DY400M1A Operation Manual

Transcription

1 DY00M1A Operation Manual edit date 7/30/09 DY01A1A Multi axis control system using Mach 3.0 CNC software The DY01 implements all required hardware for a CNC table to operate the Mach 3.0 CNC software. In addition the DY01 provides basic diagnostic tools, setup parameters and manual testing of all axis's. Full package provides; In a single enclosure, all power supplies, Gecko mount, CPU logic board, power inlet, twist lock connectors for all motors, table I/O, limit switches, PC interface, output relays and the DL202 hand held terminal, circulation fan, mounting brackets, fuses, E-Stop switch, etc. Power input; 120vac 15 amps, Nema 15-5 flanged inlet Logic input; From the personal computer: 2 parallel ports and 1 comm. port Software; Mach 3.0 CNC running on the personal computer Outputs; 3 axis standard, with optional th axis, stepper drive or DC servomotor drive Options; Plasma torch interface, high speed spindle drive interface Basic diagram of the Control Panel layout Panel, side view cable connections Push Stop twist-release Gecko motor drivers PC connections comm LPT2 LPT1 0 pin ribbon Main logic DY00 12 pin X,Y,Z motor leads X axis Y axis DL202 motors Table I/O handheld Spindle / plasma x axis y axis z axis a axis 9 9 CR2 CR vac Relay Outlets 8 amps (max) 9 9 CR CR 50 pin ribbon FU6 FU7 FU8 XFRM-1 optional CR2 CR3 CR FU3 Opt. A axis motor leads Motor Fuse indicators 10 pin control CR1 X Y Z A XFMR-2 standard 6 pin FU9,10,11,12 Motor Fuses FU FU5 XFMR-3 optional Z axis A axis optional th axis 120 VAC Power Inlet 15 amp (max) Pwr I/O assy DYX1 Hand held terminal Nema 1 enclosure 12" wide x 20" tall x 6" deep full hinged door

2 Motor driver modules; Gecko G micro-stepper driver stepper motor; 2 phase, 1.8 deg/step, wired bi-polar parallel 6.1 amps/phase, 1.53volts Gecko current set to 67% x 6.1amp =.1amps Bus voltage max = 25X 1.53volts = 38v max Gecko G320 DC servo motor driver DC servomotor; 3.25" Nema 3 DC brush motor, 90vdc, 3200 RPM with encoder option

3 DL202 Handheld Use This document describes the basic operation, connections, and various displays (also referred to as Menus) available from the handheld operator interface. This instruction sheet will refer to the handheld as the DL200 (general name) or simply handheld. (the actual part number; DL202A1A) The DL200 is a small handheld display / keypad interface. The display is a 2 row by 16 character backlite alpha-numeric LCD type. There are pushbuttons, Menu Alt Inc Dec The DL200 is equipped with a 6ft cable and a -pin twist-lock plug. The DL200 connects to the main controller via the -pin receptacle on the left side of the main panel, marked 'DL200'. The handheld receives its power from the main panel and communicates using a standard RS232 format. The handheld unit has a rubber boot with a powerful magnet bonded on the backside. This allows the unit to be easily attached to the main panel or to any other handy (steel) location. The back of the rubber boot also has a swing out leg for standing the unit up on a tabletop. The DL200 hand held is specifically designed to perform various manual tests, setup the basic operations parameters and to diagnose some problems. When not in use, the DL200 should be stored in a safe location. Care is required to prevent the unit from being dropped, exposed to water or moisture, metal cutting chips, dust and grit from a plasma torch, etc. Some users find a simple zip-lock bag is a great way to keep it protected. When not in use its recommended you disconnect the unit and store in a safe location. Its NOT recommended you store the handheld inside the main control panel unless the control panel is equipped with a bracket on the inside of the door to retain the hand held. Later units have the inside door bracket for the handheld. Note; The main panel contains high voltage and sensitive electronic circuits and should be kept closed at all times. Operation The DL200 handheld uses pushbuttons to provide the user with a simple way to move thru the various menus and to make required changes to the internal settings. Navigating and identifying each menu is done using the display number, located in the upper left corner of the LCD. Pushbuttons; (keys) Menu Alt Inc Dec The Menu key is pressed when you want to view or change the menu number. Press and hold the Menu key then use the Inc or Dec keys to move up and down thru the menu list. When you have reached the desired menu, release the Menu key to view the full menu. When you scroll to the end of the menu list the handheld will allow the menu number wrap around to the beginning of the menu list. The Alt key has multiple uses. First it allow going between three menu groups; Run, Setup, Manual. To change the active menu group, go the first menu in the group and press and hold both the Menu and Alt keys for 5 seconds, release. Use the Inc and Dec keys to select the new menu group, press alt to change to the selected group. The Alt key is also used to select or initiate a specific actions. Refer to actual menu list for more details on the Alt key The Inc / Dec keys are used to increase or decrease numbers. When the Menu key is held the Inc / Dec keys move the user up/down thru the menu numbers within the current menu group. With the Menu key is released the Inc / Dec keys are used to change specific numbers or modes listed on the display. Refer to actual menu list for more details on the Inc / Dec keys. D L H A N D H E L D MENU ALT INC DEC

4 Menu groups The handheld is divided into three menu groups each with reserved menu numbers. Run Group is 1-30, Setup Group is 31-60, Manual Group is The Mach 3 group has menus relevant for normal operation such as; Status, hand-wheel, position set points, encoder pulses, torch set points, etc The Setup group is used to set up features, such as; axis on/off, sensitivity, torch or spindle features. The Manual group lets the operator verify operation of travel limit switches, make simple jog moves, test motors and servos along with optional torch and spindle tests. Mach 3 menu group (THC) 1 Change menu groups 2 Main Status display 3 Hand Wheel Display of Bus voltage 5 Set THC voltage 6 THC operational Display 7 DY checksum and serial number 8 X Axis set point & encoder feedback freq 9 Y Axis set point & encoder feedback freq 10 Z Axis set point & encoder feedback freq 11 A Axis set point & encoder feedback freq Mach 3 menu group (SPINDLE) 1 Change menu groups 2 Main Status display 3 Hand Wheel Display of Bus voltage 5 RPM SET POINT Display 6 Spindle Voltage Setting and Spindle command Display 7 DY checksum and serial number 8 X Axis set point & encoder feedback freq 9 Y Axis set point & encoder feedback freq 10 Z Axis set point & encoder feedback freq 11 A Axis set point & encoder feedback freq SETUP menu group 31 Change menu groups 32 Set X Axis to Step, Servo, Off 33 Set Y Axis to Step, Servo, Off 3 Set Z Axis to Step, Servo, Off 35 Set A Axis to Step, Servo, Off 36 Servo Voltage Sensitivity (set 1-100% yields 2-7 volts) 37 Set THC deadband ( volts) 38 Set THC or Spindle 39 Set which output is controlled by the Hand Wheel Switch 0 Option code 1 1 Option code 2 (future option, not currently used) 2 Alarm Beeper On/off 3 Spindle Type Send/Receive New program

5 Manual menu group 61 Change menu groups 62 display EOT and Home limit switch inputs 63 display Gecko faults 6 jog X axis 65 jog Y axis 66 jog Z axis 67 jog A axis 68 Test torch 69 Test Spindle 70 Test Relays

6 Mach 3 Group 1 Change menu group 1 T H o l d M E N U + A L T o C h a n g e G r o u p Press-n-hold Menu + Alt keys hold for 5 seconds P r e s s A L T T o x x x x x x x x Use Inc / Dec keys to scroll to your selection x x x x = Stay in Run x x x x = Switch to Setup x x x x = Switch to Manual Then press ALT to select and move to the new group 2 System Status 2 S y s t e m S t a t u s x x x x x x x x (bottom row) will show one of the following titles Ready System status is ready for operation E-Stop In System disables because E-Stop switch is pushed in (Red light = off) End of Travel IN One of the end of travel limit switches is tripped Lost Charge Pump Charge pump was active but is now missing No Charge Pump Charge pump signal is not active X-Axis Runaway X axis stopped, encoder pulses missing X-Ax Gecko Fault X axis Gecko motor driver has faulted Y-Axis Runaway Y axis stopped, encoder pulses missing Y-Ax Gecko Fault Y axis Gecko motor driver has faulted Z-Axis Runaway Z axis stopped, encoder pulses missing Z-Ax Gecko Fault Z axis Gecko motor driver has faulted A-Axis Runaway A axis stopped, encoder pulses missing A-Ax Gecko Fault A axis Gecko motor driver has faulted ALT->Update Prog Program upgrade is ready, press ALT to proceed No motor voltage Program upgrade is ready, press ALT to proceed Press ALT to reset or clear an Error Press any key to silence the audio alarm

7 Run group cont. 3 Hand Wheel Mach 3.0 must have its hand wheel function set up SW FW Rv SW (alt key) lets you switch between axis's FW (Inc key) is used to jog forward Rv (Dec key) is used to jog reverse 3 H a n d W h e e l S W F W R v Bus Voltage Read the DC bus voltage used for the motor drivers xx.x Vdc B u s V o l t a g e x x x. x V d c 5 THC Setpoint Torch set point xxx Volts Enter the set point voltage value you want the plasma to use also displays what Mach 3.0 last sent as the torch set point The DY00 compares the actual tip volts read by the X board to the THC set point (volts). The DY00 then issues up and down commands to Mach 3.0. In response Mach 3.0 will move the z-axis 5 T H C S e t p o i n t x x x V o l t 6 Set FB A U D To view the plasma torch interface xxx xxx b b b (block appears below the corresponding title, b b b) Set = Tip Voltage Set point (either from Mach or entered in menu #5) FB = actual tip voltage read by the X board A -block appears when Arc Good goes active. U -block appears when UP command is active D -block appears when DN command is active 6 S e t F B U D A x x x y y y

8 7 Checksum = xxxx View the Program ID aka checksum xxxx Serial No = yyy View the Control panel serial number yyy 7 C h e c k s u m = x x x x S e r i a l N o = y y y 8 X Stp Dir Enc xxxxx R xxxxx 8 X S t p D i r E n C x x x x y z z z z 9 Y Stp Dir Enc xxxxx R xxxxx 9 Y S t p D i r E n C x x x x y z z z z 10 Z Stp Dir Enc xxxxx R xxxxx 1 0 Z S t p D i r E n C x x x x y z z z z 11 A Stp Dir Enc xxxxx R xxxxx 1 1 A S t p D i r E n C x x x x y z z z z

9 Setup group: 31 This menu lets you redirect the hand held to a different group 1 T H o l d M E N U + A L T o C h a n g e G r o u p Press-n-hold Menu + Alt keys hold for 5 seconds P r e s s A L T T o x x x x x x x x Use Inc / Dec keys to scroll to your selection x x x x = Stay in Run x x x x = Switch to Setup x x x x = Switch to Test Then press ALT to select and move to the new group 32 Setup X Axis 3 2 S e t u p X A x i s use INC/DEC keys to select your choice x x x x x xxxxx = Off or Servo or Step 33 Setup Y Axis 3 3 S e t u p Y A x i s use INC/DEC keys to select your choice x x x x x xxxxx = Off or Servo or Step 3 3 S e t u p Z A x i s Setup Z Axis use INC/DEC keys to select your choice x x x x x xxxxx = Off or Servo or Step S e t u p A A x i s Setup A Axis use INC/DEC keys to select your choice x x x x x xxxxx = Off or Servo or Step

10 V o l t S e n s x x % This Voltage Sense is used on DC servo motor applications only This menu does not apply to stepper motor applications The voltage sense is use to catch a DC motor run-a-way condition The theory is if there is a motor voltage with out encoder pulses there is a run-a-way condition. This feature is not fully developed (X,Y,Z,A appear only if the corresponding voltage input = active) 37 THC Deadband 3 7 T H C D e a d b a n d The deadband is an adjustable voltage x x. x V o l t s xx.x Volts Factory = 0.5 Volts 38 Output Config Use this menu to select which option will be active Spindle THC This only has relevance when the Option Code is Both 3 8 O u t p u t C o n f i g x x x x x x x 39 Hw Psh Button runs Hand Jog runs Hand Sw runs Hand Psh runs Scroll 3 9 H w P s h B u t t o n x x x x x x x x

11 Option Codes 0 Enter Option Code 1 xxxx 0 E n t e r O p t i o n X C o d e 1 Y Y Y Y X = 0 >> no code entered X = 1 >> THC code entered X = 2 >> Spindle code entered X = 3 >> both THC and Spn entered Y = enter the digit option code 1 Enter Option Code 2 n/a 1 E n t e r C o d e 2 O p t i o n Option Code 2 is an unused option (reserved for furure use) From Menu 0 Use the INC and DEC keys to enter the first character of your -digit code Use the ALT key to move over to the next character, repeat for all digits To verify you've entered the correct option code refer to menu 0, look at the lower line far left character (X) indicates which option code has been accepted. 0 means no code has been entered 1 means the THC code is entered 2 means the Spindle code is entered 3 means both the THC and Spindle codes are entered. If you have entered the both code you still have to select which one is active. Go to Menu 38 and select THC or Spindle. The DY01 cannot operate both the THC and the Spindle at the same time. Note; Do not use menu 1. Option Code 2 is not active. (reserved for future use) 2 Alarm Config 2 A l a r m C o n f i g Off On x x x 3 Spindle Ctrl 3 S p i n d l e C r t l Type 1 (Seperate Fwd/Rev outputs) Type 2 (Run & Rev outs) T y p e x

12 Updating the DY01 program W a i t i n g f o r C o m m a n d The Waiting for Command is a holding menu. There are three selections: ALT, INC and DEC 1. Press ALT to proceed on with update 2. Press-n-hold INC to view current program label 3. Press-n-hold DEC to view new program label P r e s s A l t t o 1. Press ALT this second time to start the update C o m p l e t e u p d a t e X f r d y 0 1 f * x x % C o m p l e t e * This screen indicates the upgrade is proceeding. * * replaced with new version revision XX% indicates the file transfer progress T a r g e t P r g L a b e l 2. Press n hold INC xxxxxxxx = the program name currently in the DY01 x x x x x x x x Target means the DY01 S t o r e d P r g L a b e l x x x x x x x x 3 Press n hold DEC xxxxxxxx = new program waiting to be transferred presently Stored in DL2 N o F i l e This screen show there is no update file available A v a i a b l e

13 Manual group, Note, The manual group of menus allows the user to operate each axis, checkout the limit switches, verify the relay outputs, the torch and spindle interface, etc. This requires all (3) cable connections with the PC be fully removed. This will ensure there is no signal interference between the PC and the DY00. Also, use caution in manual mode, the DY00 becomes fully enabled to move the axis's and the user must be prepared for possible unwanted movements H ol d M E N U + A L T Press-n-hold Menu + Alt keys hold for 5 seconds T o C h a n g e G r o u p P r e s s A L T T o x x x x x x x x Use Inc / Dec keys to scroll to your selection x x x x = Stay in Run x x x x = Switch to Setup x x x x = Switch to Manual Press ALT to select and move to the new group 62 X Y Z A Home switches and the 6 2 X Y Z A E O T EOT, End Of Travel limit switches (solid block below each display title L i m s means the switch is active) All () EOT switches are wired in series, opening any one will fault the whole set On a typical 3-axis system a jumper shunt must be installed on X3 board on A, the forth axis 63 Motor Driver Fault (Gecko Fault) 6 3 X Y Z A (solid block below each display title F a u l t means a fault is active)

14 Manual move to test each axis Holding the INC button will jog the x-axis forward. Holding the DEC button will jog the x-axis in reverse. The display shows Stp and below is the step command frequency (xxxx). Below the Dir there will be a F or R indication forward or reverse (y) If the axis is using a DC servo motor the EnC encoder frequency is shown (zzzz) If the axis is using a Stepper motor the encoder frequency will read 0. 6 X axis manual test 6 X S t p D i r E n C x x x x y z z z z 65 Y axis manual test 6 5 Y S t p D i r E n C x x x x y z z z z 66 Z axis manual test 6 6 Z S t p D i r E n C x x x x y z z z z 67 A axis manual test 6 7 A S t p D i r E n C x x x x y z z z z

15 68 Verify Torch interface 6 8 V l t S t A G U D Tip-voltage, Start relay, Arc Good, Up, Down x x x Below the Vlt is the current tip voltage set point Press ALT turns on the start relay (push on/ push off) a block appears below the ST If the arc good signal is active, a block appears below the AG press INC forces an up signal to Mach, a block appears below the U press DEC forces a down signal to Mach, a block appears below the D 69 Verify Spindle interface 6 9 S p i n d l e T e s t V = x x. x F w d R e v The analog voltage output is manually set with the INC/DEC keys ( 0-10 volts ) The analog output is use to change the spindle RPM Press 'ALT' toggles the action of the INC/DEC keys so they will be: INC = Run Forward DEC = Run Reverse (both are momentary actions). 70 Relay Test 7 0 R t r A u x 1 A u x 2 Press 'ALT' toggles on/off Press 'INC' toggles on/off Press 'DEC' toggles on/off CR (Router Relay) CR3 (Spare-1 Relay) CR2 (Spare-2 Relay)

16 Torch Voltage Jumper Selection Warning Read an understand the Jumper settings before connecting to a Plasma Torch Improper jumper settings will Damage the Torch Isolation Board 1. The DY00 system allows for connecting to a Plasma Torch to read the tip volts. 2. If the tip volts are divided down by the Plasma Torch's internal voltage divider [preferred] then you are free to connect the torch's divide tip volts directly to the DYX torch isolation bd. Note; the divide tip volts from the Plasma Torch must not exceed 38 vdc 3. If the Plasma Torch is unable to divide down its own tip volts, the installer must set the tip volts jumper to the Direct position. In the direct position the DYX3 connector bd provides a 9,000 ohm dropping resistor network. This will divide a 300 vdc tip volt down to 18.29vdc and a 600vdc tip volt down to 36.6vdc. You must never apply undivided tip volts directly to the torch isolation bd. A tip volts of (0-300Vdc) or (0-600vdc) will blow the isolation bd. fuse (If this happens DYX isolation board must be returned to the factory for repair) 5. Note; The DY00 system has used three different revisions of the DYX3 connector bd. You can identify the revision as Y, Z and A in the lower right corner of the bd. Tip volts shunt settings DIVIDED DIRECT Left position = divided tip volts The DYX3 will NOT divide the tip volts Use this setting only if the Plasma Torch divides its own tip volts down to < 38 vdc Right position = direct tip volts (factory setting) The DYX3 will divide tip volts by 16. Use this setting to directly read 300/600 vdc tip volts DYX Torch Isolation bd DYX3 Table I/O connector bd Ribbon Cable P5 P DYX3B0A.BOT Rev A TIP VOLTS DIVIDED Shunt Tip volts shunt settings Shunt Not Installed = divides tip volts (factory setting The DYX3 will divide tip volts by 16. Use this setting to divide down 300/600 vdc tip volts Shunt Installed = direct tip volts The DYX3 will NOT divide the tip volts Use this setting only if the Plasma Torch divides its own tip volts down to < 38 vdc DYX Torch Isolation Bd DYX3 Table I/O connector bd. Ribbon Cable P5 P DYX3B0Y.BOT Rev Y DYX3B0Z.BOT Rev Z

17 Torch set up for the DY00 Note; the Torch and Spindle cables are combined into one cable, DY00C5. The Spindle connections should be wrapped and taped off to prevent any unwanted connection with other voltages or ground. Most plasma torch manufactures provide an OEM connection out the rear of the torch machine. This connection is a 1 pin circular receptacle. Cutmaster and PowerMax connections have been shown. Theory The torch interface is comprised of three components; Start command, ARC verification and TIP volts. The DY00 provides a torch start command via a relay w/ NO contacts, ref. pins 10 and 1, (YEL). The torch start comes from Mach, LPT2 pin 1, active high The ARC good verification is a signal that comes from the plasma torch to indicate the ARC is good and high power current is flowing thru the TIP. There are two types of ARC good signals; dry contact and CT (current transformer). The more advance plasma torches provide a dry contact to indicate ARC good. Older torches may require a CT be added. The ARC good signal goes back to Mach thru LPT2 pin 15, active low. ARC good, (dry contact); set JP1=B to send 5vdc out pin 9 (BLU) to one side of the ARC good dry contact. The other side of the dry contact returns 5vdc to pin 7 (BLU / WHT). R6 is factory adjusted so the ARC good contact trips the detector circuit ARC good (CT): When the torch is using a CT to indicate ARC good, set JP1=A and re-adjust R6 to trip the detector circuit TIP volts is a required feedback signal for Mach to regulate the height of the Z axis and maintain proper cut performance. There are two types of TIP volt signals, 1) Raw tip volts 0-300vdc or 0-600vdc 2) divided volts where the torch manufacturer has provided an internal divide down circuit. Located on the DYX3 connector board is a jumper JP5. When the shunt is left off JP5 a Raw tip volt signal can be connected. To use a divide down tip volts signal you will need to install a shunt onto JP5. JP5 (out) divides the Raw tip volts by 16.. If you use a divided tip volt output choose a scale nearest to 16.

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19 Torch Sw (+) Torch Sw (-) WHT RED 3 CPC1R-RS rear panel connector 3 DYX3 connector bd YEL YEL DY Torch / Spindle Control Torch Start Cmd NO contact XFER OK to move NO contact YEL BLK BLU BLU 9 7 JP1=B OK to Move +5v 5 5 WHT 6 6 GRN 1 Tip Volts isolated Undivided TIP volts 0-300/600vdc (+) (-) J15 J16 Hypertherm Powermax 1000 Strain relief Set Tip Volt Shunt so the DYX3 divides the Plasma Torch raw tip volts by 16. Torch CPC1P-RS Male Pins Length (specify) 6 cond, 18 ga wire, colors, Loom.350 CPC1P-RS Male Pins DY Hypertherm Powermax 1000 DY Torch Interface WHT GRN DYX3 connector bd DY Torch / Spindle Control Torch Sw (+) Torch Sw (-) 3 3 YEL YEL Torch Start Cmd NO contact Relay K1 NO contact BLU BLU 9 7 JP1=B OK to Move +5v Torch TIP volts divided by 16.5 (all Dip sw's = 0) (+) (-) WHT (sig) GRN (com) 1 Tip Volts / Divided 0-36vdc Automation Interface PC Board p/n: 19X201 Thermal Dynamics Cutmaster 151 (100 amp 230 vac) SL100SV Torch CPC1R-RS rear panel connector Set Tip volts shunt so the DYX3 reads the pre-divided Plasma Torch volts TORCH CPC1P-RS Male Pins Length (specify) 6 cond, 18 ga wire, colors, Loom.350 CPC1P-RS Male Pins DY Thermal Dynamics Cutmaster 151 DY Torch Interface

20 Spindle Set-up for the DY00 The DY00 system is able to use and operate different spindle drives. Requires the interface cable DY00C5 combination Torch/Spindle Cable. The cable has (6) leads [ 3 pairs ] that exit near the connector for connecting directly to the Spindle Drive interface terminals. See sketch below for the (3) wire pairs; BRN and BRN/WHT Run and Forward command ORG and ORG/WHT Reverse command RED and BLK 0-10vdc speed command There are two basically ways to wire the spindle control; sinking or sourcing. Some spindle drives offer the sink/source as a selectable option, others this is fixed. The sketch below shows how to wire the DY00 spindle command outputs to operate sink or source. Basically sinking uses a common supply (2vdc) from the spindle drive and source uses a common ground from the spindle drive. Use the DL2 handheld to setup the type of Spindle control you need. Menu 3 Type 1 Type 2 Spindle Ctrl Forward command (output 1 only) starts and Runs the Spindle, turning the head forward Reverse command (output 2 only) starts and Runs the Spindle, turning the head reverse This type uses one output at a time Forward command (output 1) starts and Runs the Spindle, turning the head forward While keeping the Forward command ON the DY00 adds the Reverse command (output 2) to turn the head in reverse This type holds Forward output ON and adds reverse so both outputs are ON (collector) (emitter) CPC1 P RS 2 5 SINKING BRN Spindle Forward BRN / WHT Spindle Drive +2v RUN (FWD) (collector) (emitter) 3 6 Spindle Reverse ORG ORG / WHT REV ( speed cmd ) ( com ) RED Spindle Speed Cmd BLK Analog Input Analog gnd (collector) (emitter) CPC1 P RS 2 5 SOURCING BRN Spindle Forward BRN / WHT Spindle Drive RUN (FWD) (collector) (emitter) 3 6 Spindle Reverse ORG ORG / WHT REV GND ( speed cmd ) ( com ) RED Spindle Speed Cmd BLK Analog Input Analog gnd

21 There is a labeling error on the connector board. The EOT jumpers allow the user to jumper out each EOT limit switch. Placing the shunt over the associated 2-pin jumper will electrically short across the actual limit switch. The error is with the labeling. Above each jumper is the axis name; X, Y, Z, A. On the rev Y and Z boards the labeling is wrong, see below for the correct designation for each jumper. EOT Jumpers INCORRECT A Z Y X TIP VOLTS TIP VOLTS ISOLATOR EOT Jumpers CORRECT A X Z Y TIP VOLTS TIP VOLTS ISOLATOR

22 DY00 to PC Connections, LPT1 and LPT2 and comm. port (DB9 RS232) LPT1: DES: PIN 1 AUX PIN 2 X-STEP PIN 3 X-DIR PIN Y-STEP PIN 5 Y-DIR PIN 6 Z-STEP PIN 7 Z-DIR PIN 8 A-STEP PIN 9 A-DIR PIN 10 E-STOP, DY output PIN 11 HW-PB PIN 12 HW-SCROLL PIN 13 HW A-PH PIN 1 SPARE-Out-1 CR3* PIN 15 HW B-PH PIN 16 ROUTER Output CR* PIN 17 SPARE-Out-2 CR2* PIN GND * Relay control: CR2,3, use active high output LPT2: PIN 1 PIN 2 PIN 3 PIN PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12 PIN 13 PIN 1 PIN 15 PIN 16 PIN 17 PIN Comm Port DB9: RS232 PIN 1 PIN 2 PIN 3 PIN PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 DES: TORCH START X,Y,Z,A- EOT LS FEED-HOLD RUN STOP X-HOME LS Y-HOME LS HW-JOG A-HOME LS HW-SW THC-DN THC-UP Z-HOME LS OUT5 ARC GOOD OUT7 CHARGE PUMP GND DES: N/C PC Rx PC Tx N/C GND N/C N/C N/C N/C

23 General dimensions for mounting the DY control panel Flanged power inlet, right side Connector panel, left side Door opens and swings open to the left E-stop sw on top allow clearance for E-Stop allow clearance for cables 8" 17" mtg holes Hinge side Door latch 20" OAH Flange Inlet allow 6" up from bottom 6" 11" mtg holes 12" OAW () mtg holes,.312" dia 1/"-20 fasteners required

24 DY00 E-stop sw wiring detail E-Stop with LED Blu E-Stop n/c LED RED BLU BLK NC1 NC2 GND LED Blk Red SW Blk Blu Red GND NC2 NC1 E-Stop without LED E-Stop n/c Blu RED BLU NC1 NC2 SW GND Red Blu Red GND NC2 NC1

25 DY00 Program Update Instructions This document explains step by step how to upgrade the DY's Table Program. The DY will receive this application upgrade from a personal computer (PC) using the DL2 handheld to receive, store and transfer the upgrade on to the DY hardware. The DL2 also functions as a special Operator Interface to the DY Table Program therefore from time to time you may also need to upgrade to the DL2 internal Operator Interface Program in addition to the DY's. The DL2 is equipped with a standard RS232 comm. port. If using a PC with a USB port will require a USB to RS232 converter device. The DY and DL2 program upgrades are delivered as separate text files. Generally they will be sent as attachments to an file, but may also be sent as a CD. The text files will have the following names; DY01F1Xzz.s19 Table Program DL203F1Xzz.s19 Operator Interface Program note; ( zz is the version identifier, 01, 02, 03, etc.) Summary to upgrade the DL2 Operator Interface Program. Step One; Step two; Step three; Use a PC terminal emulator program (such as Windows Hyper Terminal) to transfer the text file from your PC to the DL2. Follow the four steps listed under the serial port test. This verifies the PC terminal settings and prepares the DL2 to receive the DY Table Program upgrade. The DL2 receives and stores the DY upgrade. Send the DL203F1Xzz.s19 program (text file) to the DL2 using Hyper Terminal, note; a special series of commands from the PC keypad is required. Summary to upgrade the DY Table Program. Step one; Step two; Step three; Step four; Use a PC terminal emulator program (such as Windows Hyper Terminal) to transfer the text file from your PC to the DL2. Follow the four steps listed under the serial port test. This verifies the PC terminal settings and prepares the DL2 to receive the DY Table Program upgrade. The DL2 receives and stores the DY upgrade. Send the DY01F1Xzz.s19 program (text file) to the DL2 using Hyper Terminal, no other commands are required. Connect the DL2 to the DY and transfer the DY upgrade to the DY hardware Hyper Terminal settings: Use menu pull downs; File/ Properties/ Connect To/ Configure 19.2K baud No Parity 8 Data bits 1 Start bit Flow control = X-on / X-off. also assign the correct comm. port; comm. 1, comm. 2, etc.

26 Serial Port Test Creates a PC to DL2 communication and verifies Hyper Terminal settings 1. Connect the DL2 to the PC's serial port running Hyper Terminal, use the supplied cable. 2. Attach the AC-DC adapter to supply power for the DL2. 3. Select the DL2 menu "Waiting for Command". Press <enter> key on your PC. Both the DL2 and PC will respond Ready If not, re-check the comm. port connection and Hyper Terminal settings. Upgrade the DL2 Operator Interface Program 1. After successfully testing the serial port and terminal settings (see above: Serial Port Test) 2. From the PC keyboard type 'xy' ( must be lower case ) followed by the <enter> key. The DL2's display backlight will turn off to confirm the command was received: The PC's display will read as follows; Boot Monitor Version xx.xx 3. Commands from the PC keyboard to direct the DL2 (either upper case or lower case OK ) R - Reset to restart the DL2 without powering down the handheld C - Calculate the program's checksum ( -digit alpha-numeric code ) L - Send a total upgrade to DL2 ( both Op Interface Program and boot monitor program) * U - Send the DL2 Operator Interface upgrade (only) ( this will not replace the boot monitor) * ( this is a special program development command and must not be interrupted ) ( please consult w/ Ditco engineer when using the L command). Type 'U' ( the <enter> key is not required ) This command erases the current Operator Interface Program and the PC will display, Ready for Program Stor. 5. From the Hyper Terminal use the Transfer pull down menu Choose ' Send Text File ' Browse to select the text file for the new DL2 Operator Interface program, filename ( DL203F1Xzz.s19 ) 6. After the new DL2 Operator Interface program transfer is complete, the PC will display, New Boot Code Required Retry using the L command If this display occurs, repeat steps, 5 using the L command instead 7. If the boot monitor was not required the PC will display, Boot Monitor Version R - Restart without powering down C - Calculate the program's checksum L - Send a total upgrade to DL2 (sends boot monitor and Op interface upgrade) U - Send the DL2 Operator Interface upgrade (sends only the Op Interface upgrade) 8. Finally use the C command to verify the checksum. (check the for the correct checksum)

27 Upgrade the DY Table Program. 1. Start with the DL2 connected to the PC Serial Port Test (same steps used to Upgrade the DL2 program) 2. Select the DL2 menu Waiting for Command 3. Press <enter> key on your PC. Both the DL2 and PC will respond Ready Note; Do not enter the xy command or any PC commands. From the Hyper Terminal use the Transfer pull down menu Choose ' Send Text File ' Browse to select the text file for the new DL2 Operator Interface program, filename ( DY01F1Xzz.s19 ) The PC will display a flood of characters as this process takes place (data and addresses) 5. After the program transfer is complete the DL2 will display Waiting for Command. 6. Final step is to re-connect the DL2 to the DY comm. port a. Select the DL2 menu Waiting for Command b. On the DL2 press the Save key (prepares DY to halt operations and receive the new file) c. DL2 displays: Press Save to Send DY01F1X (Upgrade file will now be sent) d. DL2 displays a running sequence of addresses e. When this process is complete, DL2 displays XFR Complete f. Use Shift + INC to scroll thru available menus. (this triggers the DY to run the new program)

28 If the DL202 can't communicate with DY00: Communication Failure (no comm between handheld and the DY controller) Waiting for Command Ready to Receive File Receiving Addr $xxxx (the starting display for sending a new program to the dy) (if the DL202 receives an acknowledgment, carriage return) (during file receive) Incomplete File Transfer File Corrupt Re-Load Required 2 Received dy01f1x

29 Setting up MPG (Hand Wheel) Function: DL202 Set-up: 1) Go to Set-up Group 2) Go to Address 39 Hw Psh Button 3) Select runs Hand SW (using <INC> or <DEC> on DL2) ) Return to Mach 3 Group Note: Address 3 in Mach 3 Group runs MPG functions Mach 3 Set-up: 1) Go to <Config>, <Ports and Pins> 2) Select Encoder/ MPG s TAB 3) Enable MPG # 1 ) Set A-Port # = 1 5) Set A-pin # = 13 6) Set B-Port # = 1 7) Set B- Port # = 15 8) Set Counts/Unit = 100 9) Set Velocity = ) Make sure MPG # 2 and MPG # 3 are Х Disabled 11) Click on <Apply> 12) Click on <OK> 13) Go to <Config>, <Ports and Pins> 1) Select Input Signals TAB 15) Enable OEM Trig # 5 16) Set Port # = 2 17) Set Pin Number = 10 18) Set Active Low = Х ( Not Enabled) 19) Set Emulated = Х ( Not Enabled) 20) Hot Key = ) Click on <Apply> 22) Click on <OK> While Running Mach 3 in MPG mode you will now be able to use the DL202 as a Hand wheel. <ALT> toggles between the X,Y, and Z Axis <INC> runs select axis in forward direction <DEC> runs select axis in reverse direction Note: When changing setting in MACH 3 sometimes you may need to exit the Mach 3 program, and then restart it to get proper operation.

30 Z axis dn up X axis Y axis DY00 Z Y X Cable lengths are in whole feet Y axis cables are shorter Y axis is specified as a single axis X and Z axis cables are the same length X and Z axis cables are dual axis DY00 Axis naming convention for DY00 Cables

31 CPC1 P RS CPC1 P RS Start command NO contact Torch Start YEL YEL K M (OK to Move) JP1 shunt = A CT JP1 shunt = B discrete 9 7 ARC Good BLU BLU / WHT I J (Set jumper) DIVIDED tip volts 0-36vdc DIRECTl tip volts 0-600vdc (common) 1 GRN / WHT Torch TIP Volts GRN D G CPC 1 pin recp facing view (collector) (emitter) 2 5 GRN GRN / WHT Spindle Forward Cutmaster TIP Volts 0-600vdc Plasma Torch BRN BRN / WHT PowerMax J15 J16 DY00C51 HSD Spindle Control 6 MS pin +2v 1 RUN Pro Cut 80 (collector) (emitter) 3 6 Spindle Reverse ORG ORG / WHT 2 REV ( speed cmd ) ( com ) Spindle Speed Cmd RED BLK Analog Input Analog gnd E-Stop E-Stop 8 1 Remote E-Stop WHT WHT Torch/Spindle Cable

32 CPC16 Stepper Motor DC Servo Motor X-Axis Y-Axis RED BLK BLU WHT RED BLK BLU WHT A B C D A B C D n/c n/c n/c n/c servo motor cable provides 2 wires per axis pins no. X = 1,2 Y = 5,6 Z = 9,10 stepper motor able provides wires per axis pins no. X = 1,2,3, Y = 5,6,7,8 Z = 9,10,11,15 Z-Axis RED BLK BLU WHT A B C D + - n/c n/c A-Axis RED BLK BLU WHT A B C D + - n/c n/c Motor Cable CPC9P 1 YEL 2 Home Sw BLK n/c GRN EOT SW PUR Stepper motor axis I/O cable

33 com CPC9P 1 YEL 2 Home Sw BLK Pre-assembled cable w/ 10 pin encoder connector (only 6 wires are used) +5VMB A-ph B-ph Splice zone WHT / GRN BLU WHT / BLU BRN WHT / BRN GRN WHT / GRN BLU WHT / BLU BRN WHT / BRN ENC - ENC + A+ A- B+ B pin encoder connector facing view 3 GRN PUR EOT SW Single Axis Servo Encoder manuf: USDigital Encoder part number: E5D EG E5 series D- differential drivers 500 pulses per rev /" shaft E- housing extension G- molded ears for mounting Encoder cable, 10 pin connector pin out 1 ground bare wire shield 2 ground Grn 3 index - Wht/Org index + Org 5 phase A- Wht/Blu 6 phase A+ Blu 7 +5vdc Wht/Grn 8 +5vdc blank 9 phase B- Wht/Brn 10 phase B+ Brn Cable p/n: CA-217-6FT 10 pin connector, 6 ft, PVC jacketed Order thru: US Digital, Vancouver, WA Cable end plug facing view Encoder w/ built in connector