speed is the speed at which the positioner travels during the slow speed portion of the IHS cycle Initial Height Sensing IHS The Inova offers initial height sensing capability to any plasma system The Inova uses a soft touch ohmic plate sensing technique to set the initial arc transfer height For plasma torches that do not have ohmic plate sensing capability a patented motor torque sensing technique is used The amount of torque or touch force is programmable from the optional remote control unit No external switches or other devices are required for setting the arc transfer height Manual positioning can be used if automatic initial height positioning is not desired Manual Speed Manual speed is the speed at which the positioner moves when the control is in the manual mode Note that in Manual the positioner moves at a slow speed when the up down buttons are initially pressed The speed is increased to the manual speed if the buttons are held down Pierce Height The pierce height is the height the torch is moved to after the arc transfers to the plate and the Inova receives a motion arc transfer signal from the power supply This information is subject to the controls of the Export Administration Regulations EA
63. ed on the H Bridge p c board check the continuity between P12 pins 11 and 12 on the Microprocessor p c board and P24 pins 1 and 2 on the H Bridge p c board If the Up Up Pwm Down and Down PWM LED s illuminate correctly on the H Bridge check the motor voltage between P10 pins 1 and 2 at the positioner plug It should be approximately 30VDC when the up or down buttons are pressed If the voltage is good check the wiring from P10 to the motor brushes Also check the motor brushes for signs of wear If the voltage is not present on P10 check for 30VDC between P1 pins 1 and 2 on the control console If the voltage is correct check the B cable for open wires If the voltage on P1 is incorrect check for open wires between P1 and P24 on the H Bridge p c board If the wires are good and the 30V LED on the H Bridge is illuminated replace the H Bridge 8 Loose motor shaft lead screw coupling inside positioner 9 Positioner mechanical problem clean and adjust the positioner The system continuously blows the 6A 1 Bad H Bridge Disconnect P25 from the H fuse Bridge p c board If the fuse still blows check for bad wiring between the motor transformer TR1 and P25 on the H Bridge If the fuse doesn t blow reconnect P25 and disconnect P24 If the fuse now blows replace the H Bridge Upon initial power up the system 1 Faulty Microprocessor p c board check the returns a No ULS Found error Upper Limit LED on the Microp
64. enee tetto tarte siot 2 1 BEeat teSs nion eic AEE E EE EE EE E EE EE E EA 2 1 System Reg ir mentS nesine ot dest E EE E bes ERR cede dius oe R REE 2 2 System C OM MOU atl OTS scce nnn i n e a a a E Eaa aa 2 3 Puncuons and Definitions seisan inre aa tisse AA E Ee d tate A i sue 2 8 CNC Machine Interface Signals 5 aedes wart te dates erede atts trees Ade ees 2 10 Section 3 Installation And Maintenance 1 3 1 Initial Insect ofla aoro ee rods R cee eas efe ouo cer uc Lue CC 3 1 Control Console Installation s ooo ede d smesso bocca ees stereo md M er ta de sese 3 1 Control Console Maintenances 020s eraeie t acre antt roa eo sa la ae ecx tat eia Sepe nami sid 3 1 Posr ctier Instal GI a s d oe He de ed seis a dee iecit e oS 3 1 Positioner Maintenance 2o esi ueteres n SE eben vasa ciedes teecday aesasiaae es Meas d queue mM E e DEI 3 2 Remote Installatie theca uote tie dei rn e eee eeu 3 3 BRETT Sty a INA OS Staal omnet Etape SL Lae tare MM E Ce 3 4 Collision Sensor Installation ssec tieu tete scotac ted ea cot dt roe icd nada telae it boi seat ido 3 4 Collision Sensor Maintenance ecu ces ep COR aco er TE ERE DE EA Up ed 3 4 Voltage Divider Installation General essere 3 5 KALIBURN SR 45i Voltage Divider Installation esee 3 7 KALIBURN SR 100i Voltage Divider Installation eere 3 8 KALIBURN Spirit ProLine FineLine Voltage Divider Installation
65. er correctly manually apply a start signal directly to the plasma unit If the torch still does not transfer correctly the problem is with the plasma unit Faulty E cable connection verify that the E cable is connected from the control console ground stud to the star ground on the cutting table Faulty arc hold relay on the Microprocessor p c board check for contact opening between P19 pins 5 and 6 on the Microprocessor p c board upon completion of the IHS sequence Faulty wiring between P19 pins 5 and 6 on the Microprocessor p c board and P3 pins 5 and 6 check continuity between P19 and P3 Faulty C cable check continuity between P3 and the plasma power supply Plasma power supply has no arc hold input switch to the remote control Maint screen and disable the AGI feature Mechanical problem with positioner System gain set too high switch to the remote Maint screen and lower the gain Faulty E cable connection verify that the E cable is connected from the control console ground stud to the star ground on the cutting table Erratic x y machine motion The system is not in the AVC mode check the AVC LED s on the remote control and Microprocessor p c board System gain set too low switch to the remote control Maint screen and raise the gain The system enters the Limit mode and disables AVC switch to the remote control Maint screen and disable the Limit feature This i
66. eral troubleshooting guidelines for the Inova system Please contact KALIBURN technical support for any issues not covered in this section Before any tests are performed make sure the 2 system fuses are good The 6A motor fuse is located inside the fuse holder on the outside of the control console and the 3A main fuse is located behind the cover of the power entry module Also check all voltage LED s on the system p c boards before performing any tests Problem Possible Cause Erratic no positioner movement 1 6A fuse blown Loose encoder check the set screws that secure the encoder collar to the motor shaft 3 Bad encoder check the ENC A and ENC B LED s on the Microprocessor p c board They should alternate between on and off while the positioner is traveling up or down 4 Positioner at travel limit check the Upper and Lower Limit LED s on the Microprocessor p c board 5 System is in over current check the OC LED on the H Bridge and the Over Current LED on the Microprocessor p c board If an over current condition exists check the positioner for binding Also check the Brake Off LED on the Microprocessor p c board It should illuminate when the up or down buttons are pressed 6 No up or down signal from the remote or x y machine check the Up Down Up Pwm and Down Pwm LED s on the Microprocessor p c board When the up button is pressed the Up and Up Pwm LED s should illuminate Likewise the Down and Down
67. gnal from the power supply 8 If SW2 3 on the control console microprocessor printed circuit board is in the OFF position the Inova issues a Motion signal to the x y machine 9 The torch moves to the Pierce Height and the Pierce Time timer is initiated 10 When the Pierce Time elapses the torch moves to the Cut Height 11 If SW2 3 on the control console microprocessor printed circuit board is in the ON position the Inova issues a Motion signal to the x y machine 12 The x y machine begins profiling the part 13 When the x y machine removes the Corner height freeze signal the AVC Delay timer is initiated 14 When the AVC Delay timer elapses the torch height is governed by the programmed Arc Voltage Note that the system can also be placed in Auto Voltage mode by setting the Arc Voltage to 000 0 In Auto Voltage mode the system maintains the actual feedback voltage that corresponds to the programmed Cut Height at the time the AVC Delay timer elapses 15 The programmed Arc Voltage thus the torch height can be increased and decreased while in AVC by pressing the two exterior buttons on the operator s remote 16 AVC mode is disabled thus freezing the torch height any time a Corner signal is received 17 If Limit is enabled AVC mode is disabled any time a sudden increase in arc voltage is sensed such as when crossing a kerf or running off the plate 18 If ACA automatic collision avoidance is enabled the arc volt
68. he plasma arc is fully extinguished before the positioner retracts Ifthe power supply motion output is controlled by a transferred arc current sensor enter 9999 for the retract delay This will set the retract delay feature to the Automatic mode and the torch will automatically retract at the end of a cut as soon as the cutting arc extinguishes 13 From the Maint Screen touch the Run button to return to the Run Screen ON tA This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 11 Operation Inova User s Manual Rev K Pre Cut Setup Before making a cut with the Inova system perform the following setup sequence to ensure proper operation 1 From the Run Screen touch the Menu button to switch to the Menu Screen 2 From the Menu Screen touch the Set Arc Volts button to edit the Arc Voltage on the Edit Screen Enter the recommended arc voltage for the material being cut The system can also be placed in the Auto Voltage mode by entering an arc voltage of 000 0 In Auto Voltage mode the system maintains the actual feedback arc voltage that corresponds to the Cut Height at the time the corner height freeze signal is removed at the start of a cut and the AVC Delay time has expired 3 From the Menu Screen touch the Se
69. hen a Motion signal arc transfer signal is received from the power supply the Inova issues a Motion signal to the x y machine 6 During part profile the torch height is controlled by pressing the two exterior buttons on the operator s remote Note that if Automatic mode is desired at any point during the cut the unit can be switched from Manual to Auto 7 When the Cycle Start signal is removed from the Inova the Plasma Start signal is removed from the power supply eh duce pe PStart Power Supply Start Mode 1 PStart mode is entered by pressing the PStart button on the Maintenance screen and operates the plasma power supply directly without input from the CNC controller 2 In Automatic system mode the IHS sequence takes place prior to the Power Supply Start signal and in Manual system mode the Power Supply Start signal is issued immediately when the PStart button is pressed Note that AVC is disabled in Automatic system mode 3 PStart mode is disabled by pressing the button a second time Initial Setup After the Inova system is installed perform the following setup sequence to ensure proper operation 1 From the Run Screen place the control in the Full Raise and Auto modes and also switch to IHS Test Examine the status bar to verify the system modes A mode can be toggled by touching the corresponding button on the touch screen 2 From the Run Screen touch the Menu button to switch to the Menu Screen 3 From the Men
70. her insert the mounting bolt head into the T slot When mounting the positioner it is recommended that the bottom of the positioner is at least 5 inches above the workpiece See Figure 1 3 for the positioner mounting dimensions Note The positioner cable must be routed away from the torch leads to reduce the possibility of high frequency noise interference with the Inova system This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 1 Installation and Maintenance Inova User s Manual Rev K Positioner Maintenance Refer to Pages 7 4 7 5 Positioner Illustration for the following procedures Positioner Cleaning and Lubrication The ball screw and linear guides require cleaning and lubrication every three months or 500 hours of normal operation in order to maintain a normal life expectancy The ball screw and guides should be lubricated with a light weight oil ISO VG 32 or 3 In One Oil Note The ball nut should never be removed from the ball screw for cleaning or lubrication Follow the Belt Removal and Replacement procedure in this section for cleaning and lubricating the positioner Limit Switch Replacement 1 Using a 3 32 hex wrench remove the 8 4 40 X 1 4 screws that hold the limit switch cover item 10 to the positioner
71. i 3 6 bars Lower air supply pressures will cause the collision sensor to trip with less force Higher supply pressures will require more force to activate the unit For maximum torch protection the inlet air supply should be set as low as possible 4 Connect the threaded plug on the yellow electrical connection cable to the collision sensor The other end has three wires of which only the black and brown wires are used The blue wire is not used The black and brown wires which connect to a normally closed pressure switch are usually connected to an emergency stop input to the CNC controller Alternately the wires may be connected in series with one of the start signal wires from the CNC to the Inova system In this case when the collision sensor is activated the start signal will be removed from the Inova the arc at the torch will be extinguished and the torch will be retracted away from the workpiece Note The pneumatic switch inside the collision sensor opens when the pressure inside the unit falls below 40 psi The unit must be in its home position with pressure applied for the switch to remain closed 5 Note that when the collision sensor is activated it must be reset to its home position manually Collision Sensor Maintenance Make sure the collision sensor is mounted securely to the positioner carriage plate Also make sure the torch clamp is mounted securely to the collision sensor Check the electrical cable for signs of damag
72. ial arc transfer height set by soft touch ohmic plate sensing technique or patented motor torque sensing method Corner height freeze feature allows arc voltage control to be disabled by the CNC IHS test mode to verify arc transfer height without starting the power supply Automatic or manual control of the cutting sequence Retract height selectable between full or programmed partial raise height Multiple torch operation supports up to 8 nodes Arc voltage programmable from 50 to 250 volts in 0 10 volt increments Auto Voltage mode maintains arc voltage corresponding to programmed cut height Programmable manual positioner speed Programmable arc transfer height Programmable pierce height Programmable pierce time Programmable cutting height Programmable AVC arc voltage control delay time Programmable torch retract delay time Programmable IHS initial height sensing touch speed Programmable IHS touch force when ohmic plate sensing is not used Programmable AGI automatic gas initiator starts plasma torch preflow during IHS enable disable Programmable crossover height high to low speed transition point e Programmable CTP clear the plate ohmic plate sensing enable disable e Programmable arc voltage limiter to help prevent torch crashing when crossing a kerf enable disable e Programmable arc voltage control loop proportional gain e Programmable ACA automatic collision avoidance enable disable e Opti
73. ider 5 Connect the D cable wire marked Signal to the Signal terminal on the voltage divider 6 Connect D cable wire marked Logic to the terminal marked Logic on the voltage divider 7 Connect the D cable wire marked Logic to the terminal marked Logic on the voltage divider 8 Using the single conductor red wire provided connect the voltage divider terminal labeled P S power supply positive to the green connection plug on the I O board position 1 far right hand side 9 Using the single conductor black wire provided connect the voltage divider terminal labeled P S power supply negative to the green connection plug on the I O board position 6 This is counted from right to left 1 being on the far right 10 Using the single conductor white wire provided connect the voltage divider terminal labeled Pilot Arc to the pilot arc relay This connection should be made at the same point that has a black 10AWG wire which connects to the Pilot Arc terminal on the I O board 11 Connect one of the terminals on the voltage divider labeled 120VAC to TB2 1 in the SR 451 TB2 is the bottom terminal block in the rear of the power supply Connect the other 120VAC terminal on the voltage divider to TB2 5 12 If the D cable supplied with the Inova has fast on terminals on the power supply end it will have to be modified with a plug and strain relief part numbers 709022 amp 709023 and four sockets part number 709
74. ignal and the resumption of arc voltage control Arc Voltage Limiter Limit This feature automatically inhibits arc voltage control for a short period of time when the actual arc voltage exceeds the desired arc voltage by 12 volts As soon as the actual arc voltage is less than 12 volts the control will resume arc voltage control This feature helps prevent torch crashes when crossing kerfs or when a cut piece drops away from the plate Automatic Collision Avoidance ACA This safety feature allows the control to automatically adjust the torch height during a cut to help prevent torch crashes Automatic Gas Initiator AGI The automatic gas initiator starts the plasma torch gas preflow during the IHS sequence The arc hold relay remains closed until the arc transfer height is set at which time the arc hold relay is released and the arc is initiated Clear The Plate CTP The clear the plate feature allows the Inova to sense when the torch shield cap nozzle or other sensing device has touched the plate It is used to accurately set the initial pierce height of the torch and is also the basis for the soft touch feature For plasma systems that do not have plate sensing capability the CTP feature can be turned off In this case the motor torque sensing circuit is used for setting the initial pierce height of the torch with some trade off in IHS repeatability This information is subject to the controls of the Export Administration Regul
75. inals on the power supply end it will have to be modified with a plug and strain relief part numbers 709022 amp 709023 and four sockets part number 709018 Cut off the four fast on connectors and wire the plug as follows Signal Pin 1 Signal Pin 4 Logic Pin 3 Logic Pin 2 Now connect the cable to the outside of the SR 1001 at the P7 plug This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 8 Installation and Maintenance Inova User s Manual Rev K KALIBURN Spirit ProLine FineLine Voltage Divider Installation fll WARNING TURN OFF ALL POWER BEFORE WORKING ON EQUIPMENT 1 Remove the left side panel of the power supply Four holes are provided in the center panel for voltage divider installation 2 Remove the paint around the spare hole located just above the voltage divider mounting holes This will provide a chassis ground point for the white ground wire on the voltage divider 3 Install the voltage divider with the 4 6 32 X 3 8 screws provided Orient the board so the transformer is in the lower left hand corner of the board Mount the white ground wire to the hole where the paint was removed 4 The power supply has a built in wiring harness for a voltage divider Each of the wires has a label indicat
76. ing where it is to be connected Connect the wires to their respective terminals on the voltage divider 5 If the D cable supplied with the Inova has fast on terminals on the power supply end it will have to be modified with a plug and strain relief part numbers 709022 amp 709023 and four sockets part number 709018 Cut off the four fast on connectors and wire the plug as follows Signal Pin 1 Signal Pin 4 Logic Pin 3 Logict Pin 2 Now connect the D cable plug to the outside of the power supply at the P7 plug This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 9 Installation and Maintenance Inova User s Manual Rev K Interface Cable Installation 11 WARNING TURN OFF ALL POWER BEFORE WORKING ON EQUIPMENT After all of the components have been securely mounted connect all of the cables to the appropriate connectors Refer to the desired system configuration drawing in Section 2 for interconnecting cable information All cables should be routed as far away as possible from the plasma power supply torch leads in order to reduce the chance of high frequency interference with the Inova system Cable pinouts are shown in Section 6 A brief description for each cable is given below A Cable This
77. inistration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 21 Appendix A Inova User s Manual Rev K Appendix A Error Codes When an error occurs during system operation the optional remote control unit will display a corresponding error code on the Status LED s Screen The error LED LED33 on the control console microprocessor p c board will also flash the appropriate error code If multiple errors exist they will be displayed in succession The following table lists the error codes Error Error Code Description No Initialization 1 Start signal applied before serial initialization complete Low Motor Voltage 2 Improper motor voltage on H Bridge p c board Over Current 3 The motor is drawing excessive current Invalid Motion 4 Motion signal received before plasma start signal applied Motion Lost in Cut 5 Motion signal lost before removal of plasma start signal Motion Time out 6 Multiple systems did not produce motion within a given time Early Start 7 Start signal applied on power up Shut Down 8 Shutdown due to continuous over current condition Travel Limit Reached 9 Positioner has reached upper or lower travel limit No ULS Found 10 The upper limit home switch was not found on startup This information is subject to the controls of the Export Administration Regulations EAR This informati
78. is information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 3 Parts List Inova User s Manual Rev K Positioner Assembly S 110035 Assembly HD 110036 Note See Figure Below Item Number Part Number Quantity Description 1 2 nA BW onan 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Not shown Not shown 110022 110028 110040 424184 900338 401038 424010 110500 424084 424082 110005 424193 424079 424190 424191 424183 424081 424197 424182 110021 401080 700024 700407 700275 700603 700223 700605 700285 424188 424079 424189 424185 424090 424186 709113 709025 2 HD L un I SS ph pah e e e e e e e e a a e aa ae ae ae IA A e DA A lANN Encoder Motor S Motor HD Top plate Motor ball screw coupling Brake Carriage plate Limit switch p c board Ball screw assembly Linear guide with guide blocks Limit switch cover Limit switch cover end block Bearing Outer bearing retainer Inner bearing nut Bottom plate Belt Belt guide Bottom housing Main extrusion assembly Collision sensor optional Torch clamp 1 3 8 Torch clamp 1 1 2 Torch clamp 1 3 4 Torch clamp 1 15 16 Torch clamp 2 Torch cl
79. is information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 10 Installation and Maintenance Inova User s Manual Rev K Section 3 Installation and Maintenance Initial Inspection All systems undergo full testing before being shipped from KALIBURN In the unlikely event that one of your components is defective or missing please contact KALIBURN so a replacement item can be sent to you Also KALIBURN has taken special care in packaging your Inova System If your system was damaged during shipment you will have to file a claim with the shipping company Next it will be necessary to contact KALIBURN so replacement parts can be ordered If you need additional assistance please contact KALIBURN Control Console Installation The control console should be installed in a secure safe location It may be mounted vertically or horizontally but pay careful attention to the hinging of the access door Printed circuit boards are installed on the door and the mounting plate inside the console It is important to use the insulating washers provided with the Inova system when mounting the control console These washers installed in the holes on the flange of the control console enclosure will isolate the control and prevent ground loops Note that the shoulders on the washers should rest inside the console mounting holes The E cable will
80. it 4 0x0010 Motion signal lost prior to removal of start signal Bit 5 0x0020 No motion signal from power supply Bit 6 0x0040 Upper limit switch not found on power up Bit 7 0x0080 Control console not initialized Synchronous Mode When cutting with multiple systems at the same time the Inova control consoles must be set to synchronous mode using command 247 Note that synchronous mode remains enabled until it is disabled using command 247 Next cycle start signals must be applied to the systems At this time the initial pierce heights will be set When all IHS complete signals are generated verified by status command 214 command 239 must be issued This will either release the arc hold signals when using AGI mode or generate the plasma start signals when AGI mode is disabled The cutting arcs will then ignite and the Inova control consoles will receive the motion signals from the power supplies When all motion input signals are received verified by status command 214 command 240 must be issued to the Inova controls so they will proceed as normal This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 7 Troubleshooting Inova User s Manual Rev K Section 6 Troubleshooting The following chart lists gen
81. location outside the United States contrary to the requirements of the EAR 7 9 Parts List Inova User s Manual Rev K F Cable Assembly 711730 X INOVA CONSOLE BURNY PHANTOM P4 24 POS 11 RECP PLASMA CONTROL 37 POS CABLE 711002 i STRAIN RELIEF TN cd PLUG 709020 PLUC 709095 TERMINAL POSITION NO COLOR POSITION NO TERMINAL 709018 SOCKET 1 GREEN 12 709018 SOCKET 2 BLACK 18 22 3 gt WHITE 21 4 K BLACK 15 5 RED 2 6 BLACK 1 709018 SOCKET 25 7 YELLOW XX 8 K BLACK XX 9 X BLUE xx 10 K BLACK XX 24 11 X BROWN XX 709018 SOCKET 12 X BLACK XX 709019 KEY 17 JUMPER 22 709018 SOCKET 711005 28 709018 SOCKET TOTAL SOCKET COUNT 23 THE F CABLE PART NUMBER IS 711730 X WHERE X IS THE LENGTH OF THE CABLE IN FEET This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 10 Parts List Inova User s Manual Rev K G Cable Assembly 711735 X INOVA CONSOLE BURNY P6 9 POS 35 RECP COMM 1 9 POS CABLE 711001 pu RELIEF 70901 T 4 PLUG 709016 PLUG 709016 TERMINAL POSITION NO
82. mp Fuse 6 amp Fuse holder Chassis plate Terminal block marker Terminal block Transformer 20VAC H bridge p c board Power distribution p c board Control console microprocessor p c board Control console RF shield top Control console RF shield bottom Voltage divider filter p c board plug assembly REMOTE AUX CO P4 Ft SOLE 2 X Y MACHINE POSITIONER A C NPUT 3A STAR GROUND P2 P3 P6 P7 VOLT DIV POWER SUPPLY RS 422 IN RS 422 OUT 6A MOTOR f This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 1 Parts List Inova User s Manual Rev K m m Hs NEN illi Dj ext 4 RFF BH POH OP OR HHF Epes YO itd 8 41 iw DFOR a Su e zi i i e
83. must be turned off at the operator s remote control unit or via RS 422 from the CNC controller Refer to the appropriate section for specific voltage divider installation for the plasma system you are using Voltage divider installation instructions are given for the following plasma cutting systems e KALIBURN SR 45i e KALIBURN SR 100i e KALIBURN Spirit ProLine FineLine This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 6 Installation and Maintenance Inova User s Manual Rev K KALIBURN SR 45i Voltage Divider Installation fl WARNING TURN OFF ALL POWER BEFORE WORKING ON EQUIPMENT 1 Remove the back panel of the SR 45i Four holes are provided in the upper left corner of the inside back panel for voltage divider installation 2 Remove the paint around the lower left hand voltage divider mounting hole This will provide a chassis ground point for the white ground wire on the voltage divider 3 Install the voltage divider with the 4 6 32 X 3 8 screws provided Orient the board so the transformer is in the upper right hand corner of the board Mount the white ground wire under the stand off leg where the paint was removed 4 Connect the D cable wire marked Signal to the Signal terminal on the voltage div
84. n to return to the Run Screen 8 Place the system in the correct cutting modes desired Auto Man IHS Test Run Full Partial Raise 9 Now a cut can be made with the Inova system Verify the status of the LED s on the Run Screen during operation The start LED indicates that a cycle start signal is applied to the Inova The AVC LED indicates that the Inova is automatically regulating the arc voltage of the torch The corner LED indicates that a corner height freeze signal is applied to the Inova This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 12 Serial Communication Inova User s Manual Rev K Section 5 Serial Communication Initializing the Inova Control Console The Inova control console uses RS 422 serial communications at 9600 baud to receive and respond to commands The communications ground is isolated to prevent ground loops When an Inova remote is used it automatically initializes the console with previously stored cut parameters For multiple torch networks or other systems that do not use the Inova remote the following parameters must be transmitted to the console for initialization e Pierce Height 227 e Cutting Height 229 e Arc Voltage 226 e Arc Voltage Confirmation 237 Control console initi
85. nformation is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 7 Troubleshooting Inova User s Manual Rev K Remote control screen not legible 1 Incorrect contrast setting turn dip switch SW2 2 on the Remote Microprocessor p c board to the on position to restore the factory default contrast setting Save the contrast setting and turn SW2 2 back to the off position This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 8 Parts List Inova User s Manual Rev K Section 7 Parts List Control Console Assembly 110025 Note See Figures Below Item Number Part Number Quantity Description 1 110007 2 709084 3 709002 4 709003 5 709004 6 709207 7 707006 Not Shown 711255 8 709012 9 709210 10 709010 11 110008 12 709190 13 709191 14 706003 15 110600 16 110700 17 110200 18 110010 19 110011 20 110800 0000699909900 amp 1 Oo NO CO Control console enclosure Power lug Receptacle 14 position Receptacle 9 position Receptacle 24 position Receptacle 7 position Power entry module Power cable Fuse 3 a
86. nn CB 0D AA nn CC 0D AA nn CD 0D AA nn CE 0D AA nn CF 0D AA nn D0 0D AA nn D1 0D AA nn D2 0D AA nn D3 0D AA nn D4 0D AA nn D5 0D AA nn D6 0D AA nn D8 0D AA nn D9 0D AA nn DE 0D AA nn DF 0D AA nn EO 0D AA nn El 0D AA nn E2 0D Inova User s Manual Rev K Additional Information None None Must be in manual mode Must be in manual mode None None None None Torch must be positioned at the desired crossover height Returns command 232 AGI purges preflow gas during IHS sequence AGI purges preflow gas during IHS sequence None None Returns command 236 None None ACA Automatic collision avoidance ACA Automatic collision avoidance Height in mils inches 1000 Valid Range 0 to 999 Time in ms seconds 1000 Valid Range 0 to 9999 Arc voltage in volts 100 Valid Range 5000 to 25000 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR Serial Communication Inova User s Manual Rev K Command Hex String Additional Information Set Pierce Height 227 AA m E3 0D Height in mils inches 1000 Valid Range 0 to 2000 Set Partial Raise 228 AA nn F4 0D Height in mils inches 1000 Height Valid Range 0 to 9999 Set Cutting Height 229 A
87. nsferred by any means to any location outside the United States contrary to the requirements of the EAR 7 12 Parts List IP Cable Assembly 711745 X REMOTE P21 9 POS STRAIN RELIEF 709015 STRAIN RELIEF 709015 PLUG 709016 Inova User s Manual Rev K POWER SUPPLY RS 422 PORT PLUG 709016 CABLE 711001 TERMINAL POSITION NO 709018 SOCKET 2 3 s A EX 5 B fae as 709018 SOCKET 9 2 709019 KEY 1 TOTAL SOCKET COUNT THE CABLE PART NUMBER IS 711745 X 12 COLOR POSITION NO TERMINAL RED 3 709018 SOCKET BLACK 2 WHITE 5 BLACK 4 GREEN 1 BLACK NC 709018 SOCKET WHERE X IS THE LENGTH OF THE CABLE IN FEET This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 13 Parts List J Cable Assembly 711750 X CONSOLE 1 P8 24 POS STRAIN RELIEF 709021 STRAIN RELIEF 709021 PLUG 709020 CABLE 711049 Inova User s Manual Rev K CONSOLE 2 P4 24 POS PLUG 709020 TERMINAL POSITION NO COLOR POSITION NO TERMINAL 709018 SOCKET 5 f RED 5 709018 SOCKET 6 L BLACK 6 22 15 WHITE 15 16 BLACK 16 13 BROWN 13 14 K BLACK 14 23 1 1 GREEN 1 2 XJ37 BLACK 2 7
88. ol system is the most technologically advanced arc voltage control system in the plasma cutting industry It is designed to offer arc voltage control capabilities to any plasma cutting system The Inova quickly and accurately sets the arc transfer height of the torch using a soft touch plate sensing technique A patented motor torque sensing method is used as a backup for setting the arc transfer height The Inova system uses advanced DSP digital signal processing software servo control loops to control speed position and arc voltage with unparalleled precision The system is fully programmable via RS 422 serial communications The optional operator s remote control unit utilizes a touch screen interface for easy and efficient operation The system also has built in networking capabilities to support multiple torch operation and synchronization The Inova operates with no deadband and can attain speeds in excess of 180 inches per minute in the arc voltage control mode and speeds in excess of 500 inches per minute in the position control mode The Inova torch positioner will handle weights up to 50 pounds Safety Installation as well as repairs made to the Inova System should only be performed by qualified personnel The Inova System makes use of both A C and D C circuitry for operation Remember 115VAC can be fatal if not handled in a safe manner In addition it will be necessary to make connections to the D C output of the plasma power
89. on shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR A 1 Appendix B Inova User s Manual Rev K Appendix B Dip Switch Settings Control Console Settings Dip Switch 1 SW1 RS 422 Node Termination SWI 1 and SW1 2 should be switched on if the console is the last on a string of nodes SW1 1 and SW1 2 should be switched off in all other consoles in the network Dip Switch 2 SW2 Options SW2 1 should be switched off for normal operation SW2 1 can be switched on so the system will ignore the upper and lower positioner limit switches while cutting The electromagnetic field produced by some high current plasma systems activates the limit switches adversely affecting system operation SW2 2 should be switched off for imperial units and on for metric units Note that the remote control consoles are different for imperial and metric units SW2 2 must be set to match the remote control SW2 3 should be switched off to have the x y machine motion signal issued as soon as the Inova receives the motion signal from the power supply and moves the torch from the arc transfer height to the pierce height SW2 3 should be switched on to have the x y machine motion signal issued after the Inova completes the pierce delay time and moves the torch from the pierce height to the cutting height SW2 4 is reserved for future use Dip Switch 3 SW3 Net
90. on the Microprocessor p c board If the voltage divider LED is off check for 120VAC to the voltage divider If the 120VAC is good disconnect the wire connected to the Pilot Arc terminal on the voltage divider If the LED now illuminates check the Pilot Arc wire for shorts to ground If the LED still does not illuminate when the Pilot Arc wire is removed and the 120VAC is good replace the voltage divider Positioner does not slow down to slow 1 Incorrect crossover height setting inch down speed during IHS cycle During the IHS sequence torch stops 1 Positioner is binding clean and adjust before touching the workpiece and fires positioner and arc in the air 2 Torch leads are interfering with normal positioner operation 3 Touch force setting 1s too low switch to the remote control Menu screen and increase the touch force setting During the IHS sequence torch 1 Faulty plate sensing circuit check the Plate immediately retracts to the upper limit Sense LED on the Microprocessor p c board and or remote control unit It should be illuminated until the torch touches the plate at which time it should go out If the plasma torch has no plate sensing member switch to the remote control Maint screen and disable the CTP feature If the torch has a plate sensing member check the LED on the voltage divider It should also be illuminated until the torch touches the plate at which time it should go out If it is illuminated
91. on the Edit Screen The Retract Delay time is the time between the removal of a start signal and the retraction of the positioner Auto mode only It should be adjusted such that the arc is fully extinguished before the torch is retracted from the plate The Retract Delay time can be adjusted from 0 to 9999 milliseconds mS When a value of 9999 mS is entered the retract delay is set to Automatic mode In this mode the torch will automatically retract at the end of the cut as soon as the power supply motion input signal is removed The Automatic mode is recommended if the power supply motion output signal is controlled by a transferred arc current sensor 10 View LED s Button Touch this button to go to the Status LED s Screen 11 Adjust Screen Button Touch this button to go the Contrast Screen Note If the contrast cannot be adjusted or the screen cannot be read dip switch SW2 2 on the remote microprocessor p c board can be switched to the on position to restore the factory default contrast setting 12 Set Gain Button Touch this button to edit the Proportional Gain on the Edit Screen The Proportional Gain can be adjusted from 50 to 750 Higher numbers increase the gain of the system allowing it to respond faster The factory default setting is 250 13 Status Bar Remote Control Crossover Height Screen 1 2 1 USE THE EXTERIOR BUTTONS TO MANUALLY MOVE THE TORCH 2 WHEN AT THE DESIRED CROSSOVER UA HEIGHT PRESS THE SET BUT
92. on to disable the CTP clear the plate feature Verify that there is an X beside the CTP parameter on the status bar indicating that it is disabled 9 Now touch the PStart button The torch should rapid traverse towards the plate and switch to slow speed at the Crossover Height The torch should then touch the plate and retract to the Arc Transfer Height which was set to 500 mils 12 7 mm above 10 Touch the PStart button again to disable the PStart mode The positioner should retract to the home position at rapid speed 11 Now set the AGI automatic gas initiation and CTP parameters to their proper states according to the power supply being used If the Inova arc hold output is connected to the plasma power supply arc hold input the AGI feature should be enabled Otherwise it should be disabled If the plasma cutting torch has an ohmic plate sensing member the CTP feature should be enabled Otherwise it should be disabled A check mark beside the parameter in the status bar indicates the parameter is enabled An X indicates the parameter is disabled 12 Touch the Set Retract Delay button to edit the Retract Delay parameter From the edit screen enter the time interval required to extinguish the plasma cutting arc after the plasma power supply receives a stop signal If this value is not known enter 500mS The exact value of the parameter can be determined later by trial and error The Retract Delay should be adjusted such that t
93. onal collision protection system This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 Overview Inova User s Manual Rev K System Requirements Power Requirements The Inova system has a universal power plug with integrated ground wire Correct grounding is essential for proper and safe operation of the Inova system The ground wire must be grounded according to national or local electrical codes Before applying primary electrical power to the system check the data plate on the Inova control console for input power requirements Installation Requirements The Inova control console requires initialization by the Inova remote an external PC host or a CNC controller via RS 422 serial communication To take full advantage of the Inova system and features a precision power supply such as a Spirit 50a Spirit200a Spirit275a or Spirit400a can automatically set Inova cutting parameters such as arc transfer height pierce height pierce time cutting height and arc voltage via RS 422 serial communication The following pre installation requirements should be met before the Inova is installed e The torch station to which the positioner is to be installed should be as rigid as possible All play should be removed to minimize vibration
94. ort Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 20 Parts List Remote Communication P C Board Assembly 110400 Inova User s Manual Rev K N QJ s QO ON E 29 Ree ar ait Qu Z D oes Bet X A uU 4 Lr O O gt S i Qu IN e _ 6 PET ge 3H Owc ay CQ Y xi 013 EN eX T T o gg TAOW 2 n if Od o SE tv LE AWM As So es LANUN o Liu gt lt ul gt X lt ul gt X lt JX O IY IY Shire pT Qu bj COO e Qv tv Y Qc Y a4 e hed es gt E 2n n yn en f a6 z ag a4 Sia F o LC 2 A la N aC X I l Ex o Ju EJ Go 99 s l l l amp O E M D M wv 0 n 2 ylyfAal al alalgizg 1 m g an Q x x x x N AYAYAY x X XX BA A 2 aF F Y Yu aF FE ERRO iu O e 1 D z Qd QJ E a a This information is subject to the controls of the Export Adm
95. plicit written permission from Kaliburn 4130 Carolina Commerce Parkway Ladson SC 29456 USA 843 695 4000 Phone 843 695 4001 Fax www kaliburn net This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR Inova User s Manual Rev K Limited Warranty KALIBURN expressly warrants that this product shall be free from defects in materials and workmanship under proper and normal use for the intended function of such equipment for a period of one 1 year This product is intended for commercial use and is not intended for personal family or household purposes There are no warranties which extend beyond the description on the face hereof All other warranties either expressed or implied including any implied warranty of merchantability or fitness for any particular purpose are expressly excluded If this product or any component thereof is determined to be defective in manufacture KALIBURN will repair or replace the defective component or product The buyer s remedies are limited to the return of the product for repair or replacement of any non conforming product or part at the sole discretion of KALIBURN No freight charges of any kind are covered under this warranty All returned goods shall be at the buyer s risk and expense
96. pply No machine motion upon plasma arc 1 No motion input signal to the Inova from the transfer plasma power supply check the Motion In LED on the Microprocessor p c board 2 Faulty motion out relay on the Microprocessor p c board check for contact closure between P19 pins 7 and 8 on the Microprocessor p c board upon illumination of the Motion In LED No arc voltage control during x y 1 No motion input signal to the Inova check machine motion the Motion In LED on the Microprocessor p c board 2 Comer signal continuously applied to the Inova check the Corner Freeze In LED on the Microprocessor p c board and or remote control unit 3 The system is in the Limit mode check the Limit LED on the remote Maint screen 4 The positioner is at the upper or lower limit switch check the Upper Limit and Lower Limit LED s on the Microprocessor p c board Arc voltage setting is too high Cutting height set too high Incorrect plasma system gas pressure Incorrect voltage divider ratio verify that the output on the Signal and Signal terminals is 1 40 the voltage on the P S and P S terminals 5 Faulty E cable connection verify that the E cable is connected from the control console ground stud to the star ground on the cutting table Plasma torch raises up when machine motion occurs ee Ee Arc voltage setting is too low Cutting height set too low Incorrect plasma system gas pressure Incorre
97. provide the ground reference point for the control console The E cable should be installed from the ground stud on the outside of the control console to the star ground point on the cutting table The star ground point is where all subsystems are connected to the cutting table including the work ground lead for the plasma power supply There should be one cable connected from the star ground point to the driven ground rod It is extremely important that the E cable and the plasma power supply work ground lead are both connected to the star ground point The E cable is not a safety ground It is part of the voltage feedback circuit used for arc voltage control See Figure 1 1 for the control console mounting dimensions Control Console Maintenance To check the console remove the 115 VAC control power from the Inova system Open the console door and verify that all printed circuit board connectors are firmly connected Be sure that all printed circuit boards and system components are securely mounted Verify that all AMP connectors are tight and secure and check all AMP cable clamps for any exposed wire Also verify that the star ground stud is free from any corrosion Positioner Installation The positioner should be installed on the torch station of a cutting machine It should be mounted securely to minimize any mechanical vibration The T slots accept 4 mounting hardware Note Do not insert the mounting nut into the T slot rat
98. r D m pn Es L ZAUA IAUM my oa ca Q w NIS LI a jar de jdm Q 5 kot T T 2 T T T T T T Os a 1 mm 253 Td Ta vO wsvid B 2 E EAN 22 e 2 X ome mou EC OD xu xil j s Bp RR aI Cort SSARER SFE 5 BE 2g 5 em J L T eid T m T w amp J Y wx O ux ue m T tam TELA E mn Sid m vid i 0020 Nd ASSY Z AJY 66J0 Nd 2d NVE ONI OIDITTHINNI This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR Inova User s Manual Rev K H Bridge P C Board Assembly 110600 Parts List 7 17
99. rocessor p c board If it is illuminated replace the Microprocessor p c board If it is not illuminated check the Lim LED on the Limit Switch p c board If the Lim LED is illuminated on the Limit Switch p c board but not on the Microprocessor p c board check the continuity in the wiring from the Limit Switch p c board to P18 on the This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 2 Troubleshooting Inova User s Manual Rev K Microprocessor p c board 2 The limit switch p c board has lost power check the Pwr LED on the limit switch p c board If the LED is not illuminated check the Prox Pwr LED on the H Bridge If the H Bridge LED is good check the continuity from P24 on the H Bridge to the Limit Switch p c board If the H Bridge LED is not illuminated check for 120VAC on P25 pins 5 and 6 on the H Bridge If 120VAC is present replace the H Bridge 3 Faulty limit switch Check the Lim LED on the limit switch p c board It should illuminate when the carriage travels past the limit switch If the LED illuminates correctly check the continuity from the Limit Switch p c board to P18 on the control console Microprocessor p c board 4 Faulty B cable check for continuity of all wires in the cable
100. rols of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 3 Troubleshooting Inova User s Manual Rev K moving up or down Also verify that the brake is turning off inside the positioner A clicking noise can be heard when the brake turns on and off 4 Faulty brake circuit check for at least 24VDC between P12 pins 3 and 4 on the Microprocessor p c board upon illumination of the Brake Off LED If the voltage is good check the continuity from P12 pins 3 and 4 to P10 pins 15 and 16 If the voltage between P12 pins 3 and 4 is not at least 24VDC check for 24VAC between P12 pins 1 and 2 on the H Bridge p c board If the voltage is good replace the Microprocessor p c board If the voltage is not good check the 24V Brake LED on the Power Distribution p c board If the LED is illuminated check the continuity from P12 pins 1 and 2 on the Microprocessor p c board to P22 pins 16 and 17 on the Power Distribution p c board 5 Faulty H Bridge disconnect P24 from the H Bridge p c board If the OC LED remains on replace the H Bridge The system returns an Invalid 1 Plasma power supply motion relay contacts Motion error continuously closed 2 Shorted wires between pins 3 and 4 on the C cable 3 Shorted wires between P18 pins 3 and 4 on the H Bridge
101. s information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 7 Overview Inova User s Manual Rev K Functions and Definitions Arc Hold The arc hold relay is used in conjunction with the plasma start relay to start the plasma torch gas preflow during the IHS sequence provided that the automatic gas initiation AGI parameter is enabled When the Inova receives a cycle start command the plasma start relay closes immediately The arc hold relay contacts are normally closed and prevent the initiation of the plasma cutting arc Upon the completion of the IHS cycle the arc hold relay opens and the plasma arc is ignited Arc Transfer Height The arc transfer height is the initial height setting of the torch and is set during the IHS initial height sensing sequence Arc Voltage Control AVC The AVC servo system is the most advanced voltage control available It continuously monitors the arc voltage while cutting and can respond at speeds up to 600 inches per minute This rapid response means that arc voltage control is available for high intermediate or low speed plasma arc cutting The servo loop is software controlled with adjustable proportional gain for achieving the desired system response The arc voltage can be set in increments of 10 arc volts Arc Voltage Delay The arc voltage delay is the time between a removed corner s
102. s switched to the on position the console wiring harness plug should be moved from P15 to P14 on the microprocessor p c board In this case the system will not be able to communicate with an x y controller via RS 422 serial communication SW4 3 is used to enable disable programmable partial raise from the CNC controller If the x y machine does not use the programmable partial raise feature switch SW4 3 to the on position Remote Settings Dip Switch 1 SW1 OEM Use Only SW1 should not be changed from the factory settings Dip Switch 2 SW2 Options SW2 1 is reserved for future use SW2 2 can be switched to the on position to restore the factory default screen contrast setting This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR B 2
103. s will be made directly to the diode bridge The Inova D cable connects to the signal positive Sig and signal negative Sig connections on the voltage divider The 40 1 feedback signal is sent to the Inova control console via these two connection points This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 5 Installation and Maintenance Inova User s Manual Rev K If the torch has a plate sensing member exposed nozzle metallic nozzle shield etc then 120VAC needs to be connected to the voltage divider Also connect the Logic and Logic wires on the D cable to the Logic and Logic connection points on the voltage divider If the torch has an exposed nozzle the Pilot Arc terminal should be connected to the power supply nozzle connection the pilot arc relay is usually a good location If the torch has a metallic nozzle shield or other plate sensing device the Pilot Arc terminal on the voltage divider should be connected to the wire that connects to the plate sensing device If the torch does not have a plate sensing member the CTP circuit does not have to be connected to the power supply In this case no connections need to be made to the 120VAC or Pilot Arc connections on the voltage divider The CTP feature
104. smitted Programming the Cutting Arc Voltage For safety reasons the cutting arc voltage must be transmitted to the Inova console using two different parameters To program the arc voltage first transmit the voltage using parameter number 226 then confirm the arc voltage by transmitting it using parameter number 237 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 2 Serial Communication RS 422 Serial Commands Note In the following commands nn represents the net node value of the console that is to receive the command To send a global command to all consoles in a network configuration nn should be set to C8 hex 200 decimal Command Switch to Auto Switch to Manual Move Up Move Down Switch to Full Raise Switch to Partial Raise IHS Test IHS Run 201 202 203 204 205 206 207 208 Set Crossover Height 209 at Current Position Disable AGI Enable AGI Enable Limit Disable Limit Send Status Bits Enable CTP Disable CTP Enable ACA Disable ACA Set Arc Transfer Height Set Pierce Time Set Arc Voltage Used in conjunction with 237 210 211 212 213 214 216 217 222 223 224 225 226 Hex String AA nn C9 0D AA nn CA 0D AA
105. t Arc Voltage Vx100 2 Pierce Height mils 3 Partial Raise Height mils 4 Cutting Height mils 5 Touch Force 6 Crossover Height mils 7 Retract Delay ms 8 AVC Delay ms 9 Proportional Gain 10 Manual Speed ipm 11 Slow Inching Speed ipm 12 Actual Arc Voltage Vx100 13 Encoder Position 14 Pierce Time ms 15 System Status 0 Wait 1 Ready Start command must be issued before checking system status 16 ACA Status 0O Off 1 ON 17 Software Version X 10 18 Fault Status See Fault Status 19 Transfer Height mils Returns number and parameter requested in parameter 248 Power supply command number and parameter CNC Start Nodes in LSB See LSB Node Representation CNC Corner Nodes in LSB See LSB Node Representation CNC Partial Raise Nodes in LSB See LSB Node Representation This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 5 Serial Communication Inova User s Manual Rev K Command Hex String Additional Information Node Focus 254 AA C8 FE 0D Enable serial transmission for node only Valid Node in LSB See LSB Node Representation Cycle Stop 255 AA C8 FF 0D CNC Stop Nodes in LSB See LSB Node Representation Status Bits Description When comm
106. t Transfr Height button to edit the Arc Transfer Height on the Edit Screen Enter the recommended arc transfer height for the material being cut If this data is not listed use trial and error to determine the correct arc transfer height For thinner materials try setting the arc transfer height to the same value as the pierce height For thicker materials try setting the arc transfer height to one half the pierce height 4 From the Menu Screen touch the Set Pierce Height button to edit the Pierce Height on the Edit Screen Enter the recommended pierce height for the material being cut If this data is not listed use trial and error to determine the correct pierce height For thinner materials set the pierce height the same as the cutting height For thicker materials try setting the pierce height to 1 5 or 2 times the cutting height 5 From the Menu Screen touch the Set Cut Height button to edit the Cut Height on the Edit Screen Enter the recommended cutting height for the material being cut 6 From the Menu Screen touch the Set Pierce Time button to edit the Pierce Time on the Edit Screen Enter the recommended pierce time for the material being cut If this data is not listed use trial and error to determine the correct pierce time The pierce time should be adjusted such that the torch moves from the pierce height to the cutting height after the arc pierces completely through the workpiece 7 From the Menu Screen touch the Run butto
107. te Voltage Range eoo ri be gs 50 250 volts Control ACCuraCy 5 cue d co er Rp edet 4VDC F 10 00 254 4 312 8 mm 15 50 394 14 75 375 14 00 356 BERE 6 33 161 i 899 ap vooy row bury pedi m re i our WA Figure 1 1 Control Console Mounting Dimensions This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 1 2 Specifications Inova User s Manual Rev K Remote Stock Number Imperial Units 110020 Stock Number Metric Units 110120 Ir P I 3 125 in 79 mm Width iter pta testate tardus 8 575 in 218 mm DICE cciias an RE dona pir 7 25 in 184 mm bur 4 b 1 8 kg EON S HET PERCE MEIO O CE0 Be c 3 125 79 MODE AUTO RAISE PARTIAL IHS RUN LJ INOVA PRECISION ARC VOLTAGE CONTROL WKALIBURN s 8 584 218 i 6 4 156 DIA 4 mm THROUGH HOLE i i 4 6 32 PRESS NUT INSIDE e 4 80 122 7 438 189 4 80 122 l S i e 1 418 36 943 24 i i Es E 1 067 27 6 45 164 Figure 1 2 Remote Mounting Dimensions This information is su
108. tes contrary to the requirements of the EAR 7 15 Inova User s Manual Rev K Control Console Microprocessor P C Board Assembly 110200 Parts List 7 16
109. tion and advance the cursor to the next position 2 Parameter Being Edited 3 Editing Cursor 4 Cancel Button Touch the cancel button to cancel editing and return the parameter to its value prior to editing 5 Enter Button Touch the enter button to save editing changes and set the new parameter value 6 Back Button Touch the back button to backspace the cursor This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 4 Operation Inova User s Manual Rev K Remote Control Maintenance Screen LIMIT ON OFF 1 Limit On Off Button Touch this button to enable and disable the Limit feature The Limit feature disables arc voltage control for a short period of time when a sudden rise in arc voltage is detected while cutting After a brief delay arc voltage control is resumed When cutting thin material or heavily warped plate the Limit feature may need to be disabled 2 AGI On Off Button Touch this button to enable and disable the Automatic Gas Initiation feature When enabled the plasma torch gas preflow and the IHS sequence occur at the same time thus reducing the cycle time The plasma power supply must have an arc hold input to use this feature 3 CTP On Off Button Touch this button to enable and disable the Clear the
110. to the requirements of the EAR 4 1 Operation Inova User s Manual Rev K The following sections describe the functionality of the touch screen buttons Remote Control Run Screen SET ARC VOLTAGE 120 0 CORNER ACTUAL ARC VOLTAGE 000 0 amp 8 ARC TRANSFER HEIGHT 0 100 PIERCE HEIGHT 0 150 MENU PIERCE TIME 0700 CUTTING HEIGHT 0 130 1 Auto Manual Button Touch this button to toggle the system mode between Auto and Manual In Auto mode the pierce height of the torch is set automatically and the cutting height of the torch is controlled throughout the cut In Manual all automatic functions are disabled and the torch position must be controlled by the up and down push button switches located to the right of the touch screen 2 Partial Full Button Touch this button to toggle between Partial and Full Raise In the Full Raise mode the torch will retract to the home position at the end of a cut In the Partial Raise mode the torch will retract to the programmed Raise Height distance at the end of a cut 3 IHS Run Test Button Touch this button to toggle between IHS Test and IHS Run In IHS Test mode the arc transfer height of the torch is set without starting the plasma power supply Switching to IHS Run will start the power supply Menu Button Touch this button to go to the Menu screen Run Menu Parameters Parameter Values Status Bar Status LED s OO cw Ox Mx d This information is subject to the controls of the
111. u Screen touch the Set Transfr Height button to edit the Arc Transfer Height on the Edit Screen Enter 500 mils 12 7 mm for the Arc Transfer Height This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 10 Operation Inova User s Manual Rev K 4 Touch the Set Raise Height to edit the Raise Height on the Edit Screen Enter the torch retract height desired at the end of a cut when the system is placed in the Partial Raise mode Note that lower heights increase the likelihood of torch crashes while the x y machine is traversing to the next pierce point A Raise Height value less than 1 25 4 mm is not recommended From the Menu Screen touch the Maint button to switch to the Maint Screen Touch the Set Cross Height to switch to the Crossover Height Screen 7 From the Crossover Height Screen use the push buttons to the right of the touch screen to position the torch 2 50 8 mm above the thickest material that is to be cut When the torch is at the correct location press the Set button to set the Crossover Height Note Any time the torch is moved within the torch clamp this procedure must be repeated Failure to follow this procedure can result in torch and or positioner damage 8 From the Maint Screen touch the CTP butt
112. ual Rev K System Configurations Basic System Configuration In the basic system configuration the cables should be connected according to the figure below The Inova Remote is used to initialize and edit console parameters The RS 422 I Cable allows the power supply to send default cutting parameters to the remote and console B Cable Precision Plasma C Cable Power Supply CNC Controller Electrode RS 422 Plate Contact F Cable Power Supply Machine Motor Drive Interface Interface Cable Inova Control Console Remote or Power Dual Console Network Divider Supply RS 422 Quick Connect RS 422 D Cable A Cable Cable RS 422 RS 422 Inova Remote This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 3 Overview Inova User s Manual Rev K Simplified Basic System Configuration In the simplified basic system configuration a CNC or PC Host initializes and edits parameters of the console and power supply CNC G Cable Controller Precision Plasma Cable S Cable Power Supply F Cable wd Xx ED Power Supply Machine Motor Drive Electrode Interface Interface Cable E Cable RS 422 Plate Contact Inova Control Console

INOVA 115V Users Manual

Contents

Download Pdf Manuals

Related Search

Related Contents