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iCNC Performance Operating Manual

1. Settings is described first Settings Allows changes to tool offsets rapid speed point marking and line marking Edit Allows to change parameters for the selected process delay times kerf speed etc 3 20 OPERATION Manual 0 5399 N ICNC PERFORMANCE 3 14 1 Settings On the Settings tab you can change the general parameters like Rapid Speed Language Tool locations and Marking settings TD Process Selection v1 0 8 EMEN Apply General Line marking Point marking Rapid speed 25400 mm min Marking speed 5080 mm min IHS and Plasma Start SD4 200 s Move Delay SD5 0 1 9s Wait For Arc Off ED1 100 s Torch Up ED3 1 0 53 Language English Tool location Gas Tool location Plasma Tool location Line marking Tool location Point marking x mm x 42 mm x 42 mm X 42 mm Y mm Y 62 mm Y 62 mm Y 62 mm NOTE Parameter windows may alternate based on the machine setup See instal lation service manual about setting delays and names Pictures for reference only Language Select the language used in process selection Tool Locations If a laser pointer is installed on the machine it is best to define tool locations relative to the laser pointer This way you can position and set the zero point using the laser pointer and the system knows the location of all additional tools and can automatically handle them
2. and J codes Null G is linear Absolute Incremental Load Save As Program Rotation Rotate 90 degrees Cw No rotation Cancel Line Marking Block Point Marking Black Preview ul These options apply to the saving of EIA files Code Generation Use these commands to define start and end sequences of different actions See Code Sequences for more information Manual 0 5399 NESTING 5 43 ICNC PERFORMANCE y Unit Scale These options set the unit and scale used in saved EIA files Coding If coding is set to absolute then all the X and Y coordinates are absolute Otherwise they are incremental J codes and J codes are the coordinates of the center point of an arc If set to absolute all and J codes are absolute Otherwise they are incremental If X and Y codes are set to incremental then and J are also incremental Program Rotation If rotation is selected then all generated EIA files are rotated 90 degrees counter clockwise Feed rate codes e No Rapid feed rate If this option is set then feed rates are not saved for rapid speed e Feed rates at the end of line on separate line Feed rates can be saved on their own lines or at the end of a code line This option determines which way is used See examples below Example 1 at the end of line G01 X10 Y10 F200 Example 2 on separate line F200 G01 X10 Y10 Codes Rapid move Linear cut Arc CW and Arc C
3. THERMAL DYNAMILS ICNC PERFORMANCE CNC CONTROLLER Operator Revision AA Issue Date August 19 2015 Manual No 0 5399 3163339 Thermal Dynamics com THERMAL DYNAMICS WE APPRECIATE YOUR BUSINESS Congratulations on your new Thermal Dynamics product We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry This product is backed by our extensive warranty and world wide service network To locate your nearest distributor or service agency call 1 800 752 7622 or visit us on the web at www thermal dynamics com This Service Manual has been designed to instruct you on the correct use and operation of your Thermal Dynamics product Your satisfaction with this product and its safe operation is our ultimate concern Therefore please take the time to read the entire manual especially the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products We distinguish ourselves from our competition through market leading dependable products that have stood the test of time We pride ourselves on technical innovation competitive prices excellent delivery superior customer service and technical support
4. 100 Zooming See more at Zooming gt I Pan You can pan the view by moving the mouse cursor over the work window and pressing the left mouse button or keep r mouse wheel button pressed in to pan lt eo Undo Undoes the last editing you made for the current nesting g o Trash Trashes the current nesting Manual 0 5399 NESTING 5 3 ICNC PERFORMANCE 5 3 Toolbar Functions 5 3 1 Send to Cutting When the nesting is ready for cutting click this button to send it to ProMotion Cut NOTE This tool works only on ProMotion iCNC controllers 5 3 2 New Plate When activate this tool window appears asking the length and width of the new plate Plate Options Insert the values click and new empty plate appears The of the plate appears the Plate List To create round plates simply check the round plate option and enter the diameter of the circle 5 3 3 Open Opens a file ProMotion Nest can open DXF EIA ESSI CNC 2 and DSTV files DXF files Choose layers Profile Layers DEFPOINTS DIMENSIONS Select all Line Marking Layer Point Marking Layer NESTING Manual 0 5399 N ICNC PERFORMANCE If you load a file that is in DXF format and that file includes more than one layer ProMotion Nest will ask you to select which layers are loaded to the nesting If there are line and or point markings in the DXF file they must be
5. Homing speed 2095 hm e Tz cower sottimitdisance 09mm m fo 0 _ ee zs Fere domine s o o Perceneige s o Pate contact release speed Omm e0 1099 Reference postion amm o 0 Transter eight so anster Hegn Tmo Upper Soft init Distance 5mm fo wo 4 10 IHC Manual 0 5399 N iCNC PERFORMANCE SECTION 5 NEST 5 1 ProMotion Nest ProMotion Nest is software which converts CAD pictures DXF format to cutting programs It is also possible to modify existing cutting programs EIA ESSI or CNC 2 format Basics When ProMotion Nest loads a CAD picture it adds cutting technology kerf side piercing points cutting order etc to shapes auto matically If you want you can easily change any of those settings Copy the shapes to a plate nest set cutting order etc and either send the cutting program to ProMotion Cut or save it for later use ProMotion Nest user interface ProMotion Nest user interface is a collection of several small windows buttons and bars Below is a brief description of all of them El 2158 v Tool box I LEN on Or Toolbox Nest v4 35 14 macro ED 60 Plate list a Part List I 20 Part list Status bar a 20 40 60 3
6. 5 Assurez vous de ne pas exc der la capacit de l quipement Par exemple un cable de soudage surcharg peut surchauffer et provoquer un incendie 6 Une fois les op rations termin es inspectez l aire de travail pour assurer qu aucune tincelle ou projection de m tal incandescent ne risque de provoquer un incendie ult rieurement Employez des guetteurs d incendie au besoin Pour obtenir des informations suppl mentaires consultez le NFPA Standard 51B Fire Prevention in Use of Cutting and Welding Processes disponible au National Fire Protection Association Batte rymarch Park Quincy MA 02269 CHOC LECTRI QUE Le contact avec des pi ces lectriques ou les pi ces de mise la terre sous tension peut causer des blessures graves ou mortelles NE PAS utiliser un courant de soudage c a dans un endroit humide en espace restreint ou si un danger de chute se pose 1 Assurez vous que le ch ssis de la source d alimentation est branch au syst me de mise la terre de l alimentation d entr e 2 Branchez la pi ce traiter une bonne mise de terre lectrique 3 Branchezle c ble de masse la pi ce traiter et assurez une bonne connexion afin d viter le risque de choc lectrique mortel 4 Utilisez toujours un quipement correctement entretenu Remplacez les c bles us s ou endommag s 5 Veillez garder votre environnement sec incluant les v tements l aire de travail les c bles le por t
7. 5 37 5 12 Opions Me ree 5 38 et Ce roe DS OUI 5 40 5 14 EIA input a en 5 42 5 15 EIA OO COINS ae ee 5 43 5 16 Nesting Options nee ee 5 45 5 17 Language Options LL nnns 5 46 5 18 Registration Menu ROREM 5 46 5 46 5 20 EEE 5 46 5 21 5 48 SECTION 6 MAINTENANCE AND TROUBLESHOOTING 6 1 6 2 6 3 6 4 6 5 TABLE OF CONTENTS rouse tess 6 1 Maintenance RR 6 1 Cut Quality PRE EE RE 6 1 Oxy fuel cutting quality 6 2 DOCS OO SES RES Um END EPUM D NEU EIE 6 4 Replacement parts Declaration of Conformity We Thermal Dynamics of 2800 Airport Road Denton TX 76207 U S A in accordance with the following Directive s 2006 95 EC The Low Voltage Directive 2004 108 EC The Electromagnetic Compatibility Directive hereby declare that Equipment Plasma Cutting CNC Controller Model Name Number iCNC Performance Market Release Date August 19 2015 is in conformity with the applicable requirements of the following harmonized standards Conforms to requirements of IEC 61326 1 2012 IEC 61000 4 2 2008 Electro Static Discharge Immunity IEC 61000 4 3 2006 A1 2007 A2 2010 Radiated Radio Frequency Electromagnetic Immunity IEC 61000 4 4 2012 Electrical Fast Transient Burst Immunity IEC 61000 4 6 2008 Conducted Radio Freque
8. G01X100Y400 Linear cut to point 100 400 G02X200Y4001150J400 Clockwise arc to point 200 400 arc s center at position 150 400 G321150J350 Clockwise circle of radius 50 and center at position 150 350 M05 Gas torch off M02 End of program Example 2 G00X100Y100 G32150J0 M05 M02 As you can see there is no definition of the kerf compensation programming mode or units type In this case the defaults are used The defaults can be set in ProMotion Nest s EIA options Let us assume that the programming mode is absolute but and J codes are incremental and units are millimeters In that case the program would create a circle which center would be at position 150 100 50 100 10040 If and J codes would also be absolute then the center of the circle would be 50 0 5 21 7 SendTo If you add a shortcut to ProMotion Nest into Windows Send To folder you can send files to ProMotion Nest directly from the Windows Explorer 9 21 8 ini files In the folder where ProMotion Nest is installed there is a folder named ini That folder contains some configuration files which are really useful in some cases The format of each ini file is the same The format is ID TYPE DATA INFO ID is the identification number of that setting Do not change it TYPE is the type of the DATA Do not change it DATA is the actual setting You can modify this INFO is a short description of the setting You can mod
9. Meaning of symbols As used throughout this manual Means Attention Be Alert Your safety is involved Means immediate hazards which if not avoided will result in immediate serious personal injury or loss of life C A U Means potential hazards which could result in personal injury or loss of life WARNING Means hazards which could result in minor personal injury Enclosure Class The IP code indicates the enclosure class i e the degree of protection against penetration by solid objects or water Protection is provided against touch with a finger penetration of solid objects greater than 12mm and against spraying water up to 60 degrees from vertical Equipment marked 1 215 may be stored but is not intended to be used outside during precipitation unless sheltered This product is solely intended for plasma cutting Any other use may result in per CAUTI O N sonal injury and or equipment damage If equipment is placed on a surface that slopes more than 15 toppling over may occur Personal injury and or significant damage to equipment is possible Art A 12726 E To avoid personal injury and or equipment damage lift using method and attachment points shown here D A Art A 12736 1 4 SAFETY INSTRUCTIONS Manual 0 5399 N ICNC PERFORMANCE This Page Intentionally Blank Manual 0 5399 SAFETY INSTRUCTIONS 1 5 ICNC PERFORMANCE 1 02 Pr cautions de s curit FRENCH CANADI
10. Point Distance If two points are this close to each other then they are assumed to be the same point Important Note Change the point distance before loading a file Scale always 1 1 When reading DXF files ProMotion Nest tries to detect which measurement is used in the file This detection is ignored if Scale always 1 1 is checked Then the DXF file is read in millimeters or inches depending on the measurement setting Move Shapes to Origin If this option is selected then the shape in DXF file is moved so that its minimum coordinates are at 0 0 point If the DXF file contains a nesting more than one shape then the nesting is moved so that its minimum coordinates are at 0 0 point All the shapes in the nesting are moved exactly the same distance so their relative position to each other does not change Convert text to marking If this option is checked ProMotion Nest converts DXF text entities TEXT and MTEXT to marking lines Those marking lines form the same text that was in the DXF file Note This option is part of the marking text module Marking text module is an optional module and it s not part of the basic module Extended text search Usually ProMotion Nest searches the text entities at the same region of DXF file where the other entities are located If you check this option ProMotion Nest searches text entities from the beginning of the file to the end of the file NESTING Manual 0 5399 N ICNC PERFORMANCE
11. Use this tool to align the plate with the X or the Y axis Why Automatic nesting performs better if the bottom edge of the plate is aligned with the X or the Y axis EN SELECTED Close 5 3 22 Change Split Use this tool to change between parts displayed See Edit Plate 5 3 23 Rotate Plate This tool rotates the current plate 90 degrees counter clockwise 5 3 24 Mirror Plate Use this tool to mirror the current plate in Y axis 5 3 25 Move to Origin LH This tool repositions the current plate After the plate is repositioned its minimum X and Y coordinates are equal to zero 5 3 26 Undo Plate Edit E Edit Plate tool splits a plate into two parts If you made some errors during editing use this tool to bring the original plate back Manual 0 5399 NESTING 5 19 ICNC PERFORMANCE y 5 3 27 Zooming fs fi A 100 The easiest way to zoom in and out is using your mouse wheel You can use it anytime If you don t have mouse with a wheel then you can use Zoom Minus and Zoom Plus buttons Then the zooming continues until you release the button To get back to the normal view i e where the whole nesting is visible and as large as possible just click the Zoom 100 button 5 3 28 Pan View You pan the view by moving the mouse cursor over the work window while pressing the left mouse button The picture will follow the mouse movement until you release the left mouse button 5
12. ration ou lorsque vous observez une op ration Avertissez les personnes se trouvant proximit de ne pas regarder l arc et de ne pas s exposer aux rayons de l arc lectrique ou le m tal incandescent 3 Portez des gants ignifugi s crispin une chemise paisse manches longues des pantalons sans rebord et des chaussures montantes afin de vous prot ger des rayons de l arc des tincelles et du m tal incandescent en plus d un casque de soudeur ou casquette pour prot ger vos cheveux Il est galement recommand de porter un tablier ininflammable afin de vous prot ger des tincelles et de la chaleur par rayonnement 4 Les tincelles et les projections de m tal incandescent risquent de se loger dans les manches retrous s es les rebords de pantalons ou les poches Il est recommand de garder boutonn s le col et les manches et de porter des v tements sans poches en avant 5 Prot gez toute personne se trouvant proximit des tincelles et des rayons de l arc l aide d un rideau ou d une cloison ininflammable 6 Portez des lunettes tanches par dessus vos lunettes de s curit lors des op rations d caillage ou de meulage du laitier Les cailles de laitier incandescent peuvent tre projet es des distances consi d rables Les personnes se trouvant proximit doivent galement porter des lunettes tanches par dessus leur lunettes de s curit INCENDIES ET EXPLOSIONS La chaleur provenant des flam
13. Alternatively if your ProMotion Nest has ESSI EIA saving option you can redefine the line marking code sequences to correspond the welding torch control commands 9 10 3 Machining Allowance Machining Allowance is an additional area left on cut pieces to be processed by a machining tool When activated the program displays a window with a short description of how to use this tool More important the window contains a setting needed to set machining tolerance on profiles A profile is pointed with the mouse cursor and by clicking the right mouse button the machining tolerance will be added to the whole profile If the tolerance is needed only for a part of the profile the tolerance is set with two clicks of the left button first click the point where the tolerance should start and again where the tolerance should end The machining tolerance variable is set in the Machining Allowance dialog window Enter the width of the tolerance into the edit box and click Ok The dialog window will disappear and the given width is in effect You can activate this tool also by pressing Control and A simultaneously 5 34 NESTING Manual 0 5399 N ICNC PERFORMANCE 5 10 4 Offset This tool calculates the real cutting path when kerf compensation is added This is an advantage if your controller can t do it properly or it takes too much time Kerf compensation s value is half of the kerf width set in Nesting Options NOTE This is an addition
14. ProMotion Nest rotates the shapes as many degrees as given here A full circle is 360 degrees Thus if this variable is set to 90 the shapes will be attempted to nest in four different positions if set to 1 degree ProMotion Nest tries 360 different positions Obviously the smaller the step angle the better the result but a small step angle naturally extends the nesting time e Type of Fit Shapes can be nested according to two principles the First Fit and the Center of Gravity Fit The First Fit setting tells ProMotion Nestto place the shape in the first position it determines will work The Center of Gravity Fit setting tells ProMotion Nest to calculate the position where the center of gravity of the shape is as close to the bottom line of the plate as possible The bottom line of the plate is selected in the Plate Options see below Plate Options e Collar width Sets the distance to be left between the plate s edges and the outermost shapes In other words shapes are never to be placed closer to the edge of the plate than stated in this variable e Nesting direction This option sets the axis on what the nesting process proceeds Whether the nesting process proceeds to the left or the right depends on the starting corner setting e Starting corner Determines which corner the nesting begins at NOTE If Clearance is greater than Collar width then Collar width is set to same as Clearance Leadin Options e Ignore leadins duri
15. dl Overview Main 3 1 3 2 Process Selection Plasma and Gas 3 6 3 0 Front Panel BUTTONS ecco 3 8 3 4 ON OFF Button Descriptions and 3 11 3 5 Auxiliary Button Descriptions and Functions 3 11 3 6 Plasma Button Descriptions and Functions 3 12 df Oxyfuel Button Descriptions and Functions 3 13 3 0 Staring Fi OC COU Cayce a nn 3 14 3 9 PO 3 15 DAO SP 3 15 3 11 Parameter Quick eM 3 16 3 12 To Proceed When Something 3 17 3 14 Advanced Process Selection Features 3 20 SECTION 4 HG 4 1 4 1 Pierce C t SCOR 4 1 4 2 SORA TER 4 2 4 3 VISUS eU E 4 4 4 4 System Setup amp Diagnostic Menus seeren 4 5 SECHON S NES 5 1 5 1 ProMotionO Nest 5 1 D TOODA os cadentes ieu EL DM E MM 5 3 5 3 66 16721 OO E E EEE 5 4 5 4 xciv RNC 5 20 9 9 VASA VITRE NR 5 22 5 6 1001S NETU 5 23 5 VUE ART RR 5 28 5 8 5 29 5 9 5 31 5 10 Special 001 nnns 5 34 5 11
16. options e Enable advanced CNC Some new features have been added to the Robotic CNC language Old versions of WinRobo and Pro3Nest softwares do not support these new features If you are making code to WinRobo older than version 7 5 2 or to Pro3Nest older than version 7 0 9 then do not check this option Note Export always uses the most advanced version This setting applies only to Save As CNC e Add plate to CNC program When saving in Robotic CNC this option saves the plate with all the geometries Use old style leadins This option supports older versions of Robotic and ProMotion Controllers When saving in Robotic CNC and if there are no leadins or leadouts given for a shape this option adds a special leadin code that the controller recognizes The controller has its own leadin settings which apply in cases like this Note Export always uses the leadins that you can see on screen This setting applies only to Save As CNC Rotation Angle Defines the rotation angle that the Rotate tool uses The angle is in degrees Recommended setting is Custom 5 degrees Scrap Cutting These values define the distance between the scrap cutting line piercing end point and the edge of part plate In the FROM field a negative number means that the scrap cutting starts before the edge e g outside of the plate or inside of a part In the TO field a negative number means that the scrap cutting stops before the edge e g inside of the plate or outside of
17. si rate E 100 Apply Profiles Profiles Elements lements Profiles C Program feed rate Click applies to single elements 6 500 mm min Apply Program feed rate Profile feed rate e Apply Remove and exit Close Feed rate mode C Absolute Relative ete Remove and ent Close r Pae How to use this tool When you start this tool it requests the program feed rate This feed rate is set to all profiles and elements which do not have a feed rate If every element already has a feed rate then the tool starts immediately To change a program feed rate insert the new value in the corresponding text field and click Apply When you choose the profiles or elements their feed rates change If the Profiles tab in on top then your click changes the feed rate of profiles It the Elements tab in on top then your click changes the feed rate of elements Profiles and elements get that feed rate which is set in the tab You can set the profile feed rate type in the Profiles tab If you want to use the custom feed rate type its value in the text field and choose Apply The feed rate that you select here is set to all profiles which you choose after this This change has no effect on feed rates which are already set It is applied only to those profiles that you choose To set the element feed rate type in the Elements tab If you want to use th
18. soft limit Service mode Password ready fter 1 upper Fi IHS ready 2 23 Lifter 2 upper soft limit 8 Main arc 1 24 Lifter 1 collision retract 5 Plate contact 1 25 Lifter 2 collision retract Select language 10 IHS start 1 26 Lifter 1 no arc voltage E 11 2j Lifter 2 no arc voltage E n g IS h 12 Main arc 2 28 Lifter 1 serva over current 13 Plate contact 2 29 Lifter 2 servo over current 14 IHS start 2 30 Lifter enabled 15 Torch collision 31 e Save parameters Saves current parameters only available in service mode Load parameters Loads saved parameters only available in service mode e Enter service mode Enables the use of functions and parameters only available in service mode e Select language Select the language in use 4 8 Manual 0 5399 ICNC PERFORMANCE 4 4 6 Installation Tab These parameters are password protected Some parameters are the same as on the Advanced Tab Installation Encoder pulse edges per meter 1280000 Plate contact release speed 60 0 mm min Home distance 20 mm Up limit timeout 200 8 Manual acceleration 010 g Main arc lost timeout 0 2 s Manual deceleration 030 g Upper soft limit distance 20 mm Machine acceleration 0 10 g Lower soft limit distance 212 0 mm Machine deceleration 0 50 g Reference position eror limit 2 0 mm Homing speed 600 0 mm min Voltage gain 20 Out of limit speed 1800 mm min P Gain 60 Torch collision polarity in
19. then it is linear cutting otherwise it is just rapid movement When this option is not set lines without G codes are interpreted as the same type that was the last read G code Unit Scale These options set the default units and scale used in EIA files If an EIA file has unit definition then that overrides this setting The Scale is always defined here Coding If coding is set to absolute then all X and Y coordinates are absolute Otherwise they are incremental and J codes and J codes are the coordinates of the center point of an arc If set to absolute all and J codes as well as X and Y codes are absolute If not they are incremental If X and Y codes are set to incremental then and J are also incremental NOTE Coding and I and J codes have effect only when they are not defined in the EIA file Program Rotation If rotation is selected then all new nestings read from EIA files are rotated 90 degrees counter clockwise Feed Rate and Kerf e Ignore F codes If this option is set then all F codes feed rates are ignored when reading files e Ignore codes If this option is set then all codes kerf are ignored when reading files e Codes a Value is kerf width If this option is set then the value of the code is interpreted as kerf width b Value is kerf compensation If this option is set then the value of the K code is interpreted as kerf compensation F Codes a Relative If this option is
20. ProMotion Cut Next Job Located on the left hand side of the screen the ProMotion Cut Screen is the starting point to navigate throughout the different screens NEXT JOB PREVIEW ProMotion Cut 10 7 36 PROCESS PROGRAM AUS 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 300 Cut parameters 6000 mm min A 3 2 OPERATION Manual 0 5399 ICNC PERFORMANCE PROCESS Opens the process selection window PROGRAM Selecting the Program button will open the selection to Macro Shape Library or download in ProMotion Nest PLATE Plate button open the plate alignment window UUM ame Zoom button opens the zoom window This lets you take a closer look at the parts Opens to the jog screen dialog box Functions like Drive machine to and Rip cut are located under this jog dialog box Selecting on the Act button will allow you to do a trial run of the program select on board manual and the options to open the menu bar on Promotion Cut Next Job Screen Manual 0 5399 OPERATION Z 3 3 ICNC PERFORMANCE 3 1 3 Current Job Located on the right hand side of the screen the Current Job window displays the current job being cut with real time tracking Current Job CUT PATH RECOVERY CANCEL PROGRAM Normally grayed out Activated when a cutting program is stopped by pressing the Torch On Off or the Stop Backup button located on the front panel of the controller Select
21. and fittings in good condition Follow manufacturer s operating instructions for mounting regulator to a compressed gas cylinder 2 Always secure cylinders in an upright position by chain or strap to suitable hand trucks undercar riages benches walls post or racks Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit 3 When notin use keep cylinder valves closed Have valve protection cap in place if regulator is not con nected Secure and move cylinders by using suitable hand trucks Avoid rough handling of cylinders 4 Locate cylinders away from heat sparks and flames Never strike an arc on a cylinder 5 Foradditional information refer to CGA Standard P 1 Precautions for Safe Handling of Compressed Gases in Cylinders which is available from Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment can cause injury or death Therefore 1 Always have qualified personnel perform the installation troubleshooting and maintenance work Do not perform any electrical work unless you are qualified to perform such work 2 Before performing any maintenance work inside a power source disconnect the power source from the incoming electrical power 3 Maintain cables grounding wire connections power cord and power supply in safe working order Do not operate any equipment in faulty conditi
22. fields Area Parts area Real usage or Net usage If you want to know areas click Calculate area or go to Handling options and uncheck the No area calculations option Info You can type additional info related to the current nesting or part to the Info field This info is saved to CNC2 files and when you open such files you can see the written notes To enable the Info field you must click Edit info The notes you make won t be stored until you click Save info 5 3 8 Cost Calculator Use this tool to approximate the cost to cut a part or a nesting The calculator gets the nesting data automatically but you need to provide the cost profile data such as the cutting speed of the machine If you want to use your cost profile at a later time you can save it on your hard drive You can also compare prices of different nestings It s amazing how much you can save simply by using the bridge tool only Cost Calculator 10467 x Cost Profile Nesting Info Machine Time kien Name Default Time Default Rapid En 2 36 Plate area 1 50 m2 Cutting E T2 8 57 Rapid speed 10000 mm min Plate width 1000 mm Delays 712 1200 Plate length 1500 mm Cutting speed 2667 mm min Collar vas Total active 13 49 23 03 GK start ume 7 0 es Changing consumables 2 42 4 50 Cut end time 1 0 8 Idle time 5 00 8 33 Machine hour 100 00 h Parts 32 tt t cms pU Piercings 54 Total 21
23. is used as the collar 9 0 NESTING Manual 0 5399 N ICNC PERFORMANCE Required area shows the minimum width and length of the plate that the current parts need when multiplied and used the given parameters kerf clearance and collar You can either type in a number to rows columns or click the on the grid to create desired number of copies The crosshairs define the 0 reference point for the parts NOTE Kerf clearance and collar are the same that are in the Nesting Options If you change them here their values are applied to the nesting options as well The only exception is the clearance If the clearance is negative here automatic nesting still uses zero as the minimum clearance 5 3 6 MicroCAD Use this tool to edit profiles The tools are described below Hicroc AD Add Circle Add Rectangle Round Comer Remove Rounding Add Point Remove Point Move Point Add Comer Loop Split Part Bend Part Bottom Left Center Manual Add Circle Type the diameter and the coordinates of the center point to the corresponding text fields Click Apply and the circle is added to the Shape The new circle will be the first one in the cutting order Add Rectangle First choose the center point or the bottom left corner of the rectangle Enter the length width and the coordinates in the corresponding text fields Click Apply and the rectangle is added to the shape The new re
24. n fastes inconnus pour la sant 3 Les soudeurs doivent suivre les proc dures suivantes pour minimiser l exposition aux champs lec triques et magn tiques A Acheminez l lectrode et les c bles de masse ensemble Fixez les l aide d une bande adh sive lorsque possible B Ne jamais enrouler la torche ou le c ble de masse autour de votre corps C Ne jamais vous placer entre la torche et les c bles de masse Acheminez tous les c bles sur le m me c t de votre corps D Branchez le c ble de masse la pi ce traiter le plus pr s possible de la section souder E Veillez garder la source d alimentation pour le soudage et les c bles une distance appropri e de votre corps Manual 0 5399 SAFETY INSTRUCTIONS 1 7 ICNC PERFORMANCE E LES VAPEURS ET LES GAZ peuvent causer un malaise ou des dommages corporels plus par ticuli rement dans les espaces restreints Ne respirez pas les vapeurs et les gaz Le gaz de protec tion risque de causer l asphyxie Par cons quent 1 Assurez en permanence une ventilation ad quate dans l aire de travail en maintenant une ventilation naturelle ou l aide de moyens m canique N effectuez jamais de travaux de soudage de coupage ou de gougeage sur des mat riaux tels que l acier galvanis l acier inoxydable le cuivre le zinc le plomb le berylliym ou le cadmium en l absence de moyens m caniques de ventilation efficaces Ne respirez pas les vapeurs d
25. pressures that will be used for the selected cutting process Manual 0 5399 OPERATION Z of ICNC PERFORMANCE 3 3 Front Panel Buttons The iCNC Performance operating control panel is located below the LCD graphics screen Most machine motion and cutting functions are initiated using this operating control panel THERMAL DYNAMILS a B MANUAL ZERO SPEED STOP ON OFF AUXILIARY PLASMA OXYFUEL DOWN BACKUP START POINTER PLASMA AUX 1 PREHEAT HI PREHEAT TIMER O ON O OFF AUTO DRIVE ENABLE DRIVE ENABLE DOWN PLASMA TORCH PROGRAM HEIGHT OXYGEN 3 3 1 Speed Potentiometer Turning the potentiometer counter clockwise decreases the actual speed in comparison with the programmed speed This potentiometer is only used in special cases such as temporarily slowing down the cutting speed Turning the dial down below 100 causes the Torch Hold Corner signal to be activated which freezes the automatic torch height control at that height In most cases the speed potentiometer is set at 100 clockwise 3 3 2 Direction Jog Keys MANUAL MODE must be activated before using the jog function Press and hold a directional button and the machine will move in that direction Releasing the button will cause the machine to stop Pressing and holding two adjoining directional buttons will move both axis simultaneously in a 45 degree direction 3 8 OPERATION Manual 0 5399 ICNC PERFORMANCE 3 3 3 Manual Mode Button
26. same ESSI and EIA options than the file open does Where it dif fers from the normal file open is that keeps things simple It does not try to reason which shapes are holes or where the leadins or anything else is Raw import just reads the file in as itis This way you can utilize any kind of cutting program which is not otherwise supported by the logic of ProMotion Nest i e common cutting and programmed stops 5 44 DNC Use this tool to load files from DNC connection ProMotion iLink must be running on the PC you are downloading the files from DNC COM 1 X ext Abart OO0356 CNC Raw import Load Previous File Oper Cancel mof connection Next Allows the user to browse the files available in ProMotion iLink working directory folder Available filenames are displayed in the text field just below this button Load Allows the user to start DNC download The file currently displayed in the text field starts loading You can just type the file name into the text field and choose Load Abort Allows the user to abort DNC download Load Previous Allows the user to utilize the last file again without downloading File Open Allows user to change to normal File Open dialog Use this to locate a file in the controllers hard drive or on the network that is accessible Manual 0 5399 NESTING 9 21 ICNC PERFORMANCE y 5 4 5 Import This tool imports a nesting created by ProMotion Cut 9 4 6 E
27. the left mouse button The new transferline point will be the last in the cutting order The cutting order can be changed by the Change Cutting Order tool 5 9 6 Scrap Cutting E Use this tool to create scrap cutting lines to your nesting Scrap cutting lines used to cut the scrap out of the plate when the cutting program is completed Use this tool only on ready nestings Do this e Click the point where you want to start your scrap cutting line This point should be outside of the plate or inside of a part e Now a RUBBER BAND follows your mouse e Click the next point of the scrap cutting line If that point is outside of a part and inside of the plate it will become a waypoint That means that the scrap cutting line goes through this point If the point is inside of another part or outside of the plate the scrap cutting line ends at the boundary of the part or the plate A margin is left to the beginning and to the end of the scrap cutting line These margins can be set in the Handling options Hint When crossing the plate s edge do it by drawing the scrap cutting line from part s edge to the plate s edge This way you don t have to be that exact when setting the plate s edge Manual 0 5399 NESTING 5 33 ICNC PERFORMANCE 5 10 Special Tools Special Tools are tools which are not needed by every user of this software but can be utilized in special cases 9 10 1 Point Marking Use this tool to select w
28. then left click the corner where you want the loop Loops like this make it possible to cut very sharp corners Split Part This tool splits parts Select the option and insert parameters if required then apply and click the part you want to split There are three options to split parts 1 Equal length Use this option to split part equally to given number of parts 25 Max length This option splits the part maximizing the length of new parts The max length of new parts is given as parameter D Manual Use this option to manually split parts Hold the left mouse button down and draw a line across the part and then release the button The part is split along that line you drew Bend Part This tool bends a rectangular part Set the bending value apply and then click on the part to bend it ama The bending value is the height of the arc at its highest center point as shown in the picture above Bending value is displayed as the red line If there are any holes inside the part they are shifted accordingly but they are not bent NOTE This tool can bend rectangles only Any other shapes are bent incorrectly or not at all 5 3 7 Nestinfo Nestinfo displays information about the current nesting Nestinfo contains following information Plate e Plate name the name of the current plate e Area the area of the plate square foot or square meters e Plate width inches or m
29. tomatic nesting process Click the part you want to freeze You will now see the parts highlighted in bright blue To freeze multiple parts draw a rectangle around the desired parts To unfreeze a part click it again NOTE Automatic nesting cannot nest inside holes of frozen parts If you want to nest to those holes you should do it manually and then freeze the parts inside of them too 9 8 9 AutoFill EE This tool fills the remaining area of the plate with the copied shapes ProMotion Nest nests all shapes automatically to get optimal fill The nesting options affect to the performance of this tool Follow these steps to fill a sheet 1 Copya shape by using the Copy tool 2 Click the AutoFill button 5 30 NESTING Manual 0 5399 N ICNC PERFORMANCE 5 9 Cutting 5 9 1 Optimize Cutting Order Use this tool to let ProMotion Nest to make cutting order for you ProMotion Nest will calculate the optimum cutting order so that parts are always cut near the edge of the plate Please note that when a part is cut off the plate it leaves a hole which is now the edge The idea is to prevent the heat to bend the plate If you are not happy with the result you can easily change the cutting order using the Change Cutting Order tool 5 9 2 Change Cutting Order HPE When this tool is activated the following dialog will appear Cutting order Optimize order Lock first object Change cutti
30. tool to add feed rates i e cutting speeds to your cutting program You can set feed rates for individual profiles or elements While you are using this tool you can see several flags with different colors on screen Each of those flags display what is the feed rate after the flag The color of the flag indicates the type of feed rate i e program profile and element feed rates Red flags mean error and you shouldn t see them If you do see a red flag just reset the feed rate for that element Definition of different feed rates Program feed rate The default feed rate for the whole cutting program if there are no profile or element feed rates set Profile feed rate The feed rate for a single profile The whole profile is cut with this feed rate if there are no element feed rates set The profile feed rate can be set to program feed rate or custom feed rate Element feed rate The feed rate of a single element which can be set to program profile or custom feed rate NESTING Manual 0 5399 N ICNC PERFORMANCE Feed rate modes Absolute Feed rates are given in millimeters or inches per minute Relative Feed rates are given relative 1 100 to the current cutting feed rate This type is supported only in ProMotion iCNC controllers This would be similar to turning the feed rate override potentiometer of the controller Feed Rate x feed rate 500 mm min Apply Appi Profiles Feed Rate X Program
31. treatment Cutting speed too low An abnormally low cutting speed results in heavy gouging of the cut surface and slag adhering in large globules Under this condition oxygen i and fuel gas are being wasted Cutting speed too high An extremely high cutting speed results in heavy lag as shown by the curved lag lines on the cut surface The face is reasonably smooth but somewhat concave Slag will adhere during cutting but it may be removed with ease Heavy lag cutting is recommended for straight line cuts only Nozzle too far from surface When carrying the nozzle too high above the work excessive rounding of the top edge occurs Also the cutting speed may have to be lowered With the correct nozzle clearance the preheat flames should not be over 1 4 above the top surface of the work Nozzle too near surface When the nozzle is carried too low part of the preheat flame s inner cones become buried in the cut kerf This produces grooves in the cut face and excessive melting of the top edge Also the flame becomes subject to popping and lost cuts may result Excess cutting Oxygen If the cutting oxygen pressure is too high or the nozzle size too large a reduction in cut quality non will result Nozzles are made to operate within a limited range of torch pressures Therefore excessive oxygen pressure causes distortions in the oxygen stream once it leaves the nozzle Ex
32. while cutting a program Adding tool offset in your cutting program is not required Manual 0 5399 OPERATION Z 3 21 ICNC PERFORMANCE 3 14 2 Line Marking Marking speed This is the speed selection for the marking tool SD1 SD2 and SD3 These delays are typically not used when using plasma as the marking device but are fully available and programmable SD4 Typically used for starting the Initial Height Sensing and igniting the marker Move Delay Delay before motion will begin ED1 Typically delay to wait the arc to extinguish ED2 This delay is typically not used ED3 This is the time that the controller waits after the marking is completed torch up before commanding the machine to move to the next position 3 14 3 Point Marking SD1 This delay is typically not used but is fully available and programmable SD2 Typically used for a marker down delay This is the time that it takes for the marker to descend to marking height SD3 This is the marking time or the time the marking takes place If using plasma as the marker device this would be the depth of the mark SD4 This is a marker up raise time or the time it takes for the marker to climb up to travel height Move Delay This delay is typically not used Rapid This delay is typically not used 3 22 OPERATION Manual 0 5399 N ICNC PERFORMANCE 3 14 4 Edit and create a process Process Database The iCNC Performance has a unique feature that allows building a database for speci
33. 0 100 120 140 160 Title bar The Title Bar is at the top of the ProMotion Nest window It contains the version number the name of the registered user and the name of the active job Manual 0 5399 NESTING 971 ICNC PERFORMANCE y Menu bar The Menu Bar lies just below the Title Bar and allows you to choose one of the following File Menu View Menu Tools Menu Options Menu Registration Menu Help Menu Toolbar The Toolbar lies just below the menu bar The Toolbar contains buttons for quick access to most of the important tools of ProMotion Nest i e load save macros See more at chapter Toolbar Work window The Work Window is the large white area in the middle of the screen The Active Job is displayed here and editing is also done here Coordinates Y coordinates are displayed on the left side of the work window and X coordinates are just below the work window Status bar The Status Bar lies at bottom of the ProMotion Nest window The Status Bar displays messages and hints from ProMotion Nest Italso displays the current coordinates of the mouse cursor when it is on in the work window Toolbox The Toolbox is located at the top right corner of the ProMotion Nest window It contains buttons for most editing tools 3 1997 2012 Victor Technologies ProMotion Nest ProMotion Nest v4 32 Plate list The Plate List is located just below of the toolbox The Plate List contains a list of all plates loa
34. 12 if the torch runs off the plate again 14 When the trial run is over return to ZERO 3 12 7 Other Way to Check the Cutting Area You can check if the next cutting program fits on the plate this way as well 1 Bring the cutting program to CURRENT JOB window by clicking the Next Job Preview button in it 2 Setthe torch on 0 0 point and press ZERO po Move the mouse on this window and click the left mouse button A window appears which shows the torch position with big numbers and the mouse cursor starts to follow the torch position Drive the torch on the critical corner of the program and check if there still is plate under the torch Use zoom to check the situation exactly Zoom window follows the torch automatically If the program location is OK press the MANUAL MODE button and then select return to the O 0point De qe DE od Free the mouse by pressing the left mouse button on the right screen area again This also closes the Tool Position window Manual 0 5399 OPERATION Z 9719 ICNC PERFORMANCE 3 12 8 Cut Path Recovery This tool is used to return to cut path in the event the program was stopped and the torch was moved from the path 1 Press and release the TORCH ON OFF button to stop motion and cutting 2 Turn on the MANUAL MODE by pressing and releasing the MANUAL MODE button and use the Jog key buttons to drive the torch to a convenient place to perform work on the torch 3 Disable the plasma power supply by pres
35. 3 29 Undo a Use this tool to cancel the last action 5 3 30 Trash Closes the current nesting which is seen in the work window If there are more than one nesting open the next one will be displayed in the work window 5 4 File Menu The File menu is used to open existing files save new files and exit the application Here is a list of all items in the File menu Item Action ESETA Raw impor T impor Epor NOTE Some of these tools were already explained in the Toolbar chapter Those tools are not repeated in this chapter 5 20 NESTING Manual 0 5399 N ICNC PERFORMANCE 5 4 1 Save As saves the current nesting the one in the work window in the chosen format Possible formats are ESSI EIA DXF ROBOTIC CNC and CNC 2 For more information about ESSI and EIA see ESSI Options and EIA Options In the demo version of ProMotion Nest no saving is possible It is also possible to save point marking programs This is an optional module See more at topic Point Marking NOTE ProMotion Nest cannot read ROBOTIC CNC If you want to edit your cutting programs later then the best format is CNC 2 5 4 2 Print This tool prints the current nesting to the default printer 5 4 3 ESSI EIA Raw Import Use this tool to load ESSI and EIA files to ProMotion Nest when you have a cutting program that is ready to be sent to cutting without editing Basically this is just like the normal file open This tool uses the
36. 31 35 86 Job preparation amp mn Nesting width 974 mm Effective usage 100 0 Nesting length 425 mm Material Costs Parts area 0 26 m2 Consumable set 50 00 Cut length 13876 mm Plate Pierces per set 300 Whole plate Are seconds 312 s Rectangle Change time 15 min Arc seconds per Efficiency 100 piercing 5 8 s prc Consumables 3 00 Sas por CANOU 20 00 Avg rapid speed 4538 mm min Gases 1 73 Electricity per cut hour 40 00 Electricity 3 47 Other per machine hour 10 00 Material cost calculator Save Offer Material cost 300 00 m2 Total 150 73 Save for comparison Compare Torches d Acceleration zo mg Load Save Close Total 186 65 Manual 0 5399 NESTING 5 11 ICNC PERFORMANCE y DATA Cost Profile Cost profile is a collection of variables that describe how the machine user or material affects the costs Name Profile name e g plasma iron 0 25 inches Rapid speed Usually a constant value Cutting speed Dependent on the tool material type and thickness and process Cut start time Time between the torch coming to the piercing point and the start of the cutting movement Cut end time Time between the torch coming to the end of a cut profile and the start of the rapid movement Machine hour The correct value of machine hour cost is essential to get reliabl
37. 9 OPERATION Z 3 23 ICNC PERFORMANCE 3 oet your parameters TD Process Selection v1 0 8 10 New Ok Process ID 10002 Material Mild Steel Thickness 50mm gt New omms Speed 280 Kerf 2 10 mm Creep speed 200 Creep time 20 Us Speed This is the machine cutting speed This setting duplicates the cutting speed setting in folder 1 Parameters Changing one changes the other Kerf The process kerf Creep speed The initial speed of the cutting torch will immediately be activated after the start command is given The duration of this speed is determined by the setting of the Creep Time parameter This ramp up speed is used only shortly to assist with piercing After the creep time is over the torch accelerates decelerates to the normal cutting speed Creep time Length of the time for using the creep speed Note Allows the operator to put notes corresponding the changes that were made to the process 3 24 OPERATION Manual 0 5399 N ICNC PERFORMANCE 3 14 5 Cutting Parameter Delays NOTE Parameter windows may alternate based on the machine setup If a delay is not shown it is set as hidden Delays can also be locked so that editing the time value is not possible See installation service manual about setting delays Pictures for reference only TD Process Selection v1 0 8 ai x Material Mild St
38. AN AVERTISSEMENT Ces r gles de s curit ont pour but d assurer votre protection Ils r capitulent les A informations de pr caution provenant des r f rences dans la section des Informations de s curit suppl mentaires Avant de proc der l installation ou d utiliser l unit assurez vous de lire et de suivre les pr cautions de s curit ci dessous dans les manuels les fiches d information sur la s curit du mat riel et sur les tiquettes etc Tout d faut d observer ces pr cautions de s curit peut entrainer des bles sures graves ou mortelles PROT GEZ VOUS Les processus de soudage de coupage et de gougeage produisent un p niveau de bruit lev et exige l emploi d une protection auditive L arc tout comme le soleil Qe met des rayons ultraviolets en plus d autre rayons qui peuvent causer des blessures la peau et les yeux Le m tal incandescent peut causer des br lures Une formation reli e l usage des processus et de l quipement est essentielle pour pr venir les accidents Par cons quent 1 Portez des lunettes protectrices munies d crans lat raux lorsque vous tes dans l aire de travail m me si vous devez porter un casque de soudeur un cran facial ou des lunettes tanches 2 Portez un cran facial muni de verres filtrants et de plaques protectrices appropri es afin de prot ger VOS yeux votre visage votre cou et vos oreilles des tincelles et des rayons de l arc lors d une op
39. CW set the codes which are used when saving EIA files If Null G is linear is selected then there will be no code before rapid movement or linear cut Load amp Save As If you need to save different EIA files from different sources which use various types of EIA it is useful to save the settings for each EIA type separately Save the settings by choosing Save as and load them back by choosing Load See also EIA Programming 9 44 NESTING Manual 0 5399 N ICNC PERFORMANCE 5 16 Nesting Options Nesting Options Common options e Kerf width The kerf width of the selected cutting process e Clearance Specifies the minimum distance always to be left between shapes nested on a plate If this variable is set to zero 0 the program places them as close to each other as the kerf width allows e Fit Part in Part If selected the program will attempt to place smaller shapes to the holes of the larger ones e Part sequence method Shapes can be nested either in an order set by their surface area or their perimeter If sort by area is chosen then those shapes that have largest surface area will be nested first When sort by perimeter is chosen the shapes which have largest perimeter will be nested first A shape which is long but thin has a great perimeter but a small surface area Part Options e Step angle When nesting shapes onto a plate ProMotion Nest attempts to place them on it in different positions Between each attempt
40. Check the LEADIN box Choose the type of leadin you want Check the LEADOUT box Choose the type of leadout you want Click the profile to add the leadin and leadout How to change all leadins and leadouts of Hole profiles Repeat steps 1 4 above D 8 Check the REPLACE EXISTING LEADINS box Select HOLE PROFILES Choose ADD How to remove all leadouts 1 qe Set leadin to None Set leadout to None Select target ALL PROFILES Click ADD 5 7 Marking 9 7 1 Marking Text With this tool you can insert text on plates for marking Selecting this tool activates the window below Marking text Insert the marking text here PART 36 Text height 25 Text angle e To Insert text for marking 1 Write the text you wish to mark into the field Insert the marking text here Set the text height The minimum allowed height is 5 mm 0 2 inches Set the text angle 0 360 degrees Click Apply to confirm the changes Click the part you want to mark The text is inserted to the spot you clicked NOTE This is an additional module and it is not included in the basic version of ProMotion Nest NESTING Manual 0 5399 ICNC PERFORMANCE 5 7 2 Hole to Point This tool converts round holes to point marking points You only need to click those holes you want to convert NOTE You cannot reverse the conversion If
41. ERCING UP Enter the desired time to raise the torch for piercing STAY UP Enter the desired time to stay up before the pierce lowering time begins e PIERCING DOWN Enter the desired time to lower the torch to the cutting height Manual 0 5399 OPERATION Z 3 29 ICNC PERFORMANCE NOTE The piercing up and piercing down timer values are usually set to equal amounts as not to create a ramping or stepping effect This is also true with the primary raise and lowering of the torch when no automatic capacitive height sensor is installed Examples SD4 starts the event timing sequence for piercing up down routine The initial values for piercing up time stay up time and piercing down time are set to 1 second for this example 1 Cutting oxygen turned on as torch raises to piercing height Set SD4 value from 1 9 seconds 2 Cutting oxygen turned on during stay up time Set SD4 value from 1 1 1 9 seconds 3 Cutting oxygen turned on while torch lowering to cutting height Set SD4 value from 2 1 2 9 seconds Start Move Delay is the time allocated for the initial piercing through the material After this time has expired motion automatically begins ED1 is the first delay executed after the program is finished or the cut manually interrupted by the operator This delay is usually used for the primary raising of the torch after completion of the current cut This allows the torch to clear any parts which may have tipped up prevent
42. ING Of ICNC PERFORMANCE 5 3 5 Rows and Columns Use this tool to multiply parts You can set the number of rows and columns The final number of copies will be rows x columns For example 3 rows times 4 columns will result as 3 x 4 12 copies uas D N ows an Part Width Length 120 00 mm 144 22 mm Rows defines how many rows of copies there will be Columns defines how many columns of copies there will be Kerf width The minimum kerf width is zero Clearance and kerf width define the distance between copies The distance is clearance 2 x kerf width The clearance may also be negative if you want to copy the parts closer to each other Hint If you need different clearance values in X and Y directions then do the columns first rows 1 colums n and then the rows rows m columns 1 This way you will get m x n copies Please see the below picture as an example of negative Y clearance Collar width is an extra distance that is left on the edges of the nesting This is used to avoid the edges of plate which may not be of good quality For example if you have roughly a 50 x 50 plate but the edges are not perfectly straight then you can set the collar as 1 and the usable area is then 48 x 48 The minimum collar is zero but if the clearance is greater than the collar then the clearance
43. LISH WARNING These Safety Precautions are for your protection They summarize precautionary informa A tion from the references listed in Additional Safety Information section Before performing any instal lation or operating procedures be sure to read and follow the safety precautions listed below as well as all other manuals material safety data sheets labels etc Failure to observe Safety Precautions can result in injury or death PROTECT YOURSELF AND OTHERS Some welding cutting and gouging processes are noisy p 1 and require ear protection The arc like the sun emits ultraviolet UV and other radiation and can injure skin and eyes Hot metal can cause burns Training in the proper use of the pro cesses and equipment is essential to prevent accidents Therefore 1 Always wear safety glasses with side shields in any work area even if welding helmets face shields and goggles are also required 2 Use a face shield fitted with the correct filter and cover plates to protect your eyes face neck and ears from sparks and rays of the arc when operating or observing operations Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric arc or hot metal 3 Wear flameproof gauntlet type gloves heavy long sleeve shirt cuffless trousers high topped shoes and a welding helmet or cap for hair protection to protect against arc rays and hot sparks or hot metal A flameproof apron may also be des
44. NCE 5 5 9 Change Compensation Side rt Change the compensation side by moving the mouse cursor over the element and clicking the left button 5 5 10 Change Cutting Direction Change the cutting direction by moving the mouse cursor over the element and clicking the left button 5 9 11 Split Element 4 An element be split in two by moving the mouse cursor the desired split point and clicking the left mouse button 5 5 12 Join Profiles 1 Use this tool to close an open profile join two or more open profiles Follow these steps e Hold down the left mouse button Drag a rectangle around start end points of open profile s e Release the mouse button Manual 0 5399 NESTING 5 25 ICNC PERFORMANCE 5 5 13 Leadins H By using this tool you can add remove and modify leadins and leadouts When the Leadins tool is active the dialog window below is visible Use that window to change the parameters of the leadins and leadouts If a value is shown red the lead in cannot be created picture showing too small radius CNN x Examples Hole Outer contour on Leadin Length 9 00 Radius 0 00 mm Angle Un 0 Kerf width 2 00 mm m Leadout None Length 0 00 mm Radius 0 00 mm Angle U 5 D verbum 0 00 Replace existing leadins Remove Add Close Leadin and Leadout types ee Nothing No leadin or leadout This ty
45. Overview DXF format is supported by most present day CAD softwares DXF files can be either ASCII or binary formats Because ASCII DXF files are more common than the binary format the term DXF file is used to refer to ASCII DXF files Requirements and Recommendations DXF files are an interface between CADs and nesting software like ProMotion Nest There are certain recommendations and require ments when creating and converting DXF to ProMotion Nest which should be noticed e tis useful to put geometries on their own separate layer and name that layer so that it is easily recognized e g PROFILES ProMotion Nest detects different layers and allows the user to choose which layers to load e fthere are multiple parts it is a good idea to put each of them on their own separate layer e g PART1 PART2 etc e Line and point markings must be placed on their own layers Use POINT or CIRCLE entities for point marking e Draw the parts in 1 1 ratio Do not scale them ProMotion Nest reads the coordinates as they are in a file e Try to avoid open gaps between different elements Use POLYLINE or other objects that draw a continuous line e All marking objects point marking line marking or text objects must be inside parts Outside objects are ignored e Supported objects are LINE ARC SPLINE CIRCLE POINT POLYLINE VERTEX ELLIPSE TEXT MTEXT and SEQEND 9 48 NESTING Manual 0 5399 ICNC PERFORMANCE Unsupported CAD fe
46. PERFORMANCE 5 6 Tools Menu Tools menu contains tools to manipulate nestings You can fix parts add marking nest manually or automatically set cutting order add bridges and do many other things The tools are organized in an order where they are usually used For example you should do automatic nesting before you add bridges NOTE Some tools are not part of the standard ProMotion Nest but they are options that may be bought separately Depending on the options in your license some tools may not be available NOTE Some tools of this menu were already explained in the Toolbar chapter Those tools are not repeated here 5 5 1 Remove The left mouse button activates area deletion Keep the left mouse button pressed down and move the mouse A rectangle will follow the movement of the mouse When you release the left mouse button all the profiles that are completely inside the rectangle will be deleted If you click the right mouse button only a single element or a transferline point will be deleted 5 5 2 Copy LI This tool allows user to copy different objects to the clipboard from where she he can paste them to any nesting The object that is to be copied can be chosen from the Options menu There are two kinds of objects that can be copied shapes and nestings An object can be copied by moving the mouse cursor over the part and clicking the left mouse button 5 5 3 Cut x Use Cut to move shapes to the clipboard You
47. a stand on dry boards or an insulating platform and wear rubber soled shoes Put on dry hole free gloves before turning on the power 9 Turn off the power before removing your gloves 10 Refer to ANSI ASC Standard 249 1 listed on next page for specific grounding recommendations Do not mistake the work lead for a ground cable ELECTRIC AND MAGNETIC FIELDS May be dangerous Electric current flowing through SS conductor causes localized Electric and Magnetic Fields EMF Welding and cutting current creates FS EMF around welding cables and welding machines Therefore 1 Welders having pacemakers should consult their physician before welding EMF may interfere with some pacemakers 2 Exposure to EMF may have other health effects which are unknown 3 Welders should use the following procedures to minimize exposure to EMF A Route the electrode and work cables together Secure them with tape when possible N 2 oO en B Never coil the torch or work cable around your body C Do not place your body between the torch and work cables Route cables on the same side of your body D Connect the work cable to the work piece as close as possible to the area being welded E Keep welding power source and cables as far away from your body as possible FUMES AND GASES Fumes and gases can cause discomfort or harm particularly in confined spaces Do not breathe fumes and gases Shielding gases can cau
48. a part Suggested values are From Part gt kerf width To Part lt negative kerf width From Plate edge 0 if the plate edge is set correctly else 0 and To Plate edge gt 0 Default Leadins In this section you can define what kind of leadins and leadouts are automatically added to all profiles when loading DXF or creating macros If you load EIA or ESSI files no leadins or leadouts are added because they usually have programmed leadins and leadouts Marking Options These settings affect how and which markings are saved to a CNC file and then eventually marked f Mark all is selected then both line markings and point markings are saved e f Skip all marking is selected then none of the markings are saved This is a useful option if you just want to print the part names on paper but not really mark them e f Skip line marking is selected then only point markings are saved e f Skip point marking is selected then only line markings are saved e f Extended part marking is checked then the Line marking start block please see Code Sequences is saved just before every line marking and the end block is saved right after every line marking This applies to point markings as well This option is disabled if you have Do all markings first option checked e f Do all markings first is checked then all the markings are saved first and after them the parts to be cut Go to origin after mark ing moves the machine to the ze
49. achine motion Press and release the STOP BACKUP button again to move the machine in reverse or backup on path Pressing STOP BACKUP but ton again will stop motion HINT Both the Stop Backup and Torch on off buttons work identically when running a cutting program Pressing either button will allow cutting to stop 3 10 OPERATION Manual 0 5399 ICNC PERFORMANCE 3 4 ON OFF Button Descriptions and Functions CAUTION Most buttons have 2 functions different color LEDs indicate the state Pressing a button will toggle the function ON OFF and keeping the button pressed in for 3 seconds will toggle the function to AUTO Green LED indicates ON state and orange indicates AUTO state If both LEDs are OFF then the state is OFF ON OFF 3 4 1 Input Power Switch Push the button and keep it pressed in for five seconds and it will turn on power to the CNC The only way to switch power OFF is using Windows shutdown This will switch off all power in the controller 3 4 2 Drive Switch DRIVE ENABLE e ON will turn servo enable ON and allow machine motion e OFF will prevent machine motion HINT When drive enable LED is Green the drives are enabled When the LED is orange button has been pressed but the software restricts the output to activate 3 9 Auxiliary Button Descriptions and Functions CAUTION Most buttons have 2 functions and the different color LEDs indicate the state Pressing a button will toggle the func
50. al 0 5399 iHC 4 1 iCNC PERFORMANCE 4 2 iHC User Interface The iHC can be almost invisible to the operator because the Height Control Parameters can come from the cutting program or fully automati cally from the Material Thickness Tool parameter sets This window does not hide any controls normally used to run the iCNC Performance it can be viewed at all times This chapter describes the User Interface at the controller when the automatic parameter setting features are not in use This allows for changes at the time of cutting and or settings before starting to cut To start the software select iHC exe Shortcut from the Windows Start menu g Support N ProMotion Nest b 5 System Status Operator Documents ProMotion Cut Pictures E iHC Music Games Computer Control Panel Devices and Printers Default Programs d All Programs Help and Support Search programs and files Shut down ire e sse Z Z i Main Bar 21515 gt lt lt ET 120 0 1 CUTTING MODE SE 1 l me 58 el EE The large right pointing arrow can be used to make the iHC main bar smaller This allow operator to see position and other information about the machine Info System Status HD Not Locked iHC v2 0 17 lol File view About CUTTING MODE Speed D mm min Speed m MC x 0 00 Y 0 00 100 0 0 om 7 iHC IHS Test Find plate Setup T e On the left side of the main wi
51. al module and it s not included in the basic version of ProMotion Nest 5 10 5 Anchor Use this tool to anchor the part on plate during cutting This is done by creating small gaps on the cutting profile so the cutting is ceased on these gaps The length of the gaps can be set in the tools ini see ini files 5 10 5 Common Cut Common Cut tool let s you join two parts in a way that their common section line is cut with a single cut This can save a lot of time If the cutting speed is low Follow these steps e Move two parts close to each other e Select this tool e Move mouse pointer inside one of the parts and press left mouse button e Move mouse pointer inside the other part while pressing the left mouse button e Release the mouse button and the parts will be merged NOTE The correct kerf must be set in the Nesting Options before the use of this tool 5 10 7 Drill Select Adds a special tool selection code for a point marking drill point Select the tool from the menu that pops up when you right click the screen When this tool is active you can see small flags on each point marking point The flags show the currently selected tool 9 10 8 Plate Part Plate This tool simply converts a plate to a part and vice versa Exceptions Conversion does not work if here are any parts on the plate here are multiple parts on screen Manual 0 5399 NESTING 5 39 ICNC PERFORMANCE y 5 10 9 Single Multit
52. ally locate the absolute zero home location As a default this is normally set at the bottom left corner of the cutting table however this is selectable in the set up parameters If you select No the dialog box disappears and no movement is executed CRE cx Start homing procedure Start homing lose Driving toe limit 3 10 Jog When selecting the Jog Button the Jog dialog box will appear x a op Drive tool to Bip Cut Use program rotation Offset 1 0 00 mm 0 00 mm Drive distance Offset 2 0 00 mm a ag mm Drive distance Tables me A D mm Drive to a Set Table Homes Program Zeros Number l A 157 78 mm Drive to Y 382 52 mim Set Close a absolute SEITE 0 0 here You can use the Jog tool only when a cutting program is not running and the controller is not in Manual Mode Use this tool to drive the machine to a position X Y or to drive a distance X Y from the current position Driving is usually done in rapid speed It is also possible to cut with this tool if you have checked the Rip Cut box If Use program rotation is checked the coordinates where you drive are corrected according to the program rotation The program rota tion is set in the parameter quick view screen Manual 0 5399 OPERATION Z 3 15 ICNC PERFORMANCE Offsets If there is a need to drive the same distance often i e plasma torch to the same position where gas torch was
53. ange color to indicate selection When you click the second object the first object will become unselected and the cutting order will change In the Move One Step method you just choose the object which cutting order you want to change and then use the Step arrows to change the cutting order If you click the left step arrow the selected object will be cut earlier and if you click the right arrow it will be cut later Manual 0 5399 NESTING 5 31 ICNC PERFORMANCE 7 In the Line method you draw a line over the parts or holes whose order you want to change The cutting order of the first part hole that the line overlaps won t change The rest of the overlapped parts holes will come immediately after the first one In the Free select method you just click the profiles in the order you want to cut them and then choose apply This method is named free select because you can select any cutting order between parts and holes e g you can first cut all the holes in your nesting and then all the parts This method may disarrange the internal data structures of ProMotion Nest which may cause automatic nesting and some other tools to fail You should only use this method if you can t set the cutting order with the other methods If you decide to use this method use this when you have done everything else for your nesting Apply button is used in combination with the Show order and the Free select methods Unselect button removes all selections Clo
54. arting point of the cancelled program If you want to terminate the program during the rapid movement the procedure is mainly the same The only difference is that you stop the machine using STOP BACKUP button instead of the TORCH ON OFF Manual 0 5399 OPERATION Z 3 17 ICNC PERFORMANCE 3 12 2 Difficulties While Piercing NOTE If the piercing fails in Plasma Mode the machine will stop 1 Adjust the speed slower with the SPEED knob if necessary Drive slowly backwards by pressing and holding STOP BACKUP and the machine will reverse on program path Stop the movement after passing the missed piercing point by releasing STOP BACKUP again Turn the speed back to 100 oo pe Start the program again by pressing MOVE AHEAD If the piercing fails at the first programmed piercing point start a new piercing sequence by pressing TORCH ON OFF Please notice that the movement backwards without cutting may be adjusted so that the speed is automatically reduced 3 12 3 If the Cutting Fails If the cutting is terminated e g for too high speed 1 Stop the movement and cutting by pressing TORCH ON OFF or STOP BACKUP 2 Adjust the speed slower with the SPEED knob if necessary 3 Drive slowly backwards by pressing and holding STOP BACKUP and the machine will reverse 4 Stop the movement by releasing STOP BACKUP Turn the SPEED back to 100 6 Click on READJUST CUT PARAMETERS button on the Current Job screen 7 R
55. ate has a blue bar on it it is selected These tools are available in the plate window Activate Click the name of the plate to activate it Nest Double Click the name of the plate and it will be automatically nested Popup menu Right Click the window to open a popup menu The menu contains following commands e New Plate Creates a new plate e Change plate Changes the plate s size e Trash Trashes the current plate and the nesting in it e Rename Renames the current plate e Nest Automatic nesting on the current plate e Move Nesting to see below e Marking Text Activates the marking text tool e Print Extras see below 5 46 NESTING Manual 0 5399 N ICNC PERFORMANCE Move Nesting to This tool changes the position of the whole nesting When you select this tool the window below appears Move Nesting to Left 100 0 0 Right Bottom 620 5 00 Top EH NN ME Left is the nestings distance to the left side of the plate If this number is negative it means that the nesting is over the plate s edge Right bottom and top work in the same way You can change left and bottom values When you choose APPLY the nesting moves and the values right and top in this window are updated OK is like APPLY but it also closes this window Print Extras Use this tool to add your own notes at the end of print sheet When you print a nesting these four lines will be at the bottom of the sheet Label Text Cust
56. atures e DWG or binary files are not supported at all e Other unsupported objects are INSERT IMAGE and HATCH There are others too but these are the most common Additional Notes e ELLIPSE objects are converted to lines with maximum allowed error of 0 1 mm The error level can be adjusted in ini files e Marking text TEXT and MTEXT objects requires the optional Advanced Marking software module e Scanned drawings which are converted to DXF usually make poor CNC code The scanner generates unnecessary short lines e g a one inch long straight line may be formed of one hundred 0 01 lines Often times the lines may be too short to be accepted at all When that happens ProMotion Nest leaves empty gaps in those places indicating an open profile which cannot be nested until all entities are joined That is time consuming and in efficient This will cause much larger CNC files to be generated which leads to longer operation time at the CNC controller When using scanned drawings build them with as long elements as possible 9 21 4 CNC 2 We have developed an advanced CNC language Robotic CNC 2 CNC 2 is more accurate than old Robotic CNC ESSI or EIA languages So far ProMotion Nest is the only software that supports CNC 2 CNC 2 is an excellent choice for making backup copies It saves not only the nesting but also the plate 9 21 5 Line and Point marking If a nesting contains line or point markings they are merged t
57. be minimized with the button on the far right that looks like a dash D e There are two text fields at the top right corner of the iHC window In a normal situation it should read Cutting Mode in the upper field If the height control isn t running or there is a connection problem it reads WAITING FOR REPLY on the lower text field Lower text field will also show status messages like lower software limit CUTTING MODE n Plo e You can monitor the status of the station by viewing colors changing on the screen The number field on the right from the cut height text shows when the AVC is active when IHS start is ON and when the torch is in cutting height Manual 0 5399 iHC 4 3 ICNC PERFORMANCE y 4 3 Main Settings Clicking the Setup button will open the Setup Main screen under the iHC Info Bar ProMotion iHC Setup Arc Voltage From Plate 00 18905mm ms v ae y Shade Pierce height Cut height Hold ON 100 40 50 40 300 V 50 0 mm Pierce height ime Pierce Down Time height AVC Hold OFF e delay 10s 005 055 200 V 100 s A PEEL UNE Defaults 632 1 This screen Continuously displays the actual Arc Voltage and the height of the torch from the plate the height where the plate was sensed at the time of pierce Has various tabs for more options Most of the parameters of the iHC can be directe
58. button 2 Open the dialog box by clicking JOG button Use the mouse wheel to enter the exact distance X and Y you want the machine to move 3 Checkthe Rip Cut box 4 Click on Drive Machine The machine starts the cutting cycle and drives the programmed path At the end of that path the torch is turned off and the machine stops both automatically 3 12 6 Trial Run No Cutting This will allow faster set up to reposition a program on the plate eliminating the need to reposition the plate 1 Call up the wanted program on the Next JOB screen 2 Bring the cutting program to CURRENT JOB window by clicking the Next Job Preview button 3 Press and release the MANUAL MODE button 4 Drive the torch to the wanted starting point of the program by using the jog buttons Press the ZERO button 3 Click the ACT button on the cut screen and click on the Trial Run box 6 Entera trial mode speed and click GO 7 The machine will perform the programmed path without commanding the plasma on 8 Ifthe torch runs off the plate press and release the TORCH ON OFF button 9 Turn on the MANUAL MODE by pressing and releasing the MANUAL MODE button Set a slow speed with the SPEED knob and use the jog key buttons to reposition the torch back on the plate 10 Click the MOVE PROGRAM text on the Current Job Screen 11 Turn off the MANUAL MODE by pressing and releasing the MANUAL MODE button 12 Press the TORCH ON OFF button again 13 Repeat steps 8
59. can paste shapes from the clipboard to nestings Follow these steps 1 Activate the Cut tool by choosing Cut see the picture above 2 Pressthe left mouse button and keep it down focus rectangle appears 3 Surround the shapes you want to cut with the focus rectangle and release the left mouse button 5 5 4 Paste Use this tool to paste the copied cut objects nesting When choose ss a dialog window appears see below If you want more than one copy change the paste multiplier in the dialog window The paste multiplier tells how many times the copied objects are to be pasted Click on the editing area and the objects are pasted ProMotion West H Faste multiplier Manual 0 5399 NESTING 5 23 ICNC PERFORMANCE y 9 9 9 Edit Move Shape Use this tool to manually change the position of a shape Move the cursor over a shape and press the left mouse button down Now the shape will follow the movement of the mouse until you release the button This tool also activates Collision Tools VOTE Colliding means that you move a shape as close to another as possible ProMotion Nest provides collision tools for this purpose To collide a shape you should first move the shape close to its final position and then use the appropriate collision tool There are four tools for colliding shapes up down right or left There is a 8 button in the middle of collision tools buttons Pressing this button
60. ce from the position of the limit switch Lower soft limit is supposed to be determined so that short motion below table surface is allowed but limiting the lifter from hitting the hard stop of the lifter e Reference Position Error Limit If there is a cumulative error in the position of the limit switch the Reference Position Error Limit determines how large of an error can be tolerated If the Reference Position Error Limit is exceeded the torch performs homing Voltage Gain Determines how much force the system uses to correct the difference between the actual voltage and the target volt age e P Gain Used to tune the movement Too large of a value can cause the lifter to oscillate and too small of a value makes the movement soft and inaccurate e Gain Used to fine tune the movement of the lifter Torch collision polarity inverted Select NC or NO use of a collision sensor Manual 0 5399 iHC 4 9 ICNC PERFORMANCE 7 4 4 7 Parameter Limits Parameter name Default MIN MAX 39ommmm 5o i999 _ Coniston recovery dey is o e Colision retract height imm o wo os Encoder pulses per meter som o 25 Find pate speed 50 5000 eo sos gh oa speed 30tommimin eo 2009 Cod of AVG ay 0 f o do
61. cess preheat flame Inexperienced operators often try to increase cutting speeds by using a heavy preheat flame Excessive preheat causes melting of the top edge and may actually lower the speed of cutting In addition oxygen and fuel gas are wasted Dirty nozzle used The nozzle has been fouled by some adhering scale causing the oxygen stream to lose its parallel form The cut surface is no longer smooth or squared with proof of pitting undercutting heavy slag and scale The nozzle should be cleaned with care so as not to distort or bell mouth the cutting oxygen bore Manual 0 5399 MAINTENANCE TROUBLESHOOTING 6 3 ICNC PERFORMANCE 6 4 Troubleshooting 6 4 1 Error messages Problem Cause jWnatochek Limit switches Limit switch active Drive machine out from limit switch Broken cable Cable for wear and tear DENEN Broken switch Measure proper operation of switch Collision Torch collision active seat torch holder properly Broken cable Cable for wear and tear as Broken switch Measure proper operation of switch No inbit 04 Plasma did not fire Check troubleshooting for piercing issues Main arc on Rapid Torch ON while travers Check plasma off delays motion ing No motion detected Enable button set to OFF Put Enable button to ON TT nopowertoseno Check that servos are powered PY E stop pressed in Check external stop buttons System halted all E stop pressed in Check external stop
62. ctangle will be the first one in the cutting order Round Corner Insert the radius of the rounding to the Radius text field and click Apply to verify the radius Moving the cursor over a corner changes the cursor to a cross Click the corner and it will be rounded with the radius you just set Remove Rounding Changes arcs to two 2 lines Move the mouse cursor over an arc and it changes to a cross Click to remove rounding Add Point Adds points lines to a shape If the shape contains open profiles the line is drawn from the last point of the first open profile to the point you added If there are no open profiles then new line and profile is created from the 0 0 point to the point you added Adding new points is simple Just type in the coordinates and click Apply Remove Point Removes single points from a profile Move the mouse cursor over a point and it changes to a cross Click and the point is removed If the point was the last or the first point of the profile then the entire element is removed otherwise the previous and the next point are connected with a line Manual 0 5399 NESTING 5 9 ICNC PERFORMANCE y Move Point This tool moves a point to another location Click a point to select it a small box appears over the point Enter the new coordinates to the coordinate fields and click Apply The point moves to the new location Add Corner Loop This tool adds a loop to a corner First select the radius of the loop and
63. cut If TORCH ON OFF is pressed and released during the cutting process machine motion and cutting stops Pressing this button again starts machine motion and the cutting sequence with any programmed delays HINT You can t use TORCH ON OFF for manual cutting eg scrap lines Manual button on push the TORCH ON and the pierce sequence will begin Immediately after pushing TORCH you can start pushing a directional button the machine won t start to move before the pierce sequence has ended Manual 0 5399 OPERATION Z 3 9 ICNC PERFORMANCE 3 9 8 Speed Up amp Speed Down Buttons MW M Short pushes increase or decrease the actual and set speed in small steps Long lasting pushes change the speeds at a faster rate The pushbuttons will illuminate during automatic corner acceleration and deceleration respectively 3 3 9 Move Ahead Button EN The MOVE AHEAD button is illuminated whenever a program is running Pressing the Torch On Off button will stop the machine and the Move Ahead button will turn off At this point pressing the MOVE AHEAD button will cause the machine to move forward on programmed path without cutting Pressing the MOVE AHEAD button again will stop machine motion HINT Turn speed potentiometer counter clockwise when using the Move Ahead feature for more precise control 3 9 10 Stop Backup Button Press and release the STOP BACKUP button once during the cutting process to stop the cutting sequence and halt m
64. d in the Setup window The upper middle part of the Setup window consist of buttons and fields which are always displayed This screen is used for intuitive setting of iHC operation parameters When setting any of these parameters the process diagram visually indicates what each parameter means Slow Down Height is the distance from the last known plate height where the lifter should slow down the motion for plate sensing to avoid a hard hit Ignition Height determines the distance from the plate where the torch will be ignited Pierce Height determines the distance from the plate where the actual piercing will be done after igniting the torch Pierce Height Time determines how long the torch will stay on pierce height Pierce Down Speed determines the transfer speed from pierce height to cut height Cut Height determines the torch height for cutting after piercing is complete Cut Height AVC Delay determines the time given for the arc voltage to stabilize after reaching the cut height to allow for control of the torch height based on measured Arc Voltage also proper cutting speed is required Hold ON Cutting voltage increase required to freeze torch motion while crossing kerf Hold OFF Cutting voltage increase below while torch motion recovers to AVC control Transfer Height determines the height where the torch will be lifted after the cut for rapid transfer to the next pierce point Use high enough value to avoid collisions Transfer Heigh
65. ded to ProMotion Nest See Plate list for more information Part list The Part List is located at the bottom right corner of the ProMotion Nest window The Part List shows all of the shapes loaded to ProMotion Nest See Part List for more information 9 2 NESTING Manual 0 5399 ICNC PERFORMANCE 5 2 Toolbar ProMotion Nest toolbar looks like this Le Jens e EASAN 21520 wii Here is a brief description of each tool se Send to cutting Sends the current nesting to ProMotion Cut and activates it New Plate Creates a new plate See more info at topic New Plate under File Menu File open Opens a CNC or a DXF file Macro Starts the macro tool See more info at topic Macro under File Menu Rows and Columns Multiplies part or parts See more info at topic Rows and Columns MicroCAD Starts the MicroCAD tool See more info at topic MicroCAD Nestinfo Activates the Nestinfo window See more info at topic Nestinfo Cost Calculator Activates the Cost Calculator tool See more info at topic Cost Calculator ii Nest Automatic nesting See more info at topic Nest Feed Rates Add feed rates to your cutting program See more info at topic Feed Rates D m Optimized Holes Add optimized cutting parameters for holes to get best possible cutting quality Requires ProMotion Optimizer software Plate Editor Edit the plate with this tool more at chapter Plate Editor fs fA
66. e 2 Pressing the MANUAL MODE button activates the capability to jog and reposition the machine CAUTION Pressing the MANUAL MODE button again will turn off the manual mode and will ask if you want to return the machine to the last known parked position 3 9 4 Zero Button Resets the X amp Y counters to ZERO after locating a new starting point on the table using the jog function keys HINT Pressing the zero button will automatically turn off the manual mode button if it was activated on 3 3 5 Start Button sends the cutting program from the next job preview screen to the current job screen to be executed and starts the cutting cycle sequence The START button illuminates and is on during the entire execution of the program No programs can be transferred to the current job screen if the START button is on HINT If this button is pressed during a programmed delay the delay is terminated at once without memorizing the interrupted time of the delay in cutting parameters 3 3 6 Torch ON OFF Button Pressing the TORCH ON OFF button when manual mode is activated will either manually start or turn off the cutting process CAUTION When the start button is activated and the cutting sequence is initiated the TORCH ON OFF but ton will automatically illuminate indicating the torch is on and the cutting sequence has started When the program ends the light will go out automatically indicating end of
67. e lectrode torche et la source d alimentation 6 Assurez vous que tout votre corps est bien isol de la pi ce a traiter et des pi ces de la mise la terre 7 Sivous devez effectuer votre travail dans un espace restreint ou humide ne tenez vous pas directement sur le m tal ou sur la terre tenez vous sur des planches s ches ou une plate forme isol e et portez des chaussures semelles de caoutchouc 0 Avant de mettre l quipement sous tension isolez vos mains avec des gants secs et sans trous 9 Mettez l quipement hors tension avant d enlever vos gants 10 Consultez ANSI ASC Standard 249 1 list la page suivante pour des recommandations sp cifiques concernant les proc dures de mise la terre Ne pas confondre le c ble de masse avec le cable de mise la terre CHAMPS LECTRIQUES ET MAGNETIQUES comportent un risque de danger Le courant lec N trique qui passe dans n importe quel conducteur produit des champs lectriques et magn tiques FN localis s Le soudage et le courant de coupage cr ent des champs lectriques et magn tiques autour des c bles de soudage et l quipement Par cons quent 1 Un soudeur ayant un stimulateur cardiaque doit consulter son m decin avant d entreprendre une op ration de soudage Les champs lectriques et magn tiques peuvent causer des ennuis pour cer tains stimulateurs cardiaques 2 L exposition des champs lectriques et magn tiques peut avoir des effets
68. e 0 00 Rectangle 133 00 Rectangle 133 00 Rectangle 0 00 Efficiency 100 r4 Efficiency 100 0 00 Efficiency 100 0 00 Consumables 9 00 Consumables 9 00 Consumables 0 00 Gases 1 73 Gases 1 73 Gases 0 00 Electricity 3 47 Electricity 3 47 Electricity 0 00 Others 455 Others 3 59 Others 0 00 Total 150 79 Total 150 79 Total 0 00 Total 186 65 Total 186 65 Total 0 00 Relative to parts area Savings day 0 00 Productivity increase 0 Savings week 0 00 This window compares the costs The Previous frame shows the results of that cost calculation which you saved for comparison in Cost Calculator The Current frame shows the latest cost calculation the one you were looking when you chose Compare in the Cost Calculator You can see the difference of these two in the Difference frame If you look at the Current frame you can see that there is a checkbox Relative to parts area That is because sometimes you can fit more parts to the same plate by nesting the parts better This kind of situation gives false results because if you cut more parts out of plate you will use more time and money But when you compare the parts area you can see that you have less wasted material and thus you have saved more That s why this option is here If both nestings have same parts then this option has no effect to the result savings per day is the sum how much you save if you cut this kind of jobs for 8 hours Savings per week is the
69. e ces mat riaux 2 lVeffectuez jamais de travaux proximit d une op ration de d graissage ou de pulv risation Lors que la chaleur ou le rayonnement de l arc entre en contact avec les vapeurs d hydrocarbure chlor ceci peut d clencher la formation de phosg ne ou d autres gaz irritants tous extr mement toxiques 3 Une irritation momentan e des yeux du nez ou de la gorge au cours d une op ration indique que la ventilation n est pas ad quate Cessez votre travail afin de prendre les mesures n cessaires pour am liorer la ventilation dans l aire de travail Ne poursuivez pas l op ration si le malaise persiste 4 Consultez ANSI ASC Standard Z49 1 la page suivante pour des recommandations sp cifiques concernant la ventilation AVERTISSEMENT Ce produitcontient des produits chimiques notamment du plomb reconnu par l Etatde la Californie pour causerdes malformations cong nitaleset d autresdommages touchant le syst me reproductif Se laver les mainsapr s manipulation MANIPULATION DES CYLINDRES La manipulation d un cylindre sans observer les pr cautions n cessaires peut produire des fissures et un chappement dangereux des gaz Une brisure sou daine du cylindre de la soupape ou du dispositif de surpression peut causer des blessures graves ou mortelles Par cons quent 1 Utilisez toujours le gaz pr vu pour une op ration et le d tendeur appropri concu pour utilisation sur les cylindres de gaz compr
70. e custom feed rate type its value to the text field and choose Apply The feed rate that you select here is set to all elements which you choose after this This change has no effect on feed rates which are already set It is applied only to those elements that you choose If you have checked Click applies to single elements in the Elements tab then your clicks change the feed rates of single elements If it is not checked then you have to click the start and the end element All the elements between start and end also get the same feed rate If you click an element with the left mouse button then the whole element is selected Right click splits the element and the feed rate is set only to the other half Right click works only if Click applies to single elements is not checked You can remove all the feed rates by choosing Remove and exit This also closes this tool You can easily set all feed rates to the whole nesting with the use of Feed rate profiles tool Manual 0 5399 NESTING 215 ICNC PERFORMANCE y 5 3 13 Feed Rate Profiles Feed Rate Profiles X Arcs Radius lt CIRE CA CIRE PT A Feed rate mode Absolute Relative Circles Diameter lt mm min Program feed rate C Absolute f Relative 100 Feed rate profiles let you set feed rates to all arcs and circles at the same time You don t need to choose each of them separately This is how you use feed rate profiles Start this to
71. e results The cost of machine hour is often priced so that it includes the profit expectations that were set when the machine was purchased This cost is usually 60 100 if the machine is in active use 60 100 is also a correct value if you need to order some of the work from subcontractors If the machine is used only occasionally you can choose to use just the cost of labor Job preparation The time that the machine stands idle during job preparation Job preparation time includes not only bringing the plate to the cutting table setting plate alignment loading the cutting program setting the cutting parameters but also those actions taken after the program is cut collecting the cut parts from the table cutting scraps off the remnant plate taking the remnant plate away etc This time should be set so that it covers all the time between the moment the cutting table is empty and the moment when the table is empty again excluding the time when the machine is running a cutting program Effective usage An alternative to the Job preparation If you know that the job preparation time in your machine is usually half of the machine time set this to 5096 Consumable set The cost of a consumable set Pierces per set How many piercings can be done with a single consumable set Change time The time it takes to change a consumable set Gas per cut hour Electricity per cut hour Other per machine hour Material cost How much does a square f
72. e the speed 6 4 4 Boot and power issues TT Unit will not power up Measure 24VDC power input replace power supply Check for proper power connector connection Over current fuse tripped Remove all cables leave power off for 1min Connect only the power cable and try to boot If CNC powers up connect cables 1 at a time to find out which one is causing the issue Unit shuts down during Poor input power Check that power supply is rated minimum of 6 5A Check that volt IHS Start age does not drop during rapid torch movement Unit will not boot Temperature too low Check that temperature is inside specs Wait until system warms white screen up Unit will not boot to Bios settings lost Change correct bios settings see service manual for correct bios windows settings Data on the screen fills Bios settings lost Change correct bios settings see service manual for correct bios only part of the screen settings Manual 0 5399 MAINTENANCE TROUBLESHOOTING 6 5 ICNC PERFORMANCE 6 5 Replacement parts Power Supply Lifter motor Lifter axis coupler Collision sensor Collision sensor cable Laser pointer Voltage divider board Nema23 motor Nema23 gearbox Nema34 motor Nema34 gearbox Power supply 75VDC Servo adpater card Name Part number 2ADCPSU S 24VDC PSU 15 6025 15 2119 15 2091 15 6003 15 6004 15 6005 15 6021 MAINTENANCE TROUBLESHOOTING Manual 0 5399 This page in
73. eJuene Road Miami FL 33126 ANSI ASC 749 1 Safety in Welding and Cutting AWS 5 1 Recommended Practices for Plasma Arc Welding AWS 5 2 Recommended Practices for Plasma Arc Cutting AWS 5 3 Recommended Practices for Air Carbon Arc Gouging and Cutting AWS 5 5 Recommended Practices for Gas Tungsten Arc Welding AWS C5 6 Recommended Practices for Gas Metal Arc Welding AWS SP Safe Practices Reprint Welding Handbook ANSI AWS F4 1 Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances 9 CSAStandard W117 2 Safety in Welding Cutting and Allied Processes SIGNIFICATION DES SYMBOLES Ce symbole utilis partout dans ce manuel signifie Attention Soyez vigilant Votre s curit est en jeu Signifie un danger imm diat La situation peut entrainer des blessures graves ou mortelles Signifie un danger potentiel qui peut entrainer des blessures graves ou mortelles AVE SS E M E Signifie un danger qui peut entra ner des blessures corporelles mineures Classe de protection de l enveloppe a eS L indice de protection codification IP indique la classe de protection de l enveloppe c est dire le degr de protection contre les corps solides trangers ou l eau L enveloppe prot ge contre le toucher la p n tration d objets solides dont le diam tre d passe 12 mm et contre l eau pulv ris e
74. eadjust cutting speed to a lower value by clicking inside the box and use the mouse wheel to enter new value and click OK 8 Start the cutting delays and the cutting with TORCH ON OFF After the start delays machine movement starts automatically 9 Adjust the starting speed with the SPEED knob if required 10 While cutting the cutting speed can be easily readjusted by pressing the blue SPEED UP DOWN buttons Every short press increases or decreases the speed about 1 2 ipm 10 mm min 3 12 4 Manual Cutting 1 Pressand release the MANUAL MODE button Drive the machine to the wanted piercing point by using the jog buttons Press and release TORCH ON OFF button to start the cutting cycle Press the JOG buttons of the desired direction to start the movement Press TORCH ON OFF to stop the cutting and release JOG button to stop the movement D co A N Press and release ZERO button if you want to stay in that place MANUAL MODE ends automatically If you want to return to that point where you started the MANUAL MODE just press and release the MANUAL MODE button The button starts to flash and machine runs back to that point 3 18 OPERATION Manual 0 5399 N ICNC PERFORMANCE 3 12 5 Programmed Manual Cutting NOTE The MANUAL MODE button must be OFF when using this procedure On the Cut Screen there is a JOG button for programmed manual cutting 1 Drive the torch to the desired piercing point and press and release the ZERO
75. ected process kerf Overburn length Overburn means that when the machine has cut around a profile it starts to cut the profile again it goes for a next round and cuts it some length That length is defined here Just enter the value to the text box and click at the pierce point or select target and click Add Target Select the type of profiles where you you want to modify leadins outs Replace existing leadins Check this option if you want to change existing leadins or leadouts Otherwise you can only add new leadins or leadouts to profiles which has no leadins or leadouts Examples How to add a leadin out 1 Choose the type of leadin you want Set Length Radius etc 2 Choose the type of leadout you want Set Length Radius Overburn etc Leadins x Examples Hole Outer contour Leadin Length 3 00 mm Radius 0 00 mm Angle 05 Kerf width 2 00 mm Fr Leadout None Length 0 00 mm Radius 0 00 mm Angle TIE verbum 0 00 mm Target All Replace existing leadins Remove Add Close Manual 0 5399 NESTING 9 27 ICNC PERFORMANCE 3 Click the profile where you want to add a leadin How to change a leadin into another Repeat steps 1 2 above 3 4 Check the REPLACE EXISTING LEADINS box Click the profile that has the leadin you want to change How to add a leadin and leadout to a profile Th mo de p
76. eel Thickness 50 New CUT DELAYS Start SD4 SD2 Ignition 5 0 9s Piercing Up 1 0 9s SD3 Hi PreHeat and capacitive 60 0 8 Stay Up 0 5 88 SD4 Cut Oxygen 10 53 Piercing Down 10 9s SD5 Move Delay 1 0 5 501 is generally not used but is fully programmable SD2 provides a time for igniting the torch The ignition output is activated for this user selectable time After time has elapsed the igniter will turn off To override the feature in the event that the machine is not equipped with auto ignition set timer value for SD2 to zero SD3 is generally used for a high preheat timer and turning capacitive height sensing ON This determines the time allocated for pre heating the material before piercing The time is user defined based on the type of material and thickness The thicker the material the higher the timer value To override the feature in the event that the machine is not equipped with auto high preheat set timer value for SD3 to zero SD4 is generally used for Cut Oxygen This determines the time allocated for heating the material with cutting oxygen normally with thicker materials This is best used with the pierce Up Down function See below To override the feature in the event that the machine does not need extra pierce with cutting oxygen set timer value for SD4 to zero Pierce up down event timing Activating the feature 1 START Select the start delay at which the timing is to begin execution eg 504 PI
77. eep the mouse button pressed On top right corner is a yellow label where you can see the distance from the start point to the current mouse location Manual 0 5399 NESTING 5 37 ICNC PERFORMANCE 5 12 Options Menu The Options menu provides tools to configure the ProMotion Nest software 5 12 1 Handling Options Handling Options Measurement Rotation angle CNC Options f Metric v 90 M Enable advanced C Inches C Custom 90 00 M Add plate to CHC program se old style leadins DXF Options Scrap Cutting Point distance Star End point adjustment IE 005 Bun Default leadin C Medium 030 2 00 200 Arc Y Large 1 00 Plate ed 2 00 2 00 Nor Length D00 mm Custom 0 30 5 00 mm Marking Options M Scale always 1 1 Angle 0 Mark all M Move Shapes to Origin Kerk width 0 00 mm Skip all marking Convert text ta marking r C Skip line marking Default leadout Extended text search Skip point marking None d Miscellaneous Extended part marking Length mm Show crosshair M Do all markings first Radius mm Vertical Horizontal Bridging Go to origin after marking Angle In Use Wide Bridges Fr Stop after marking Overburn 0 00 mm Torch on Right Software Keyboard DNC Enabled Cancel Ok Anchor width 0 00 Measurement Measurement is either in millimeters or inches This option defines which DXF Options
78. en un personnel qualifi N effectuez aucune r paration lectrique moins d tre qualifi cet effet 2 Avant de proc der une t che d entretien l int rieur de la source d alimentation d branchez l ali mentation lectrique 3 Maintenez les c bles les fils de mise la terre les branchements le cordon d alimentation et la source d alimentation en bon tat N utilisez jamais un quipement s il pr sente une d fectuosit quelconque 1 8 SAFETY INSTRUCTIONS Manual 0 5399 N ICNC PERFORMANCE 4 N utilisez pas l quipement de facon abusive Gardez l quipement l cart de toute source de chaleur notamment des fours de l humidit des flaques d eau de l huile ou de la graisse des atmosph res corrosives et des intemp ries 5 Laissez en place tous les dispositifs de s curit et tous les panneaux de la console et maintenez les en bon tat 6 Utilisez l quipement conform ment son usage pr vu et n effectuez aucune modification INFORMATIONS SUPPL MENTAIRES RELATI VES LA S CURIT Pour obtenir de l information A suppl mentaire sur les r gles de s curit observer pour l quipement de soudage l arc lectrique et le coupage demandez un exemplaire du livret Precautions and Safe Practices for Arc Welding Cutting and Gouging Form 52 529 Les publications suivantes sont galement recommand es et mises votre disposition par l American Welding Society 550 N W L
79. er pail sand bucket or portable fire extinguisher Be sure you are trained in its use 5 Do not use equipment beyond its ratings For example overloaded welding cable can overheat and create a fire hazard 6 After completing operations inspect the work area to make certain there are no hot sparks or hot metal which could cause a later fire Use fire watchers when necessary 7 For additional information refer to NFPA Standard 51B Fire Prevention in Use of Cutting and Weld ing Processes available from the National Fire Protection Association Battery march Park Quincy MA 02269 Manual 0 5399 SAFETY INSTRUCTIONS t i ICNC PERFORMANCE e ELECTRICAL SHOCK Contact with live electrical parts and ground can cause severe injury or death DO NOT use AC welding current in damp areas if movement is confined or if there is danger of falling 1 Besure the power source frame chassis is connected to the ground system of the input power Connect the work piece to a good electrical ground Connect the work cable to the work piece poor or missing connection can expose you or others to a fatal shock Use well maintained equipment Replace worn or damaged cables Keep everything dry including clothing work area cables torch electrode holder and power source Make sure that all parts of your body are insulated from work and from ground Do not stand directly on metal or the earth while working in tight quarters or a damp are
80. ext position and click again A new line appears from the previous point to this point e Continue as above until you reach the edge of the plate Click the edge and the plate is split into two parts but only one of them is displayed e fthe wrong part is displayed use the Change Split tool to change it 5 3 17 Edit Plate With The Machine Motion This tool is exactly the same as the Edit Plate tool with the following exceptions e Mouse cursor does not respond to the mouse movement Mouse cursor shows the position of the torch and moves if the torch moves e The plate in the ProMotion Nest s work window is rotated to the same angle as the real plate When you stop using this tool the plate is rotated back to its original angle e The Space button works as the left mouse button the left mouse button works too e The Esc button cancels editing The original plate is displayed and the mouse works normally e This tool is usable only with ProMotion iCNC controller 5 3 18 Teach Plate Use this tool to teach the shape of the plate Just drop the plate on the cutting table and then use the laser pointer or the torch to Show the edges of the plate Teach plate Manual 0 5399 NESTING 5 17 ICNC PERFORMANCE y Follow these steps e Place the plate on the cutting table e Start this tool A new window opens see above e Move the laser pointer or the torch over the edge of the plate Then click Accept point e Move the
81. fic cutting parameters based on material thickness gas and tool Based on material thickness and tool selected the cutting parameters can change automatically for kerf cutting speeds and other parameters Once a database is built up with all the correct information the guess work of where to set the cutting parameters will be minimized This would be helpful when a new operator is trained to operate the cutting machine assuring consistent cut quality Process Selection v1 0 8 43 mel Cancel Mew Ok rocess ID 10002 laterial Mild Steel Thickness 50 mm Mew DELAYS Speed 280 mm min 2 10 mm Creep speed 200 time 20 25 Notes Tip 70 NOTE It is not necessary to use all three fields to set the database e g use mate rial and thickness only and leave tool at Default Setting up the Database 1 Click Edit on the process selection screen and then click New 2 Select the wanted Thickness or create a new thickness by clicking New Thickness X Type new thickness Ok Name 50 mm Value 50 00 Or select from these lists Metric list 50 mm Inch list Name Thickness that is shown in the process selection Value Thickness that is used internally example the process list is arranged by the value not by the name Metric Inch list Pick a common thickness from the list Click Ok after thickness settings have been set Manual 0 539
82. for more information 5 13 1 Code Sequences x Program Sequences Start Sequence End Sequence 5 40 NESTING Manual 0 5399 N ICNC PERFORMANCE In ESSI and EIA options it is possible to modify the code sequences which are added to the beginning and the end of certain actions when saving files The caption of the upper frame shows which actions sequences are currently being modified e g in the picture above they are the sequences of gas cutting Start and end sequences can be seen in the edit fields Some actions need the specification of the kerf side e g all cutting sequences sequence Explanation The beginning and the end of Program a Cutting program Gas Cutting profile to be cut with gas torch Plasma a profile to be cut with plasma torch Not supported at the moment Plasma 2 a profile to be cut with plasma 2 torch Not supported at the moment Line Marking a single line marking profile Point Marking a Single point marking Line Marking Block all line markings Point Marking Block all point markings Example The picture above shows the gas cutting sequences of ESSI files Kerf side is set to the left The start sequence is 6 rapid move off 29 kerf left 7 gas cutting on The end sequence is 8 gas cutting off 38 kerf off 5 rapid move on With these settings the following code is generated 6 start sequence 29 start sequence l start sequence 14 1000 a profile 1000 a pr
83. he bridge The red line is the other side The wide bridge will be created between these lines e Select the side of the red line left or right e Enter the width of the bridge If you enter a width that is less than 0 1 mm 0 004 inches a normal bridge is created instead of a wide one Click OK Activate Wide Bridge feature in handling options NESTING Manual 0 5399 ICNC PERFORMANCE 5 9 4 Chain Cutting ui This tool is used to chain profiles together This way you can cut several profiles with a single piercing Follow these steps e Click the point where you want the chain to begin Now a RUBBER BAND follows your mouse movement and shows the route of the chain e Move the mouse cursor to the next point you want the chain to go and click again e When you click a profile it is added to the chain e Continue these steps until your chain is ready Choose READY on the chain cutting dialog see picture below Chain Cutting show Chain Cutting points e The chain is ready If you want create a new chain repeat the procedure above Special cases e fthe profile has a leadin or leadout the chain automatically goes to the beginning of the leadin and continues from the end of the leadout e fthe profile is not closed the chain automatically goes to the beginning of the profile and continues from the end of it 5 9 5 Add Transferline Point T A new transferline point can be added by clicking
84. he list If you want to create a new group write its name to the field and choose Create Now you can see the new group in the list and in the geometry list window When you have copied all the shapes you want from this nesting choose Close Please note that all other tools are disabled while this tool is active Manual 0 5399 NESTING 5 29 ICNC PERFORMANCE y How to create a nesting group e Activate Groups tool e Create a new group type its name to the text field labeled The name of a new group and choose Create e Select the group you just created from the list Select group where to copy e Select the shapes you want add to your group click all of them e Choose Copy e Close groups tool and activate your group from the geometry list left click the name of your group in the list e Right click the geometry list and select Toggle Group On Off from the pop up dialog box Now you can see an asterisk in front of the geometry name This means that this geometry is actually a group e Now you can manually move and rotate the parts in your group Move them close to each other e When your group is ready right click the geometry list again and this time select Copy to Nesting Enter the number of groups you want to nest and finally you have groups in your nesting 5 8 4 Freeze Use this tool to freeze parts for the duration of the automatic nesting process Frozen parts do not change their position during au
85. he nesting f there is no plate or ready nesting then you can approximate the material consumption with a probable effective usage TOOLS oave Offer saves your current price calculation as a simple text file Material Cost Calculator Allows you to calculate how much a square foot or meter of plate cost See more in chapter Material Cost Calculator Save for Comparison This saves the current cost calculation to the computer memory You can compare this to later calculations by using the compare tool Compare Opens the compare window See more in chapter Compare Load Loads a saved cost profile Save Saves the current cost profile Close Closes the cost calculator 5 3 9 Compare x Previous Current Difference m Machine Time Machine Time Machine Time Time Time Time Rapid 1 25 2 36 Rapid 1 25 2 36 Rapid 0 0 00 Cutting 5 12 8 67 Cutting 5 12 8 67 Cutting 0 0 00 Delays 7 12 12 00 Delays 712 12 00 Delays 0 0 00 Total active 13 49 23 03 Total active 13 49 23 03 Total active 0 0 00 Changing consumables 2 42 4 50 Changing consumables 2 42 4 50 Changing consumables 0 0 00 ldle time 5 00 8 33 ldle time 5 00 8 33 ldle time 0 0 00 Total inactive 7 42 1283 Total inactive 7 42 12 83 Total inactive 0 0 00 Total 21 31 35 86 Total 21 31 35 86 Total 0 0 00 m Material Costs Material Costs Material Costs Plate Plate Plate Whole plate Whole plate 0 00 Whole plat
86. hich holes will be point marked This tool is part of an optional point marking module Follow these steps to select holes for point marking 1 Hold the left mouse button down and drag a rectangle around all the holes you want to mark 2 Release the left mouse button and all holes which are inside the rectangle turn to black They are selected for marking 3 When you have selected all the holes you want to mark save the point marking program by using the Save As Point tool If you accidentally selected a wrong hole you can unselect it by drawing a new rectangle around it If you want to un select just one hole you can just left click it NOTE This tool works only for single shapes not for entire nesting NOTE This is an additional module and it s not included in the basic version of ProMotion Nest 5 10 2 Coating Lines If your machine has a welding torch you can coat shapes easily with this tool Follow these steps 1 Setthe distance between lines and other settings in Special Tool Options 2 Activate this tool from the menu Actions gt Special Tools gt Coating Lines 3 Hold the left mouse button down and drag a rectangle around those shapes you want to coat 4 Release the mouse button and all the selected shapes are filled with black horizontal lines coating lines ProMotion Nest saves the coating lines as line marking lines You should configure your machine so that the welding torch replaces the line marker
87. ify this if you want to NESTING Manual 0 5399 ICNC PERFORMANCE This is an example from tools ini 10 1 1 DNC COM Port default 1 ID 10 TYPE DATA 1 INFO DNC COM Port default 1 A brief description of some ini files tools ini is probably the most important of ini files There you can change the behavior of some tools and set some error margins The settings here are such that you shouldn t need to touch these in most of the cases These settings are for special cases where standard is not working well enough ui ini contains some settings related to the user interface 5 21 9 Command line parameters There are a couple of command line parameters which can be used when starting ProMotion Nest min Starts the software with its window minimized is This parameter must be used with a cnc file When using this parameter ProMotion Nest reads the file in with raw import After that it sends the file to cutting trashes the nesting and minimizes itself This parameter is useful only when using an iCNC controller Example of usage pmnest exe is C CuttingPrograms testFile eia Manual 0 5399 NESTING 9 91 ICNC PERFORMANCE This Page Intentionally Blank 9 92 NESTING Manual 0 5399 iCNC PERFORMANCE SECTION 6 MAINTENANCE AND TROUBLESHOOTING 6 1 Maintenance Weekly Check buttons for wear and tear Monthly Check cables for wear and tear Check all connectors are properly connected Clean and check rail
88. ignals that come from other devices to iHC and outputs signals that go from the iHC to other devices I O bits Input Output 1 Torch Collision 4 System Eror Inverted 2 Upper Limit Switch 15 Optional 3 Plate Contact 16 Sense 24V 4 IHS Start 17 IHS Active 5 Main Arc 18 Main Arc 6 Marking 19 Marking 7 Hold 20 Plasma start 8 Up Bb 2 Stepper enable 9 Down 22 Stepper direction 10 Laser pointer B o Stepper pulse 11 Motor power 24 Laser pointer 12 Maintain ARCV 13 Optional ewm NEN Inputs 1 Torch Collision in case the lifter has a breakaway collision sensor signals from the sensor can be wired into Torch Collision input Torch Collision will activate System Error output to CNC Upper Limit Switch used to find home position when iHC is turned on Plate Contact inbit becomes active on plate contact during IHS or cutting sequence IHS Start inbit from CNC becomes active when the IHS sequence starts Main Arc inbit from plasma which indicates plasma arc has ignited Marking inbit to put height controller to marking mode m sw me de Hold AVC turns off when Hold inbit turns active Hold is used during cutting to prevent the torch from diving into the plate when movement slows down ie during tight corners 8 Upinbit from CNC that moves the torch up 9 Downinbit from CNC that moves the torch down 10 Laser pointer inbit from CNC to turn on the laser pointer output 11 M
89. illimeters e Plate height inches or millimeters e Collar width this is defined in Nesting Options inches or millimeters e Net usage the relation between the parts area and the plate area in percentage Part e Parts nested the number of parts in the nesting e Nest width the width of the nesting e Nest height the height of the nesting e Parts area the total area of all parts square foot or square meters e Piercings the number of the piercing points in the nesting 9 10 NESTING Manual 0 5399 N ICNC PERFORMANCE Nominal Areas e Parts the total of all parts nominal sizes e Used Plate nominal size of used plate This is exactly nest width 2 x collar width x nest height 2 x collar width e Nominal Usage 96 the relation between nominal size of all parts and used plate e Real Usage 9 the relation between real area of all parts and used plate x Plate Parts Plate Name Default Parts nested 3 Area 1 50 Nest width 974 00 Plate width 1000 00 Nest height 42600 Plate length 1500 00 Parts area 27 Collar width 10 00 Piercings 54 Net usage Calculate Area Nominal Areas Parts 0 30 Used Plate 0 44 Edit Info Nominal Usage 2 68 69 Emme Real Usage 4 22 Save Info Close If you have checked the No area calculations option in Handling options there is no data in the
90. im N utilisez jamais d adaptateur Maintenez en bon tat les tuyaux et les raccords Observez les instructions d op ration du fabricant pour assembler le d tendeur sur un cylindre de gaz comprim 2 Fixez les cylindres dans une position verticale l aide d une chaine ou une sangle sur un chariot manuel un ch ssis de roulement un banc un mur une colonne ou un support convenable Ne fixez jamais un cylindre un poste de travail ou toute autre dispositif faisant partie d un circuit lectrique 3 Lorsque les cylindres ne servent pas gardez les soupapes ferm es Si le d tendeur n est pas branche assurez vous que le bouchon de protection de la soupape est bien en place Fixez et d placez les cylindres l aide d un chariot manuel appropri Toujours manipuler les cylindres avec soin 4 Placez les cylindres une distance appropri e de toute source de chaleur des tincelles et des flam mes Ne jamais amorcer l arc sur un cylindre 5 Pour de l information suppl mentaire consultez CGA Standard P 1 Precautions for Safe Handling of Compressed Gases in Cylinders mis votre disposition par le Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 ENTRETIEN DE L QUIPEMENT Un quipement entretenu de facon d fectueuse ou inad quate peut A causer des blessures graves ou mortelles Par cons quent 1 Efforcez vous de toujours confier les t ches d installation de d pannage et d entreti
91. improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING PROTECT YOURSELF AN D OTHERS ASSUREZ VOUS QUE CETTE INFORMATION EST DISTRIBUEE L OPERATEUR VOUS POUVEZ OBTENIR DES COPIES SUPPLEMENTAIRES CHEZ VOTRE FOURNISSEUR ATTENTION Les INSTRUCTIONS suivantes sont destin es aux op rateurs qualifi s seulement Si vous n avez pas une connaissance approfondie des principes de fonctionnement et des r gles de s curit pour le soudage l arc et l quipement de coupage nous vous sugg rons de lire notre brochure Precautions and Safe Practices for Arc Wel ding Cutting and Gouging Brochure 0 5407 Ne permettez PAS aux personnes non qualifi es d installer d op rer ou de faire l entretien de cet quipement Ne tentez PAS d installer ou d op rer cet quipement avant de lire et de bien comprendre ces instructions Si vous ne comprenez pas bien les instructions communiquez avec votre fournisseur pour plus de renseignements Assurez vous de lire les R gles de S curit avant d installer ou d op rer cet quipement RESPONSABILITES DE L UTILISATEUR Cet quipement op rera conform ment la description contenue dans ce manuel les tiquettes d accompagnement et ou les feuillets d information si l quipement est install op r entretenu et r par selon les instructions fou
92. in their own separate layers Line and point marking layers are chosen in the same dialog as the profile layers In the example above the layer PROFILES is selected for containing the profiles The layer POWDER is selected as line marking layer and there is no selected point marking layer Select all loads all layers to the nesting To speed up the loading process and to cut off all auxiliary elements like measure lines ProMotion Nest starts to load elements from the DXF file after it has found a certain keyword from the file Sometimes there is a need to load elements before that keyword Raw Load is made for cases like this It loads every possible element from the DXF file to your nesting Other files ESSI and EIA files don t have any layers to choose Just make sure that your options are set correctly oee also Line and point marking Opening DSTV files is an optional module 5 3 4 Macro Shapes When you select this tool the macro list window picture 1 opens This window displays small images of the available macros There are only 20 macros displayed at a time but you can see more macros by choosing NEXT and PREVIOUS Select Macro CELL isis gioca LLL Click to select a macro Picture 1 Manual 0 5399 NESTING 9 9 ICNC PERFORMANCE Creating a new shape with macros Select the macro you want by double clicking it The window below picture 2 opens Enter your measurements in the boxes pr
93. ing Cancel Program will terminate the current job being cut or trial run MOWE PROGRAM Normally grayed out it becomes activated when a cutting program is stopped and the Manual Mode button is selected When confirming if a part program fits on a plate i e in Trial Run mode it will re position the program the same distance as the torch movement CUT FATA REO VERT Normally grayed out Activated when a current program is stopped and the Manual Mode button is se lected selecting Cut Path Recovery will re start the pierce cycle at the point the torch is located and will allow travel back to the original program path READJUST CUT PARAMETERS selecting the Readjust Cut Parameters button will allow the operator to change certain param eters i e cutting speeds creep speed time and delays to the cutting program on the fly This will elimi nate the need for stopping the machine to make these changes iedraw Refresh the current job screen selecting the Next job preview will transfer the next program from the Next Job Preview screen without acti vating the cutting sequence This is grayed out during cutting View track selecting the view track during cutting will zoom in on the cutting path 3 4 OPERATION Manual 0 5399 N ICNC PERFORMANCE Reload saved job The Cut again box allows the opportunity to suspend and save a current job and restart a saved job e Cancel Cancel any selected functions under the Cu
94. ing damage or misalignment of the torch Set the value to zero to prevent the torch from raising after completion of a cut ED2 is typically not used End Move Delay is typically used to allow excess cutting oxygen to bleed off through the cutting tip before rapid traverse to the next piercing location occurs This prevents the cutting stream from nicking prior cut parts when the traverse path is directed over a part Typically set to 1 2 seconds when the cutting oxygen valve is located on the inlet of torch If the cutting oxygen valve is located on the gas manifold allow additional time OPERATION Manual 0 5399 iCNC PERFORMANCE SECTION 4 iHC 4 1 Pierce Cut Sequense T3 e gt T1 Pierce Cut Flow Sequence 1 IHS Start activated torch starts to find the plate 2 Torch reaches slowdown height and starts to move slowly 3 Torch touches the plate 4 Torch moves to ignition height and gives command to start the plasma 5 Plasma arc ignites and gives ok to move signal to the height controller Pierce time T1 starts 6 Torch moves to pierce height Pierce height delay T2 starts 7 After Pierce time T1 ends iHC XT Ok to move signal output activates and cutting motion starts Torch moves to cut height after pierce height timer ends 8 AVC control starts after AVC delay T3 ends 9 Cuth path ends 10 Torch moves to retract height 11 If idle for long enough torch retracts to home position Manu
95. ion 3 torches Multitorch options First torch Lett C Right Torch distance tolerance 2 Torch distance Nest area width 200 Cancel Apply NESTING Manual 0 5399 ICNC PERFORMANCE Nest area width Nest area is the area per torch which is left when the plate collar the torch distance tolerance and the nesting clearance has been taken out of it The nest area should be wide enough for the parts to be nested Minimum width for the nest area is the part s width plus two times the kerf width Finally When you have selected the type of the operation and set all the necessary options choose Apply and then Ok Important Nesting options Clearance and Collar are used during the torch distance calculations Thus you should set them before you set any of the multitorch settings 9 10 10 Pick Part Use this tool to pick any part from a nesting The picked part will be copied to its own nesting and then moved to the origin When you have activated this tool just click the part that you want to pick 5 10 11 Show Parts Lists the names of all parts in the current nesting Even if there are several copies of a part its name is listed only once Click a name in the list and all parts of that name will be colored in the work window 5 11 Ruler Use this tool to measure distances in your nesting Press the left mouse button where you want to start the measuring Then move the mouse and k
96. irable as protection against radiated heat and sparks 4 Hot sparks or metal can lodge in rolled up sleeves trouser cuffs or pockets Sleeves and collars Should be kept buttoned and open pockets eliminated from the front of clothing 5 Protect other personnel from arc rays and hot sparks with a suitable non flammable partition or curtains 6 Use goggles over safety glasses when chipping slag or grinding Chipped slag may be hot and can fly far Bystanders should also wear goggles over safety glasses FIRES AND EXPLOSIONS Heat from flames and arcs can start fires Hot slag or sparks can also cause fires and explosions Therefore 1 Remove all combustible materials well away from the work area or cover the materials with a protective non flammable covering Combustible materials include wood cloth sawdust liquid and gas fuels solvents paints and coatings paper etc 2 Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below Make certain that such openings are protected from hot sparks and metal 3 Do not weld cut or perform other hot work until the work piece has been completely cleaned so that there are no substances on the work piece which might produce flammable or toxic vapors Do not do hot work on closed containers They may explode 4 Have fire extinguishing equipment handy for instant use such as a garden hose wat
97. it s useful to save these kinds of distances as default offsets offset 1 and 2 This way you can drive the default offset by just clicking one button Tables It is possible to define several different home positions These can be used to define the home positions of different plates on the cutting table or different cutting tables Select the Table Number from the list and click the Drive to button The machine drives to the defined home position of the selected table Program Zeros iCNC Performance will save the coordinates for last 5 program starts relative to the absolute 0 0 position You can choose the wanted program zero point from the drop down list and click drive to Set absolute zero home position by clicking the Set absolute 0 0 here button This tool is needed if the programmed working area limits are in use Those limits force the machine to stop before it hits the electrical limit switches Setting absolute zero position can also be automatic when the machine is driven to the pre defined zero position every time the controller is turned on Absolute zero position is also needed if there is a need to set several home positions 3 11 Parameter Quick View The parameter quick view screen opens automatically when a program is sent to cutting from Promotion Nest or when the Setup button is clicked The quick view screen allows the operator to change the most commonly used variable parameters quickly It also provides options for p
98. laser pointer over the next corner of the plate Click Accept point again Repeat this step while you have shown all the corners of the plate e Finally click Close shape and your plate is ready e f you ever do a mistake while teaching the shape just click Cancel point to remove the last point Hint You can use this tool to teach new parts for cutting if you convert the plate to a part by using the tool Plate Part Plate NOTE This tool can be used only with a ProMotion iCNC controller 5 3 19 Set Origin a This tool sets one of the plate corners to the origin e lick one of the corners to set it as a new origin In this case CORNER means one end of an element which is one of those elements that form the plate profile Thus it is possible that it is not a corner at all 5 3 20 Show Nesting Area E Use this tool to define nesting areas on the plate Nesting areas are useful with combination of automatic nesting and multitorch tools Follow these steps to show nesting area e Start Plate editor e Select this tool A red rectangle appears inside the plate The rectangle is the new nesting area e Move the mouse cursor over the edge of the rectangle and press the left mouse button down The border of the rectangle now follows the movements of the mouse e Modify the rectangle as you like and finally close Plate editor to confirm your changes NESTING Manual 0 5399 ICNC PERFORMANCE 5 3 21 Align Parts ez
99. late alignment and advanced set up Parameter quick view Kerf width mm Cutting speed 2286 mm min Program rotation 0 00 Zero IHS Start Plasma 20 00 90 Pierce Delay 0 40 5 Process 10030 Material Mild Steel Edit Thickness 10mm Tool 100 02 Air Plate alignment Dk bl Advanced Cancel Setup Kerf Width opecifies the amount of kerf compensation that will be applied to the cutting program Caution should be taken when selecting the amount of kerf To high a value can cause the program to be altered especially when a radius of an arc is smaller than the kerf value Cutting Speed This is the speed of the cutting process Program Rotation Any value degree will rotate the cutting program When a plate alignment is performed the rotation of the skewed plate is automatically entered here Also by clicking on the 90 the part program will rotate at 90 degree intervals Clicking on the zero box will clear any value of rotation to zero degrees 3 16 OPERATION Manual 0 5399 N ICNC PERFORMANCE IHS Plasma Start Time for the torch to go ignition height and ignite the plasma arc Any excess time will be discarded and next delay will be performed Pierce Delay Pierce Delay This is a move delay after the pierce has started Parameter Set Plasma If selected in the Advanced Setup screen the material type thickness and tool used will appear here to guide the operator on the current pa
100. lement is the atom of a nesting Element is the smallest part that can be edited There are four different kinds of elements lines arcs circles and points Profile is a combination of one or more elements which are connected to each other At the starting point of a profile the sheet is pierced and cutting starts At the end point of a profile the torch is raised up and cutting stops Shape contains one or more profiles Shape is a logical part which has a boundary and possibly has some holes Nesting contains all the shapes but can also be empty Transferline Transferline is a path that the torch follows when it is not cutting 5 21 2 Problems We have listed here some problems which occur time to time and solutions to them 1 When starting ProMotion Nest displays the following message Registration error Please contact your dealer Running in demo mode and starts in the demo mode OFFICE PC ProMotion Nest requires an activation file license txt and a dongle to work Please check the following things e The dongle is plugged into the PC s USB or LPT port e You have installed drivers for the dongle e There is a license file license txt in the ProMotion Nest folder If all of the above are ok then there may be something wrong with your license file Please contact your dealer ICNC CONTROLLER Try to close ProMotion Nest and then start it again If that didn t help please contact your dealer 9 21 3 DXF
101. ls from the service manual 0 5401 N WARNING Do not operate or service the device without proper training Manual 0 5399 SPECIFICATIONS 2 ICNC PERFORMANCE This Page Intentionally Blank 252 SPECIFICATIONS Manual 0 5399 ICNC PERFORMANCE SECTION 3 OPERATION The main screen is divided into three parts e Info Systems Status e Promotion Cut Next Job Preview Current Job Perr PrP Te PPT rst ets het Tt iS 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 300 2 Manual 0 5399 OPERATION 3 1 ICNC PERFORMANCE 3 1 1 Info System Status This is located on top of the screen The info screen shows system information and is used for diagnostics and troubleshooting Info System Status HD Not Locked File View About Speed 0 mm min Speed Operating panel 0 00 Y 000 100 VW ID BA eR 0 0 EFEFF BB seos iHC e Speed IPM or metric indicates machine speed e X amp Y readouts indicate absolute position of the cutting tool e Speed Bar in This is interfaced directly with the Speed Potentiometer and will reflect the speed pot setting e Jogging direction indicator Monitors and shows which direction jogging key is pressed e Operational Panel Interfaced with the 9 push buttons Monitors which button is pressed or activated e System Running Indicates that the second CPU is activated and functionally properly 3 1 2
102. m Nitride buildups may create difficulties if the steel is welded after the cutting process Manual 0 5399 MAINTENANCE TROUBLESHOOTING 6 1 ICNC PERFORMANCE Direction of Cut The plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas This swirl effect results in one side of a cut being more square than the other Viewed along the direction of travel the right side of the cut is more square than the left Clockwise Left Side Cut Angle lt __ Right Side scrap Cut Angle AE s Clockwise Scrap Workpiece 00512 Art A 04182 Swirl Effect on Side Characteristics Of Cut To make a square edged cut along an inside diameter of a circle the torch should move counterclockwise around the circle To keep the square edge along an outside diameter cut the torch should travel in a clockwise direction 6 3 Oxy fuel cutting quality Note Always follow manufacturers guide lines on adjustments and cutting parameters 6 3 1 Igniting and adjusting a neutral flame 1 Ignite the flame 2 Add gas until the flame separates from the tip and then slowly decrease the gas until the flame touches the tip again 3 Slowly start to add oxygen and watch the inner cone the blue inner cone will start to shorten as you increase the oxygen flow Increase the oxygen until the inner cone reduces to the same length as the small preheat flame 4 At this point the flame temperature and in
103. mes ou de l arc peut provoquer un incendie Le laitier incandescent ou les tincelles peuvent galement provoquer un incendie ou une explosion Par cons quent 1 loignez suffisamment tous les mat riaux combustibles de l aire de travail et recouvrez les mat riaux avec un rev tement protecteur ininflammable Les mat riaux combustibles incluent le bois les v te ments la sciure le gaz et les liquides combustibles les solvants les peintures et les rev tements le papier etc 2 Les tincelles et les projections de m tal incandescent peuvent tomber dans les fissures dans les planchers ou dans les ouvertures des murs et d clencher un incendie couvant l tage inf rieur Assurez vous que ces ouvertures sont bien prot g es des tincelles et du m tal incandescent 3 lVex cutez pas de soudure de coupe ou autre travail chaud avant d avoir compl tement nettoy la surface de la pi ce traiter de facon ce qu il n ait aucune substance pr sente qui pourrait produire des vapeurs inflammables ou toxiques N ex cutez pas de travail chaud sur des contenants ferm s car ces derniers pourraient exploser 4 Assurez vous qu un quipement d extinction d incendie est disponible et pr t servir tel qu un tuyau d arrosage un seau d eau un seau de sable ou un extincteur portatif Assurez vous d tre bien instruit par rapport l usage de cet quipement 1 6 SAFETY INSTRUCTIONS Manual 0 5399 N ICNC PERFORMANCE
104. ncy Electromagnetic Immunity IEC 61000 4 8 2009 Power Frequency Magnetic Field Immunity CISPR 11 2009 A1 2010 AC Mains Conducted Emissions CISPR 11 2009 A1 2010 Radiated Emissions Meets IEC 61010 1 2010 Safety requirements for electrical equipment for measurement control and laboratory use Part 1 General requirements Classification The equipment described in this document is Class A and intended for industrial use WARNING This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low voltage supply system There may be potential difficulties in ensuring electromagnetic compatibility in those locations due to conducted as well as radiated distur bances Manufacturer s Authorized Representative Steve Ward V P Europe and General Manager Signatur Address Victor Technologies International Inc j Europa Building Chorley Industrial Park Steve Ward Chorley Lancashire Full Name England PR6 7BX V P Europe and General Manager Date August 19 2015 Position WARNING This Class equipment is not intended for use in residential locations where the electrical power is provided by the public low voltage supply system There may be potential difficulties in ensuring electromagnetic compatibility in those locations due to conducted as well as radiated distur bances N iCNC PERFORMANCE SECTION 1 SAFETY 1 01 Safety Precautions ENG
105. ndow there is a display showing the set value for Arc Voltage The Arc Voltage can be modified using the left and right arrows on the sides of the slider One click changes the voltage 1V or 0 1V lt lt _120 0V 1200 V gt 00V x 189 05 mm e f AVC Sampling is used the left side of the main window will show the cutting distance One click changes the cut height 0 5mm 0 1mm 4 2 IHC Manual 0 5399 ICNC PERFORMANCE e he UP and DOWN buttons can be used to move the torch in manual mode e IHS Test button causes the torch to drive down to find a plate This feature can be used to test that the iHC plate sensing works properly The text on IHS Test button changes to Cancel after being pressed Clicking Cancel returns the torch immediately to the home position Torch will stay at ignition height after plate has been sensed IHS Test e Find Plate feature is used when thicker material is placed on the table this feature is used before the cutting process to make sure the torch will not collide to the plate on first piercing point Find Plate uses the Find Plate Speed to conduct the Plate Contact Test After finding the plate the torch returns to Home Position When Find Plate is clicked the text on the button changes to Cancel Clicking Cancel returns the torch immediately to the home position plate BE e Clicking on SETUP opens the Setup window The iHC window
106. ng nesting When selected all leadins and leadouts are ignored during the nesting process This is a useful option if shapes are going to be nested and then bridged Bridging removes extra leadins that can be ignored Manual 0 5399 NESTING 5 45 ICNC PERFORMANCE 5 17 Language Options Language Options Choose language Changes the language used by the user interface of ProMotion Nest 9 18 Registration Menu Tools to register your ProMotion Nest software 5 18 1 Registration Form Please fill this out form to order software or new software options It is also recommended to use this form if you have some technical problems especially license related 5 18 2 Registrate Use this dialog to enter your new license number If you received your new license as a license file simply copy that file to the ProMo tion Nest directory If you received the license by fax then you should fill in the form carefully and completely 9 19 Help Menu Help menu has the following items e Contents Opens the help file on your screen e About Provides information about your version of ProMotion Nest software 9 20 List Windows There are two list windows on the right hand side of ProMotion Nest user interface Those windows are Plate List and Part List They both offer several tools for your use 5 20 1 Plate List This window contains a list of all plates which are opened The list is sorted alphabetically The active pl
107. ng order of f Parts Holes Line marking Point marking Method Show order C Swap Move one step Line Free select Unselect Ea E NN Close You can let ProMotion Nest to do the cutting order for you by clicking the Optimize order button See more details at Optimize Cut ting Order You can also do the cutting order yourself by using this tool The cutting order can be changed between Parts shapes Holes Line Marking Profiles and Point Marking points There are five methods which can be used to change the cutting order Show Order Swap Move One Step Line and Free Select In the Show Order method you just click the objects in that order they are about to be cut or marked When you click an object it will change its color to indicate that it is selected If the color of the object will not change then you cannot change its order it s probably the wrong type Selections can be removed by clicking the Unselect button The option Lock First Object can be used with this method If itis selected then you cannot change the cutting order of the objects which are before the first selected object in the cutting order When you are ready choose Apply to create the new cutting order This is the only method that you can use on line and point markings In the Swap method you choose two objects and their positions in the cutting order will be changed between them When you click the first object it will ch
108. o the shapes of the nesting You cannot add move or alter the markings unless you also move the shapes The only thing you can do to the markings themselves is to remove them When ProMotion Nest generates cutting program it will place possible markings before the cutting in the cutting order That means If shape contains line or point markings the markings will be done first and the cutting is done after the markings The line marking profiles are drawn in black color The point marking points are drawn as black circles with a cross inside the circle 5 21 5 EIA Programming About functions There are two types of functions Those which define movement of the cutter and those which define some other specific action i e torch on All functions have a certain identifier which can be changed in EIA options see ProMotion Nest s options Syntax of functions Key to syntax ID is a string that defines the function X Y and J are coordinates Character X Y or J must be first and immediately after them should the coordinates follow like X123 456 Y 12 3 11234 JO Rapid movement ID X Y Linear cut line ID X Y Arc IDX Y J Circle ID J All other functions ID Example 1 Comments are in parenthesis 90 Absolute mode G21 Use metric units millimeters G00X100Y300 Move to point 100 300 Manual 0 5399 NESTING 5 49 ICNC PERFORMANCE 7 G41 Kerf compensation left M03 Gas torch on
109. ofile 1000 a profile 1000 a profile 8 38 5 Manual 0 5399 NESTING 9 41 ICNC PERFORMANCE 5 14 EIA input Options EIA Input Options Codes Unit Scale Absolute coding c90 Metric C Inches Incremental coding G91 Inches G20 C 1 100 mm C 121000 Metric C21 C 1 10 mm C 1400 Rapid move coo 1mm C 140 Linear cut col C 10mm gi Arc Cw co2 ae Eee Coding ze Absolute Incremental left G41 Kerf right G42 andJ codes Boul BER Absolute M07 C Incremental Gas Off a M15 1 Program Rotation MAG C Rotate 90 degrees CCW qum No rotation Plasma 2 Off M18 e na MOS FeedRate and Kerf Ere mar v Ignore F codes Point mark MOS Message start v Ignore codes Message end K Codes Stop Values kerf width End of program M02 Value is kerf compensation Null G is linear F Codes Advanced x EnH Absolute Load Save Cancel Ok These options are used when ProMotion Nest reads EIA files Codes EIA files are interpreted according to these codes These codes should match the codes used in the EIA file Null G is linear When this option is set ProMotion Nest interprets lines without G codes as linear movement If the cutting is on
110. ol by choosing Profiles in the Feed Rates dialog Select absolute or relative feed rates Set the diameter and the corresponding feed rate values for circles If you don t need all the diameter feed rate pairs you can disable them by un checking the box at the beginning of the line Set the radius and the corresponding feed rate values for arcs Disable extra lines Set program feed rate if you use absolute feed rates Click Apply to set the feed rates according to your given profile All existing feed rates are removed and the feed rates defined in the profile are applied to the nesting Save the profiles for future use This is handy when you need different profiles for different tools Click Save and enter the file name Click Load to reuse the file 5 3 14 DiameterPro gt NOTE DiameterPro requires ProMotion DiameterPro to work 5 3 15 Plate Editor Oo ous Plate editor is a set of tools which are used to change the shape and position of a plate Click Plate Editor button to activate the editor The button stays down until you click it again A small tool window appears The tool window contains the plate editor s tools Click the button again to close the plate editor NESTING Manual 0 5399 N ICNC PERFORMANCE 5 3 16 Edit Plate Use this tool to remove parts out of a plate Follow these steps e Move the mouse cursor over the edge of a plate and click it e Move the mouse cursor to the n
111. om of the Thermal Screen s Thermal v1 15 7 Connecting to plasma Transmit node 50 No response CUT PROCESS CNC amp THC SETUP CCM Power Supply DMC DPC Live Values Material Mild Steel Selected process 10023 Plasma Thickness 1 2 in Current process not ready 3 Consumables 10023 Shield Cup 21 1016 Shield Cap 21 1027 Shield Gas Distributor 21 1272 Tip Plasma Gas Distrib Electrode Cartridge 21 1020 Shield Retainer None Show Picture 100A21 es 10023 Curent 1 Use the drop down boxes to select the material and thickness to be cut 2 The available cut processes for the selected material and thickness will be displayed along with information indicating which process is B for Best cut quality F for Fastest cut speed R using the robotic consumables for beveling M indicating maximum piercing thickness Select the desired process by clicking on the Cut Process number and clicking the Apply button When Current process equals Selected process the plasma is ready to cut If red Plasma not ready is on check that the plasma is enabled via a switch located on the CNC panel 3 This area shows the consumable to be used for the selected process Click on Show Picture to see a picture of the consumables 4 This area shows the cutting current and gas
112. omer Thermal Dynamics 5 20 2 Part List This window contains a list of all geometries which are opened The list is sorted alphabetically The active geometry has a blue bar on it it is selected These tools are available in the geometry window Activate Choose the name of the geometry to activate it Copy to the active plate Double Click the name of the geometry Popup menu Right Click the window to open a popup menu The menu contains following commands e Open e Trash e Rename which renames the active geometry e Copy to nesting which copies the active geometry to the active plate e Move shapes to origin moves the nesting so that it s minimum X and Y values are equal to zero e Add plate creates a plate puts the nesting on that and moves the job to the plate list plate window e Toggle Group On Off toggles the status of the active geometry geometries to group or to normal If there is an asterisk before the name of the geometry then it is considered as a group e DSTV properties shows a little window which displays data read from a DSTV file e Nominal size is by default the part s width x parts length This opens a dialog box which shows the part s nominal size and you can change it if you wish Nominal size is used in Nestinfo e Marking Text Manual 0 5399 NESTING 5 47 ICNC PERFORMANCE 5 21 Miscellaneous 9 21 1 Terminology Nesting Nesting is divided in the following way E
113. on 4 Donotabuseany equipment or accessories Keep equipment away from heat sources such as furnaces wet conditions such as water puddles oil or grease corrosive atmospheres and inclement weather 5 Keep all safety devices and cabinet covers in position and in good repair Use equipment only for its intended purpose Do not modify it in any manner ADDITIONAL SAFETY INFORMATION For more information on safe practices for electric arc weld A ing and cutting equipment ask your supplier for a copy of Precautions and Safe Practices for Arc Welding Cutting and Gouging Form 52 529 The following publications which are available from the American Welding Society 550 N W LeJuene Road Miami FL 33126 are recommended to you ANSI ASC 749 1 Safety in Welding and Cutting AWS 5 1 Recommended Practices for Plasma Arc Welding AWS 5 2 Recommended Practices for Plasma Arc Cutting AWS 5 3 Recommended Practices for Air Carbon Arc Gouging and Cutting AWS 5 5 Recommended Practices for Gas Tungsten Arc Welding AWS C5 6 Recommended Practices for Gas Metal Arc Welding AWS SP Safe Practices Reprint Welding Handbook ANSI AWS F4 1 Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances 9 CSAStandard W117 2 Safety in Welding Cutting and Allied Processes Pe co T ee Dor Manual 0 5399 SAFETY INSTRUCTIONS 1 3 ICNC PERFORMANCE
114. on and safe practices for arc welding and cutting equipment we urge you to read our booklet Precautions and Safe Practices for Arc Welding Cutting and Gouging Booklet 0 5407 Do NOT permit untrained persons to install operate or maintain this equipment Do NOT attempt to install or operate this equip ment until you have read and fully understand these instructions If you do not fully understand these instructions contact your supplier for further information Be sure to read the Safety Precautions before installing or operating this equipment USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and or inserts when installed operated maintained and repaired in accordance with the instructions provided This equipment must be checked periodically Malfunctioning or poorly maintained equipment should not be used Parts that are broken missing worn distorted or contaminated should be replaced immediately Should such repair or replacement become necessary the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased This equipment or any of its parts should not be altered without the prior written approval of the manufacturer The user of this equipment shall have the sole responsibility for any malfunction which results from improper use faulty maintenance damage
115. oot or meter of plate cost Torches Quantity of torches Acceleration Machine acceleration that affects the average rapid speed Nesting Info This data is provided automatically by the software Name Name of the nesting Plate area Plate width Plate length Collar A safety zone left by automatic nesting to the edges of a plate Real usage Percentage of the parts area to the plate area Nominal usage Percentage of the nominal area of the parts compared to the plate area or compared to the area of a rectangle which is drawn around the parts Parts Piercings Nesting width Nesting length Parts area Cut length Arc seconds Arc seconds per piercing Average rapid speed This is affected by the machine acceleration If the machine has slow acceleration and or the average rapid movement is short then the machine probably never reaches the maximum rapid speed NESTING Manual 0 5399 ICNC PERFORMANCE Machine time Shows the active and inactive times along with their costs calculated from the given data Active time is the time that it takes to run the cutting program Inactive time is the time that it takes to prepare a job like changing the plate and change the consumables Material costs This frame shows the consumption of material consumables gases etc and their costs The material consumption can be handled in several ways e You can select the entire plate to be consumed or just the rectangle surrounding t
116. opening the High Preheat solenoid valve 3 3 Record Time o D RECORD TIME During any start or end delay of the cutting process you will see this button light up At the same time a counter on the screen counts down remaining seconds for current delay If this button is pressed during a programmed delay the delay is terminated at once The system memorizes the interrupted time of the delay and uses this new delay time in next pierces 3 4 Up Down e Up Down button will move the oxyfuel torch Up Down Manual 0 5399 OPERATION 3 13 ICNC PERFORMANCE 3 7 5 Ignition On Off Auto K e ON position will activate the igniter e AUTO position will allow the cutting program to activate the igniter when necessary e OFF position will prevent the cutting program from activating the igniter 3 7 6 Auto Height On Off Auto U t 1 ON position will activate the capacitive height sensing AUTO position will allow the cutting program to activate the capacitive height sensing when necessary e OFF position will prevent the cutting program from activating the capacitive height sensing 3 7 7 Cutting Oxygen On Off Auto U e ON position will open the cutting oxygen solenoid e AUTO position will allow the cutting program to open the cutting oxygen solenoid when necessary e OFF position will prevent the cutting program from opening the cutting oxygen solenoid valve 3 8 Starting Procedure Switch on the system by pre
117. orch settings Select the type of the operation from the following list Normal nesting Removes all multitorch data from the plate and it becomes a normal plate again otrip There is only one torch but the automatic nesting process uses only a narrow strip instead of the whole plate The strip s width is given to the textbox Nest area width It is also possible to show nesting area with Show nesting area tool n torches You can set the maximum number of torches in Handling options This operation divides the plate into n parts of equal size and divides the shapes of the current nesting between them Only those shapes which the first torch will cut are displayed normally and the rest are displayed as shadows Hultitorch Strip Select the type af the op ration 3 torches Normal nesting Strip 2 torches torches Fixed torch distance Nest area width Cancel Apply JE V Multitorch options First torch Sets the first torch on left or right Torch distance tolerance The maximum error allowed in distance between two torches and also in distance measured from the first torch Torch distance The distance between two torches The system calculates this for you if you haven t chosen the fixed torch distance Fixed torch distance If you want to set the torch distance by yourself check this option This way you can define narrow nesting areas Hultitorch Strip Select the type of the operat
118. otor power inbit telling is the motor power turned ON 12 Maintain ARCV reserved for future use 13 Optional reserved for future use Manual 0 5399 iHC S 4 7 ICNC PERFORMANCE 7 Outputs 14 System Error Inverted can be connected to CNC controllers external stop 15 Optional reserved for future use 16 Sense Relay 24VDC Output for voltage divider board 17 IHS Active outbit which is active form the time IHS Start turns active until Ignition Height has been reached 18 Main Arc outbit to CNC which becomes active when the main arc inbit is activated and the transfer delay has passed 19 Marking outbit to turn ON the marking output 20 Plasma Start outbit to tunr on the plasma start output 21 Stepper Enable step motion enabled disabled 22 Stepper Direction DIR signal active 23 Stepper Pulse step pulse signal active 24 Laser pointer outbit to turn ON the laser pointer output 4 4 5 Service Tab This window contains information about iHC software version status and errors Also displays the following Service PIC 10 25 Status HIT Homing 02 0 Error 16 Lifter 1 plate sensing force exceeded Diagnostics Homing 00 1 IHS Enabled 17 Lifter 2 plate sensing force exceeded c 2 Cut Height 1 18 Lifter 1 max allowed force exceeded 3 Cut Height 2 18 Lifter 2 max allowed force exceeded Ton 4 AVC 1 20 Lifter 1 lower soft limit 5 AVC 2 21 Lifter 2 lower soft limit 6 IHS ready 1 22 Lifter 1
119. ovided In the picture on the left side of the window you can see the shape and red lines Those red lines are measure lines and they show you which measurement you are entering When you have entered all the measurements you can preview the shape by choosing PREVIEW If you want to change the measurements after you have previewed them simply choose BACK and adjust your mea surements When you are satisfied choose OK and the shape appears in Nest s work window NOTE You can input numbers by using the number pad or the wheel of your mouse Macro Shapes Measures 1 100 Preview e 00 3 0 00 4 0 00 Cancel Picture 2 Chain cutting macros Chain cutting macros are simple shapes circles triangles and rectangles which are cut in a single line with just one piercing It is also possible to make common cut shapes where two rectangles or triangles have one mutual side Using chain cutting macros is really simple Just insert the correct parameter values and click OK When you change the parameters you can see the effect of those changes immediately in the preview area Chain cutting macros Macro Type Circle Rectangle Common cut rectangle Common cut triangle Quantity d Diameter 100 00 mm Leadin soo mm Kerf width 2 311 mm Scrap 10 00 mm Overburn 2 og mm Cancel Picture 3 NESTING Manual 0 5399 ICNC PERFORMANCE Editing the mac
120. ow much the coating lines will be drawn over the edges of a shape Minimum Gap is the smallest width of a hole that is not jumped over when the coating lines are drawn Manual 0 5399 NESTING 5 39 ICNC PERFORMANCE 5 13 ESSI Options xj 551 Codes Unit Scale Comment start Comment end Code Generation Inches Kert left 17100 mm 121000 Kerf right Gas Cutting 110mm 100 Kerf off C 1mm Bas an Plasma Cutting C 10 Gas off Plasma an Plasma 2 Cutting Program Hatatian Flasma off Rotate 90 degrees CW Line marking on rotation Line marking off Linie Marking Point Marking dae TREE Required area Program end Line Marking Black Rotate 30 degrees Cw E Feed rate Ma rotation fe Point Marking Block Preview Cancel These options are used when reading and writing ESSI files Essi Codes ESSI files are interpreted according to these codes These codes should match the codes used in the ESSI file Program Rotation If the rotation is selected all the new nestings which are read from ESSI files will be rotated 90 degrees counter clockwise Unit Scale These options set the default units and scale used in ESSI files Code Generation Use these commands to define start and end sequences of different actions These sequences are used in writing ESSI files See Code Sequences
121. pe has a special purpose if you generate CNC code for old ProMotion controllers If there is no leadin then the controller adds one Straight A straight line which has the same direction as the first or the last element of a profile 90 degrees A straight line which is on 90 degrees angle on the kerf side compared to the first or the last element of a profile An arc which has a 90 degrees central angle Connects the first or the last element of a profile tangentially 0 179 degrees A straight line which is on 1 to 179 degrees angle on the kerf side compared to the first or the last element of a profile J A leadin that contains a straight and an arc Straight section always points to the center of the hole Restirctions are arc radius cannot be smaller than of kerf length needs to be bigger than arc radius semi circle A half circle Connects the first or the last element of a profile tangentially Custom This is a user defined type read from a file ESSI and EIA programs often has this kind of leadins or leadouts You cannot add this kind of leadins 5 26 NESTING Manual 0 5399 N ICNC PERFORMANCE Leadin Leadout selection To add remove or modify leadins click on the pierce point or select Target check box Replace existing leadins and click Add Length Length of the leadin straights Radius Radius of the leadin arcs Angle Angle of the leadin Free angle Kerf Sel
122. rameter selection NOTE Additional delays or adjustable time dialog boxes may appear depending on how the controller has been set up by an OEM or installer 3 11 2 Plate Alignment Activating Plate Alignment allows for a quick and easy way to pick two points on the edge of a skewed plate Performing this exercise will automatically rotate a part or program nest the same amount as the plate skew so that it will fit precisely onto the plate reducing scrap or manual plate squaring LA Plate alignment To show plate alignment to the controller you must set two points along the plate edge BEEN I GL GNI Which program direction you want to go to point 2 B Confirm p 2 here To use the Plate Alignment feature locate a corner or plate edge and click Set point 1 here Select which direction the next point is relative to the first location travel to the second point and click on Confirm point 2 here This will automatically rotate the program to match the skewed plate 3 12 How To Proceed When Something Happens 3 12 1 How to Cancel a Cutting Program 1 Stop the machine movement and cutting by pressing TORCH ON OFF or STOP BACKUP button 2 Usethe left mouse button to click the CANCEL PROGRAM button located at the top of the current job screen 3 Wait until a new dialog box opens telling that the machine must return to 0 0 point Click OK and machine runs back to 0 0 point original st
123. rnies Vous devez faire une v rification p riodique de l quipement Ne jamais utiliser un quipement qui ne fonctionne pas bien ou n est pas bien entretenu Les pi ces qui sont bris es us es d form es ou contamin es doivent tre remplac es imm diatement Dans le cas une r paration ou un remplacement est n cessaire il est recommand par le fabricant de faire une demande de conseil de service crite ou par t l phone chez le Distributeur Autoris de votre quipement Cet quipement ou ses pi ces ne doivent pas tre modifi s sans permission pr alable crite par le fabricant L utilisateur de l quipement sera le seul responsable de toute d faillance r sultant d une utilisation incorrecte un entretien fautif des dommages une r paration incorrecte ou une modification par une personne autre que le fabricant ou un centre de service d sign par le fabricant ASSUREZ VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D UTILISATION AVANT D INSTALLER OU D OP RER L UNIT PROT GEZ VOUS ET LES AUTRES This Page Intentionally Blank TABLE OF CONTENTS SEBTION T SAT ELE a 1 1 1 01 Safety Precautions ENGLIS 2 1 1 1 02 Pr cautions de s curit FRENCH CANADIAN 1 6 SECTION 2 SPEBIFIBATIUNS 2 1 2 1 System 61 etat bg ue iren 2 1 2 2 verre DIL EL TE 2 1 SECTION 3 3 1
124. ro point of the plate when all the markings are done If Stop after marking is checked then the machine stops after markings Miscellaneous Options e Show Crosshair If this box is checked a crosshair will be drawn at the current cursor position e Vertical Horizontal Bridging If this box is checked bridging is done vertically or horizontally See Bridge tool for further informa tion e Use Wide Bridges This is an option for bridging tool If this option is selected a solid area is left between bridged profiles so they will stay together when cut from the plate See Bridge tool for more information e Torch on right Changes the origin point from the bottom left corner to the bottom right corner e Software keyboard If you don t have a keyboard you can always use the software keyboard for text input If you set this option then the software keyboard is automatically displayed when text input is needed Please note that you can use the mouse wheel for numerical input in ProMotion Nest e DNC enabled This option sets the default download behavior of ProMotion Nest when requested from ProMotion Cut If this option is set then download automatically activates when you click DOWNLOAD in ProMotion Cut See more info about DNC in chapter File Menu 5 12 2 Special Tool Options These are options for special tools Coating Lines Distance between lines is the distance between two coating lines Leadin Leadout is the measure h
125. rolist Choose EDIT MACROLIST in the first window picture 1 to open the macrolist edit window see below The list CURRENT MACROS shows the macros currently in the list The list AVAILABLE MACROS shows all the macros which you can add to the macrolist The dashed line in the CURRENT MACROS list shows where the page break is There can be only 20 macros visible in any time in the macro list see picture 1 Edit Macro List a Current Macros Available Macros Add Remove Up Down up Cancel Oss 2 Picture 4 How to change the order of macros in the macro list e Select one of the macros in the list CURRENT MACROS The macro you selected is displayed in the small picture box just below the list e Choose UP to move the selected macro one step towards the beginning of the list e Choose DOWN to move the selected macro one step towards the end of the list How to remove a macro from the macro list e Select one of the macros in the list CURRENT MACROS The macro you selected is displayed in the small picture box just below the list e Choose REMOVE and the macro you selected is removed from the list How to add a macro to the macro list e Select one of the macros the list AVAILABLE MARCROS The macro you selected is displayed the small picture box just below the list e Choose ADD and the macro you selected is added to the end of the list Manual 0 5399 NEST
126. s Clean lifter Screw and rails 6 2 Cut Quality Cut Quality Cut quality requirements differ depending on application For instance nitride build up and bevel angle may be major factors when the surface will be welded after cutting Dross free cutting is important when finish cut quality is desired to avoid a secondary cleaning opera tion Cut quality will vary on different materials and thicknesses Kerf Width o o NE Right Side 7 Cut Surface Bevel Angle Left Side Cut Angle Cut Angle 2 P Dross Build Up Cut Surface A 00007 A 00512 Drag Lines Cut Surface The condition smooth or rough of the face of the cut Bevel Angle The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate A perfectly perpendicular cut would result in a 0 bevel angle Top Edge Rounding Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the workpiece Dross Build up and Top Spatter Dross is molten material which is not blown out of the cut area and re solidifies on the plate Top spatter is dross which accumulates on the top surface of the workpiece Excessive dross may require secondary clean up operations after cutting Kerf Width The width of material removed during the cut Nitride Build up Nitride deposits which may remain on the cut edge of the carbon steel when nitrogen is present in the plasma gas strea
127. same but for 40 hours Productivity increase shows how much less time you need to cut this job Manual 0 5399 NESTING 5 13 ICNC PERFORMANCE 5 3 10 Material Cost Calculator x Material density 7658 kgm Plate thickness mm Material cast z so Ska Material cast 176134 mz Material Calculate C Aluminium Llose Use to calculate the price of one square foot or meter of your plate Select first the material from the material frame If you selected any other material than the Other then the calculator automatically sets the material density Set the plate thickness and the material price per pound or kilogram Choose Calculate and you are ready 5 3 11 Nest joo This tool activates the automatic nesting process It nests all the parts in the current nesting to the current plate If you haven t defined a special nesting area See Show nesting area automatic nesting uses the whole plate You can modify the process by changing the nesting options In the following cases part is not nested but moved to the right side of the plate e The part does not fit on the plate or on the nesting area e There is at least one open profile in the part f you are using multitorch and the number of copies of the part are not evenly divided between the torches the remaining modulo parts are not nested See also MultiNest Triangle Nest and Nestinfo 5 3 12 Feed Rates Use this
128. se asphyxiation Therefore 1 Always provide adequate ventilation in the work area by natural or mechanical means Do not weld cut or gouge on materials such as galvanized steel stainless steel copper zinc lead beryllium or cadmium unless positive mechanical ventilation is provided Do not breathe fumes from these materials 2 Donotoperate near degreasing and spraying operations The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene a highly toxic gas and other irritant gases 3 If you develop momentary eye nose or throat irritation while operating this is an indication that ventilation is not adequate Stop work and take necessary steps to improve ventilation in the work area Do not continue to operate if physical discomfort persists 4 Refer to ANSI ASC Standard 249 1 see listing below for specific ventilation recommendations 5 WARNING This product contains chemicals including lead known to the State of California to cause birth defects and other reproductive harm Wash hands after handling 152 SAFETY INSTRUCTIONS Manual 0 5399 N ICNC PERFORMANCE CYLINDER HANDLING Cylinders if mishandled can rupture and violently release gas Sudden rupture of cylinder valve or relief device can injure or kill Therefore 1 Usethe proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder Do not use adaptors Maintain hoses
129. se button closes the dialog 9 0 3 Bridge With this tool it is possible to create a bridge between two more complete shapes Bridge is a two way line which two shapes Bridge can be created by pressing the left mouse button down and moving the cursor over all the shapes which will be bridged A RUBBER BAND will follow the mouse movement and shows the location of the future bridge When the left button is released the bridge will be created If Vertical Horizontal Bridging option is chosen from Handling Options then all the bridges will be either vertical or horizontal If the RUBBER BAND is more horizontal than vertical then the bridge will be horizontal Otherwise it will be vertical The Y coordinate of the horizontal bridge is the same as the Y coordinate of the starting point of the RUBBER BAND Likewise the X coordinate of the vertical bridge matches the X coordinate of the starting point of the RUBBER BAND NOTE Leadin and leadout of the first shape will be copied to the final shape Possible leadins and leadouts of the other shapes are removed Wide Bridge Wide bridge is like a normal bridge above but it leaves a solid area between two profiles You can create wide bridges just like normal bridges The only exception is that when you release the mouse button the window below appears C Left G e The black line represents the line you just drew It is also the other side of t
130. set then F codes are interpreted as percentage of the full feed rate b Absolute If this option is set then F codes are interpreted as millimeters or inches per minute 9 42 NESTING Manual 0 5399 N ICNC PERFORMANCE Load amp Save As If you need to read different EIA files from different sources it is useful to save the settings for each EIA type separately Save the settings by using the Save as button and load them back with the Load button See also EIA Programming 5 14 1 Advanced EIA D Advanced EIA codes xi Codes Outbit 1 ON mer Outbit 1 OFF ini Outbit 2 ON Vues Dutbit 2 OFF Outbit 3 ON aac Outbit 3 OFF All Qutbits OFF rD Codes Enable Configure Cancel Here you can configure the outbits for EIA input The meaning of these outbits are explained in the ProMotion Cut manual D codes are predefined kerfs used in some systems Choose Configure to change the kerf values of D codes 5 15 EIA Ouput Options EIA Output Options x Unit Scale Matric Feed rate cades No Rapid feed rate Feed rates C Atthe end of line f On separate line Code Generation Program Gas Cutting Plasma Eutting Inches C 1 00 mm 14000 C 1 10 C 14100 1mm C 10 10mm 1 Plasma 2 Cutting anh Coding jua MENE Goo Line Marking FUIS near cut coi Arc Cu coz Incremental Auc Pw Point Marking Ie
131. sing the Plasma ON OFF button and service the torch if needed After finished enable the plasma power supply by pressing the button again 4 Turn off the MANUAL MODE by pressing and releasing the MANUAL MODE button the button starts to flash and the torch travels back to exit point of the program path 3 Press and release the TORCH ON OFF button to ON and cutting will start again and continue cutting on programmed path 3 12 9 How to pierce in the Scrap Area Prior to Finding the Cut Path 1 After Step 4 turn on the MANUAL MODE again by pressing and releasing the MANUAL MODE button 2 Usethe Jog key buttons and reposition the torch close to the end of the cut Stay on the scrap side Click on Cut Path Recovery button located on the Current Job Screen and machine will automatically start the piercing at this point and pick up the cut path to continue cutting on the programmed path 3 14 Advanced Process Selection Features The process selection screen allows the operator the flexibility to change more parameters if needed Process selection has tabs contain ing different settings You can get to the different settings by clicking either Settings 1 or Edit 2 when a process is selected You can also build a material database of common materials being cut and save different speeds and kerf values within each profile and for each process you edit TD Process Selection v1 0 6 B 212i xl MidStel t 50mm Speed mm min Kerf Imm a
132. ssing the power button located on the far left hand side of the unit for 5 seconds When power is applied the iCNC Performance will take approximately 1 2 minutes to go through internal diagnostics and fully boot up After full power up the Promotion Work Screen displaying Promotion Cut Next Job Preview and Current Job along with Info System Status will be displayed In addition you will see the yellow Zero button flashing This will stop automatically HINT The flashing Zero button indicates that the second CPU used for machine motion has booted up correctly The Zero button flashes 41 times Turn ON the drive enable the drive enable to enable the drives A dialog box may appear START HOMING PROCEDURE 3 8 1 Shutting Off Removing Power After locating a safe parked position disable the drives by turning the drive enable to OFF Turn off the controller using the normal Windows shutdown method Click on Start bottom left hand corner on Window s task bar then click Shut down After the controller goes through a proper cycle down procedure the controller will turn off HINT If applicable parking the machine near the homing switches will make Machine Homing quick and easy when the iCNC Perfor mance is powered up again 3 14 OPERATION Manual 0 5399 iCNC PERFORMANCE 3 9 Homing Procedure During initial power up the iCNC Performance may display a Start homing procedure dialog box If you select Yes the machine will automatic
133. switches buttons Check continuity between E1 outputs disabled and E2 in the power connector 6 4 2 Piercing issues oem caus Plasma will not pierce Worn out consumables Check consumables ErrorinPlasma Check plasma power supply for eror messages Plasma start time set too Check plasma start delay time Short Plasma set to off Check plasma button is on Auto Plasma starts but Worn out consumables Check consumables crashes to plate ErrorinPlasma Check plasma power supply for eror messages AVC set too low Check arc voltage setting Collision rebound offset Check collision rebound ofset setting on iHC set too low Plasma arc lost in the Worn out consumables Check consumables middle of a cut ErrorinPlasma Check plasma power supply for eror messages DEBER Wrong gas pressures Check plasma gas pressures 6 4 MAINTENANCE TROUBLESHOOTING Manual 0 5399 N ICNC PERFORMANCE 6 4 3 Motion issues Problem Motors won t move Enable OFF Turn enable switch to ON SW Enable OFF Speed set to 0 Turn the speed potentiometer to 100 press the speed up button to increase the speed External stop active Check continuity between E1 and E2 in the power connector Motors move slowly Limit switch tripped Check limit switches Collision tripped Check collision sensor opeed set to low Turn the speed potentiometer to 100 and or press the speed up button to increas
134. t Timeout determines how long the system waits at this height for the new pierce command before lifting the torch all the way up to home position Arc Voltage Display shows actual arc voltage in real time when cutting is active Plate Position shows where the plate was last sensed in comparison to the Torch Lifter Home position iHC Manual 0 5399 ICNC PERFORMANCE 4 4 2 Marking Tab Arc Voltage used when marking Cut Height used when marking e Ignition Height used when marking e Pierce Height used when marking e Pierce Height Time used when marking e Pierce Down Time used when marking Cut Height AVC Delay used when marking Manual 0 5399 iHC 4 5 ICNC PERFORMANCE f 4 4 3 Advanced Tab Provides the option for more detailed control of the system behavior Main Advanced o bas naar High jog speed 1500 0 mm min 3000 Collision retract enable 30000 mm sin Colsionretract height 1 0 mm Homing speed 6000 mm min Colision recovery delay Find plate speed _ 6000 Ohmic plate contact enable Plate contact release speed 60 0 mm min Main arc lost timeout 02 s Plate sensing force enabled Collision rebound offset 01 mm Default Values Imperial Metric High Jog Speed 59 06 IPM 1500 mm min is ES Collision retract enable Enables the collision re
135. t again box e Show new start point Selecting this function allows the user to point the pierce point that will start the cut Parts before the selection will be ignored e Restart After locating a new pierce point select Restart to start cutting cycle e Zoom Allows easier pierce point location on a nest by zooming in on a part e Save job Will store existing suspended program to a temporary file e Reload saved job Brings back the suspended saved program from the temporary file Manual 0 5399 OPERATION Z 3 5 ICNC PERFORMANCE 3 2 Process Selection Plasma and Gas TD Process Selection v1 0 6 T 0I xl Mild Steel Material Edit e TO oa tae In this window you can select the process used to cut or edit existing processes 1 Clicking Gas will open the gas parameter set selection Clicking Plasma will open the plasma process window Settings opens common setting like tool offsets rapid speed etc Minimizes the window shows the material If there are more than one material you can change between materials select thickness Applies the selected process and sets all cutting parameters pe 1o gt Gr a Se Iw Lets you edit the selected process NOTE See more details from 3 14 Advanced Process Selection Features on page 3 20 3 6 OPERATION Manual 0 5399 N ICNC PERFORMANCE 3 2 1 Plasma Setup Definition of areas under the Cut Process Tab are shown on the bott
136. tensity is at its maximum Inner cone Blue flame same size as inner cone Flame ignited Blue cone no oxygen oxygen added Biuish flanie Bluish flame almost invisible almost invisible 6 3 2 Effect of preheat on cut quality Characteristics of proper preheat 1 edge is quite square and less than 1 16 2 melt over top rounding 2 Face of the cut contains an easily removable thin layer of slag which covers a clean surface with well defined drag lines from top to bottom 3 Bottom edge contains little to no easily removable slag Characteristics of too much preheat 1 Top edge contains heavy roll over and occasional protrusions 2 Black heavily crusted slag will accumulate on the face of the cut making it difficult to clean 3 Upper portion of cut has little to no drag lines and lack of detail because of melting 6 2 MAINTENANCE TROUBLESHOOTING Manual 0 5399 N ICNC PERFORMANCE Characteristics of too little preheat 1 Top edge is almost perfectly square 2 Torch is constantly on the verge of losing cut 3 Some difficulty is experienced in getting through heavy plate Correct cutting technique The cut surface is smooth and square and the kerf walls are parallel The lag lines are almost vertical There is little slag adhering to the bottom edge The top edge is slightly rounded when the preheat flames are properly adjusted This surface is ideally suited for many applications without further
137. tentionally blank Denton TX USA U S Customer Care Ph 1 800 426 1888 tollfree Fax 1 800 535 0557 tollfree International Customer Care Ph 1 940 381 1212 Fax 1 940 483 8178 Oakville Ontario Canada Canada Customer Care Ph 1 905 827 4515 Fax 1 800 588 1714 tollfree EUROPE Chorley United Kingdom Customer Care Ph 44 1257 261755 Fax 4 44 1257 224800 Milan Italy Customer Care Ph 39 0236546801 Fax 39 0236546840 ASIA PACIFIC Cikarang Indonesia Customer Care Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 603 6092 1085 Melbourne Australia Australia Customer Care Ph 1300 654 674 tollfree Ph 61 3 9474 7400 Fax 61 3 9474 7391 International Ph 61 3 9474 7508 Fax 61 3 9474 7488 Shanghai China Sales Office Ph 86 21 64072626 Fax 86 21 64483032 Singapore Sales Office Ph 65 6832 8066 Fax 65 6763 5812 THERMAL INNOVATION TO SHAPE THE WORLD DYNAMICS U S Customer Care 800 279 2628 FAX 800 535 0557 Canada Customer Care 905 827 4515 FAX 800 588 1714 International Customer Care 940 381 1212 FAX 940 483 8178 2015 Thermal Dynamics Corp thermal dynamics com Printed in Finland
138. tion ON OFF and keeping the button pressed in for 3 seconds will toggle the function to AUTO Green LED indicates ON state and orange indicates AUTO state If both LEDs are OFF then the state is OFF AUXILIARY 3 9 1 Pointer i e ON position will activate the Pointer output e OFF position will prevent activating the Pointer output 3 5 2 Plasma ON OFF 9 PLASMA ON position will turn on the plasma power supply e OFF position will turn off the plasma power supply Manual 0 5399 OPERATION 3 11 ICNC PERFORMANCE 3 5 3 AUX 1 3 On Off Auto ON position will activate the auxiliary device example water table e AUTO position will activate the auxiliary device example water table when a cutting program is active e OFF position will turn off the auxiliary device example water table 3 5 4 Down Draft On Off Auto ON position will activate the fume extractor AUTO position will activate the fume extractor when a cutting program is active e OFF position will turn off the fume extractor 3 6 Plasma Button Descriptions and Functions CAUTION Most buttons have 2 functions and the different color LEDs indicate the state Pressing a button will toggle the function ON OFF and keeping the button pressed in for 3 seconds will toggle the function to AUTO Green LED indicates ON state and orange indicates AUTO state If both LEDs are OFF then the State is OFF PLASMA 3 6 1 Up Down e Up Down bu
139. together with excellence in sales and marketing expertise Above all we are committed to developing technologically advanced products to achieve a safer working environment within the welding industry WARNING Read and understand this entire Manual and your employer s safety practices before installing operating or servicing the equipment While the information contained in this Manual represents the Manufacturer s best judgement the Manufacturer assumes no liability for its use ICNC Performance Operator Manual No 0 5399 Published by Thermal Dynamics Corporation 2800 Airport Rd Denton Texas 76207 www thermal dynamics com Copyright 2013 2014 2015 by Thermal Dynamics Corporation All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this manual whether such error results from negligence accident or any other cause Publication Date August 19 2015 Revision Date Record the following information for Warranty purposes Where Purchased Purchase Date Power Supply Serial Torch Serial Be sure this information reaches the operator You can get extra copies through your supplier These INSTRUCTIONS are for experienced operators If you are not fully familiar with the principles of operati
140. tract feature that lifts the torch when plate contact has occurred while cutting This feature is mainly used to protect torch consumables from hot slag emerging on top of the plate after piercing Higher pierce height must be used to protect consumables while piercing If Collision Retract activates all the time while cutting check system for proper cutting speed arc voltage and gas pressure Note that on small radius holes while using lower speeds the slag might shoot up to the torch and retract the torch if this occurs and hole quality is more important than consumable life you can disable this feature Collision retract height sets the height for the torch where it retracts to after plate contact has occurred while cutting is active Collision recovery delay determines how long the torch will remain in the collision retract height until automatic height control is activated again e Ohmic plate contact enable using this function requires a connection between the torch shield cap and the voltage divider This method is more accurate and sensitive than the Plate sensing by force Ohmic plate contact enable should always be used as the main plate sensing feature if possible This function is not usable when cutting under water Ohmic plate contact enable V 4 6 Manual 0 5399 ICNC PERFORMANCE 4 4 4 1 0 Bits Tab This tab displays the status of various system signals for diagnostic purposes 1 0 bits are separated to inputs s
141. tton will move the plasma torch Up Down 3 6 2 Plasma On Off Auto J ON position will activate the plasma start output e AUTO position will activate the plasma start output when a cutting program is active e OFF position will turn off the plasma start output 3 12 OPERATION Manual 0 5399 ICNG PERFORMANCE 3 7 Oxyfuel Button Descriptions and Functions CAUTION Most buttons have 2 functions and the different color LEDs indicate the state Pressing a button will toggle the function ON OFF and keeping the button pressed in for 3 seconds will toggle the function to AUTO Green LED indicates ON state and orange indicates AUTO state If both LEDs are OFF then the state is OFF OXYFUEL 3 7 1 Preheat On Off Auto 7 1 _ This switch handles the Fuel Low Preheat gases e ON position will open the low preheat solenoid valve e Switch the gases OFF by pressing the button once e AUTO position will allow the cutting program to open the High Preheat solenoid when necessary e OFF position will prevent a cutting program from opening the Preheat solenoid valve 3 7 2 High Preheat On Off Auto _ This switch handles the Oxy Fuel High Preheat gases ON position will open the Hi Preheat solenoid valve e Switch the gases OFF by pressing the button once e AUTO position will allow the cutting program to open the High Preheat solenoid when necessary OFF position will prevent a cutting program from
142. un angle de jusqu 60 degr s de la verticale Les quipements portant la marque IP21S peuvent tre entrepos s l ext rieur mais ne sont pas concus pour tre utilis s l ext rieur pendant une pr cipitation moins d tre l abri Ce produit a t concu pour la d coupe au plasma seulement Toute autre N G A M utilisation pourrait causer des blessures et ou endommager l appareil Manual 0 5399 SAFETY INSTRUCTIONS 1 9 ICNC PERFORMANCE MISE EN GARDE L quipement pourrait basculer s il est plac sur une surface dont la pente d passe 15 Vous pourriez vous blesser ou endommager l quipement de fa on importante 1 Art A 12726 illustr s afin d viter de vous blesser ou d endommager l quipement Soulevez l aide de la m thode et des points d attache 1 10 SAFETY INSTRUCTIONS Manual 0 5399 N iCNC PERFORMANCE SECTION 2 SPECIFICATIONS 2 1 System Description iCNC Performance is intended for shape cutting control iCNC Performance has motion control 1 0 user interface and an optional plasma height control built all in one package These units are not field repairable Unauthorized opening of the unit will void the warranty 2 2 Specification 2 Intel secondary processor for motion amp 1 0 Operating system Windows 7 Embedded Ethernet por 15 With touch panel resistive CNC protection device CAUTION See full technical detai
143. verted e Encoder pulse edges per meter Determined by the type of encoder and the threaded shaft of the lifter e Full Speed The maximum speed of the lifter Full Speed is used above Slow Down Height Home Distance The distance of the home position from the limit switch e Manual Acceleration amp Manual Deceleration Used on jog when AVC is on e Machine Acceleration amp Machine Deceleration used when the software drives the lifter e Homing Speed The speed used in the homing process Qut Of Limit Speed The speed used when the torch is moving out of limit switch e Plate Contact Release Speed The speed used when driving out of plate until contact is released e Adjust Speed Used in arc voltage control process to determine the maximum control speed of the lifter Up Limit Timeout When moving up the torch halts after this timeout if the limit switch is not found e Main Arc Lost Timeout Typically 0 15 to avoid losing the cut without real cause Hold OFF AVC Delay Additional delay after Hold OFF which can be useful after piercing and in corners e Upper Soft Limit Distance Upper soft limit which is located above the limit switch The position of the upper soft limit is determined by adding the Upper Soft Limit Distance to the position of the limit switch e Lower Soft Limit Distance Lower soft limit which is located below the plate The position of the lower soft limit is determined by subtracting the Lower Soft Limit Distan
144. will cause the shapes to appear in different color if they do not have enough space between them Releasing the button allows the parts to revert to their normal color So how great should the distance be between two shapes In the Nesting Options check the kerf width and clearance parameters The distance between two shapes should be twice the kerf width and once the clearance This formula is used by the colliding tools and overlap checking NOTE Collision tools are visible only when the Move Shape tool is active 5 5 6 Rotate Shape Allows the user to rotate a shape simply by grabbing it with a mouse The part will follow the mouse movement rotate The rotation steps can be set in Handling Options Recommended steps are 5 or less degrees 5 5 7 Mirror El This tool allows you to mirror shapes in X or Y axis If you move the mouse cursor over a shape and click the left mouse button the shape will be mirrored in Y axis If you click the right mouse button the shape will be mirrored in X axis 5 5 8 Change Piercing Point There are two ways to change the current piercing point To change the pierce point to the first point of the element move the mouse cursor over the element and click the left mouse button If you want to choose any point on the element move the mouse cursor to the desired start point and click the right mouse button This tool can only be used on complete profiles NESTING Manual 0 5399 N ICNC PERFORMA
145. xport This tool exports the current nesting to ProMotion Cut Please note that the exported nesting won t open automatically in ProMo tion Cut To open it you must use the import tool of ProMotion Cut 9 4 7 Exit This tool closes the ProMotion Nest software Important All nestings will be closed and all data they contain will be lost upon exiting If you want to save one or more of those nestings you should save them before exiting 5 5 View Menu In View menu you can change the appearance of ProMotion Nest and the way how it draws your nestings Black and White view This option turns drawing color to black Outbits If this option is checked then ProMotion Nest displays special outbits if there are any in the nesting For more info see the ProMo tion Cut manual Transferlines Hide All Transferlines can be toggled on or off by selecting this option e Show Cut When selected you can see transferlines between cutting profiles This is the default setting e Show Line Marking When selected you can see transferlines between line marking profiles Show Point Marking When selected you can see transferlines between point marking points show Large Buttons This option turns all buttons in ProMotion Nest toolbar and toolboxes to large ones This setting is recommended for touch screen use NOTE You need to restart ProMotion Nest to have this change take effect NESTING Manual 0 5399 ICNC
146. you make a mistake please use Undo tool 5 7 3 Cut to Line Marking This tool converts holes to line marking profiles You only need to click those holes you want to convert NOTE You cannot reverse the conversion If you make a mistake please use Undo tool 5 8 Autonest 9 0 1 Triangle Nest This tool nests the parts into the smallest possible rectangle For example two triangles are nested so that their sides are facing each other This tool works well with triangles and that s where the name comes 5 8 2 MultiNest MultiNest nests all shapes automatically If shapes do not fit on the current plate MultiNest creates new copies of the current plate and continues nesting on them until all the shapes are nested 5 8 3 Groups This tool allows you to copy shapes to nesting groups Nesting group is a group of parts which all move and autonest together like a single shape When this tool is active the dialog below is visible Copy to Group Select group where to copy The name of a new group a Close When this tool is active you can select and unselect shapes by clicking on them or drawing a rectangle around them The list Select group where to copy shows all possible groups where you can copy shapes Actually this list contains all geometries from the geometry window and you can later turn them to groups see example below Copy button copies all the selected shapes to the group selected from t

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