PAA CNC Control Retrofit Kit Contents Overview... 2 Kit Contents... 2 Hardware... 2 Software... 2 Miscellaneous Small Parts... 2 Installation... 2 Tools and Materials... 2 Preparation... 3 Operator s Station... 3 CNC Control... 3 Cables... 4 Commissioning... 4 PLC... 4 Appendix A File-Based Write Filter (Windows Hard-Disk Protection)... 5 Older GUI... 5 Newer GUI... 6 Appendix B Adapter Cards... 9 Overview... 9 Axis Board... 9 Input / Output Boards... 10 Appendix C Photographs... 11 Kit Contents... 11 Enclosure, Front and Rear Views (before installation)... 12 HI800 CNC Control... 13 PA8000-LW CNC Control (as installed)... 13 Enclosure (Rear) After Installation... 14 Operator s Station (after installation)... 15 Appendix D Wiring Diagrams... 16 1
PAA CNC Control Retrofit Kit Overview This kit replaces the Higerman HI-800 CNC Control and Higerman Operator s Control Station used in some early Flow Waterjet-Pro machines with a Power Automation PA-8000LW CNC Control and Power Automation CP-121 Control Panel. This kit is a Plug-And-Play solution; all components and cables simply plug together with no modifications required to the original enclosure or wiring. Kit Contents Hardware There are two (2) main hardware components of the kit: 1. A 17 x 17 panel containing the PA-8000LW CNC Control, a wiring harness, and plug-in boards (pre-installed) to adapt to the Higerman connectors used in the Flow Waterjet-Pro. 2. A replacement Operator s Control Station with CP-121 Control Panel (pre-installed), drilled and tapped to mount into the existing enclosure and accept the existing Higerman Operator s Switch Panel. Also included are the cables necessary to connect the PA-8000 CNC with the CP-121 Panel and a 2.5- meter long USB cable with screw cap that can be mounted in the existing keyboard cable hole in most WJP enclosures or in a 19mm hole elsewhere on the enclosure (to be drilled by the customer as desired). Software All necessary software is pre-installed per order and requires little or no configuration in the field (see Commissioning Instructions). The supplied PLC program is a very slightly modified version of the original Flow PLC (because Higerman numbered the Digital Input connectors IN-5 and IN-6 in reverse order compared to the Power Automation standard). Miscellaneous Small Parts A small bag of fasteners, wire ties, etc. is included with the kit. In it you will find: QTY Item Description Notes 4 #10 Flat Washer To attach Electrical Panel to Enclosure 4 #10 Split Lock Washer (as above) 4 #10-32 Hex Nut (as above) 15 4-inch Nylon Wire Tie 5 1-inch Adhesive Wire Tie Mount Installation Tools and Materials You will need the following tools to remove the Higerman components and install the kit: Small Yankee (flat) screwdriver, about 3/32 blade 2
PAA CNC Control Retrofit Kit Medium Yankee (flat) screwdriver, about 3/16 blade Large Yankee (flat) screwdriver, about 1/4 blade Medium (#2) Phillips screwdriver Nut-drivers or sockets for small SAE and Metric fasteners Magnetic pick-up tool (you KNOW you will drop a screw down in there somewhere!) Sharpie marker, blue painter s tape to label connectors, provide a third hand Included in the kit are all of the fasteners, wire-ties, etc. that you should need to complete a professional-looking installation. We have tried to provide details and photographs to guide you, but a few pictures snapped with your own phone before taking anything apart is always a good idea. While this job CAN be performed by one person (and a roll of duct tape) some things are just easier with an extra hand or two. Preparation READ THESE INSTRUCTIONS BEFORE STARTING. Some steps are unnecessarily difficult if performed in the wrong order. Remove the front, back and side panels of the enclosure. This will make it MUCH easier to both see and reach the fasteners and cables that need to be removed and replaced. Good, bright lighting is essential; a droplight and flashlight will be helpful. Operator s Station Disconnect the cables connected to the display (upper) portion of the Operator s Station. Leave all wires connected to the lower (switch panel) portion. Remove and save the screws holding the Switch Panel to Operator s Station. Gently pull the Switch Panel forward, then turn the top edge toward you and slip the Switch Panel through the hole in the Operator s Station. It can rest there for the next few steps. From the back side remove and save the screws holding the Operator s Panel to the Enclosure. The old Operator s Panel, with the Display attached, will be discarded. Now is a good time to remove the old CNC and mount the new Electrical Panel. Skip down to the next section (CNC Control) and come back here after mounting the Electrical Panel. Carefully run the mounting screws into the tapped holes in the new Operator s Station to clear any paint from the threads. This will make it MUCH easier to start the screws when the panel is in place. Remove the screws and mount the new Operator s Station to the front of the Enclosure. Carefully slip the Switch Panel through the cutout in the Operator s Station and secure with the original screws. CNC Control Remove and save the screws retaining the bracket with the power strip and set the power strip to the side (some of that tape will be handy now). 3
PAA CNC Control Retrofit Kit With marker and tape in hand, carefully remove and label each connector from the HI-800 CNC (the rectangular black box). Lay the cables to the sides so that you have unrestricted access to mount the new Electrical Panel (more tape!). Unbolt the HI-800 CNC and remove it from the Enclosure. Loosen the four (4) screws that will mount the Electrical Panel to the Enclosure. This allows the screws to wiggle a little and makes getting them into the slots in the Enclosure easier. Carefully lift the Electrical Panel into the Enclosure and guide the mounting screws into slots. Slip washers, lock-washers and nuts onto the screws but do not tighten them yet; first tighten the screws into the tapped holes in the Electrical Panel, then complete tightening the nuts. Cables Some repositioning of cables will be necessary because connector locations are different. Try to route cables so that they can be attached to the Enclosure with wire ties in such a way as to minimize the strain on the connectors and Converter Boards. Carefully secure the Axis connectors with the screws in the connectors shells. When connecting the 8-pole Euro connectors (IN5, IN6, OUT3, OUT4) try to squeeze them with your fingers rather than pushing, to avoid flexing the Converter Boards. The new Operator s Station Display requires different Video and Keyboard cables (included). Excess cable should be coiled and secured to the Enclosure with wire ties. The power cable for the CNC WILL reach if all restraining wire ties are cut and the cable rerouted. Alternatively, you can splice on an extra foot of cable. The power supply for the Operator s Station Display (LCD) is provided with a German (2-pin) plug. Although this can be plugged into the power strip in the Enclosure it is not recommended, as this power is not switched on and off with the CNC. A better solution is to cut off the plug and wire the cable to the same terminal blocks as the CNC power cable, or make a Y splice to power both the CNC and Display. The Display power supply can be secured to any convenient location with a wire tie or two. The supplied USB cable can be mounted in the existing hole in the Enclosure (see photo) and plugged into any USB port on the PA8000-LW CNC Control. Commissioning All appropriate configurations should have been pre-loaded before your kit was shipped. By convention backup copies of the configuration files are kept in various folders in the D:\PAData\ folder, and a master copy of the kit files is in the folder D:\Install\Configurations. A full set of Power Automation documentation (in PDF format) can be found in the folder D:\PA Documentation. PLC There are only two (2) options in the Flow WJP PLC, each controlled by setting a variable TRUE or FALSE, then compiling and installing the PLC: 4
PAA CNC Control Retrofit Kit (*These are for configuration - enable both for Jplex with vac assist pressure control*) USE_WATER_SENSOR: BOOL:=TRUE; USE_TRISTATE_PRESSURE: BOOL:=FALSE; Water Pressure Sensor If there is no Water Pressure Sensor connected (to the INLET PRESSURE connector on the enclosure) and no jumper on the connector then there will be a persistent error INLET WATER PRESSURE IS TOO LOW.. To disable this test, change the variable USE_WATER_SENSOR to TRUE. Tri-State Pressure Control The LO/HI Water Pressure Button can be configured to act as either LO/HI (2 states) or OFF/LO/HI (3 states) depending on the value of the USE_TRISTATE_PRESSURE variable; FALSE = 2 States, TRUE = 3 States. NOTE! Read the following section concerning the FBWF before making any changes! Appendix A File-Based Write Filter (Windows Hard-Disk Protection) FBWF is a tool built into the Windows Operating System by Power Automation to reduce the chance of corrupting the Hard Disk Drive (volume C:, the System Drive). When enabled all writes to the disk are temporarily redirected to memory, and then discarded when the system is restarted. This prevents the system from becoming corrupted by viruses, unexpected shutdowns, careless users, etc. This means, however, that in order to make modifications to the system the FBWF must first be disabled, or all of your hard work will be discarded when you reboot! Older GUI Earlier builds of Windows Embedded automatically launch the Graphical User Interface (GUI) for the FBWF when you log in as Admin: 5
PAA CNC Control Retrofit Kit Newer GUI More recent builds of Windows Embedded have an icon in the System Tray to launch the FBWF GUI, but you still must log into Windows as Admin in order to make changes to the FBWF. Disable / Enable the FBWF Log onto Windows using the Admin account (password PA009). In the lower-right corner of the screen is the System Tray area, in which you will find the Write Protect icon: Note that hovering your mouse over the padlock icon reveals the current state of the Write Filter; in the example to the left the C: drive is shown as Protected. Click the padlock icon to open the FBWF control panel. Note the first line ( State ) in the Overview: the Current setting is Enabled and the setting After Reset is also Enabled. This means that the FBWF will be enabled after rebooting. To make the state Disabled after the next reboot click the Configure button to open the FBWF Configuration Dialog. 6
PAA CNC Control Retrofit Kit Click the Filter state enabled checkbox to un-check it: Then click the OK button to return to the previous dialog. Note that now the After restart state is Disabled, although the Current state is still Enabled. Click the Close button. From the Start button select Restart to re-boot Windows. 7
PAA CNC Control Retrofit Kit When Windows restarts you can verify that the FBWF is not active by hovering your mouse over the padlock icon in the System Tray: Once you have made any changes and verified correct operation you should enable the FBWF by following the preceding steps, this time checking the Filter state enabled checkbox. After restarting Windows verify that the FBWF is actively protecting the C: drive by hovering your mouse over the padlock icon in the System Tray: Remember to instruct the customer to NEVER try to save ANYTHING to the C: drive! 8
PAA CNC Control Retrofit Kit Appendix B Adapter Cards Overview The Higerman HI-800 CNC Control was built using core technology originally licensed from Power Automation, but with non-compatible hardware. In order to adapt standard Power Automation hardware to replace the Higerman HI-800 several electrical differences had to be addressed. PA I/O logic is sourcing ; outputs supply +24 VDC when active, inputs require +24 VDC to be turned on. Higerman logic is sinking ; outputs sink to 24-volt common, inputs are pulled to 24-volt common to be turned on. PA axis (encoder) connectors are DB15-S sockets and carry ONLY the encoder signals and power. Analog command signals are all on one (separate) plug-in connector. Higerman axis connectors are HD26-S sockets and carry, in addition to the encoder signals, the analog command for each axis and some miscellaneous digital I/O signals. Power Automation America has developed a set of converter boards that solve these connection and logic-level problems without the use of additional relays, breakout boards, etc. Axis Board 9
PAA CNC Control Retrofit Kit Input / Output Boards 10
PAA CNC Control Retrofit Kit Appendix C Photographs Flow built several variations of the Waterjet Pro series, and there seems to have been considerable variation in wire and cable routing from machine to machine, even of the same model. The photographs that follow, therefore, represent the general practices to be followed, not the exact appearance of any particular machine. Indeed, they are a compilation of several different models and builds. The pictures illustrate several stages of the retrofit project, starting with an un-modified WJP-1313 enclosure. Kit Contents 11
PAA CNC Control Retrofit Kit Enclosure, Front and Rear Views (before installation) 12
PAA CNC Control Retrofit Kit HI800 CNC Control PA8000-LW CNC Control (as installed) 13
PAA CNC Control Retrofit Kit Enclosure (Rear) After Installation 14
PAA CNC Control Retrofit Kit Operator s Station (after installation) 15
PAA CNC Control Retrofit Kit Appendix D Wiring Diagrams There are two (2) basic variations of this kit: without Gantry (3 axis motors and drives) and with Gantry (4 axis motors and drives). Currently these are for use with WJP-1313 and WJP-1318 (no Gantry) and WJP-2031 (with Gantry). The designs are substantially similar, but the non-grantry version uses a 5-volt Handwheel connected via the fourth RMS channel of the CNC whereas the Gantry version uses a 24-volt Handwheel connected via the digital inputs IN3.7 and IN3.8 (because all four RMS channels are used for motors). The diagrams for your version (with or without Gantry) are provided separately from this document. 16