Adtech ADT-HC4500 User Manual

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Copyright

Adtech (Shenzhen) Technology Co., Ltd. (Adtech hereafter) is in possession of the copyright of this manual. Without the permission of Adtech, the imitation, copy, transcription and translation by any organization or individual are prohibited. This manual doesn’t contain any assurance, stance or implication in any form. Adtech and the employees are not responsible for any direct or indirect data disclosure, profits loss or cause termination caused by this manual or any information about mentioned products in this manual. In addition, the products and data in this manual are subject to changes without prior notice.

All rights reserved.

Adtech (Shenzhen) CNC Technology Co., Ltd.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Basic Manual Info

Item No. First uploaded on Version No.

Pages Compiled by Typeset by

Tan

XT20110101 2010/03/07 A0101 111

Xiaodan

Tan

Xiaodan

Revision

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Precautions

Transportation and storage

H

The packaging boxes shouldn’t be stacked more than six layers

H

Do not climb onto, stand on or put heavy objects on the packaging box

H

Do not drag or convey the product with a cable connected to the product

H

Do not impact or scratch the panel and display

H

Keep the packaging box away from moisture, insulation and rain

Unpacking and checking

H

Unpack and check whether the product is the one you ordered

H

Check whether the product is damaged during transporting

H

Check whether the parts are complete and intact according to the packing list

H

If the model doesn’t match, any accessories are missing or damaged, please contact us immediately

Wire connection

H

The personnel for wire connection and checking should be qualified

H

The product must be grounded reliably (resistance < 4 ) and do not use neutral wire to replace the earth wire

H

The wires must be connected properly and firmly to avoid failures and accidents

H

The surge absorption diode must be connected to the product properly, or else it will damage the product

H

Please cut off the power supply before inserting/removing the plug or opening the enclosure

Checking and repairing

H

Please cut off the power supply before repairing or replacing the components

H

Check the failure if short circuit or overload occurs, and restart after eliminating all failures

H

Do not connect/cut off the power supply frequently; wait for at least one minute before restarting

Others

H

Do not open the enclosure without permission

H

Please cut off the power supply if it won’t be used for a long time

H

Prevent dust and iron powder from entering the controller

H

If non-solid state relay is used for output, please connect freewheeling diode to relay coil in parallel. Check whether the connected power supply is qualified to avoid burning out the controller

H

The lifetime of the controller depends on the environment temperature. If the temperature of processing field is too high, please install cooling fan. The allowable temperature range of the controller is 0 -60

H

Avoid using in the environment with high temperature, moisture, dust or corrosive gas

H

Install rubber cushion if the vibration is severe

Maintenance

Under normal condition (environment: daily average 30 , load rate 80%, running rate 12 hours every day), please perform daily and periodic checking according to the items below.

Daily checking

Daily

Confirm environment temperature, humidity and dust

Whether there is abnormal vibration or sound

Whether the vent hole is blocked by yarn

Periodic checking

1 year

Whether the fixed parts are loose

Whether the terminal block is damaged

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Contents

Chapter I: Introduction

..................................................................................................... - 7 -

1. Function ..................................................................................................................................................... - 7 -

2. Features ...................................................................................................................................................... - 7 -

3. Application environment ........................................................................................................................... - 8 -

Chapter II: Quick Guide

................................................................................................... - 9 -

1. Get help info ............................................................................................................................................ - 10 -

2. Restore default parameters ...................................................................................................................... - 10 -

3. Graphics library ....................................................................................................................................... - 11 -

4. Copying processing file ........................................................................................................................... - 11 -

5. Importing processing file ......................................................................................................................... - 12 -

6. Adjusting cutting speed ............................................................................................................................ - 13 -

7. Adjusting manual speed ........................................................................................................................... - 15 -

8. Controlling corner cutting quality ............................................................................................................ - 16 -

9. Adjusting preheating time while flame cutting ........................................................................................ - 18 -

10. Power failure treatment .......................................................................................................................... - 20 -

11. Break point setting ................................................................................................................................. - 20 -

12. Replacing torch nozzle .......................................................................................................................... - 20 -

13. Shift and punch ...................................................................................................................................... - 21 -

14. Moving workpiece ................................................................................................................................. - 22 -

15. Selecting line/point ................................................................................................................................ - 22 -

16. Array ...................................................................................................................................................... - 23 -

17. Mirror..................................................................................................................................................... - 26 -

18. Rotate ..................................................................................................................................................... - 28 -

19. Correct ................................................................................................................................................... - 29 -

20. Selecting cutter point ............................................................................................................................. - 32 -

Chapter III: Detailed System Operation and Instructions

.......................................... - 34 -

1. Auto ......................................................................................................................................................... - 34 -

1.1 Program running description ......................................................................................................... - 36 -

1.2 Submenu description of Auto interface .......................................................................................... - 38 -

1.3 Basic operation .............................................................................................................................. - 48 -

2. Graphics library ....................................................................................................................................... - 49 -

2.1 Simple operation instruction .......................................................................................................... - 49 -

3. Edit .......................................................................................................................................................... - 51 -

3.1 Submenu description ..................................................................................................................... - 52 -

3.2 Editing processing files .................................................................................................................. - 60 -

3.3 Basic operation .............................................................................................................................. - 62 -

4. Parameters ............................................................................................................................................... - 63 -

4.1 System configuration ..................................................................................................................... - 63 -

4.2 Speed ............................................................................................................................................. - 67 -

4.3 Adjustment ..................................................................................................................................... - 68 -

4.4 Control ........................................................................................................................................... - 70 -

4.5 Precision ........................................................................................................................................ - 73 -

4.6 Storage ........................................................................................................................................... - 75 -

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

5. Diagnosis ................................................................................................................................................. - 75 -

5.1 Submenu description ..................................................................................................................... - 75 -

6. Upgrade ................................................................................................................................................... - 79 -

6.1 Submenu description ..................................................................................................................... - 79 -

6.2 Reset .............................................................................................................................................. - 80 -

6.3 Upgrading through USB disk ........................................................................................................ - 83 -

6.4 Connecting to PC and upgrading ................................................................................................... - 87 -

6.5 Burning program ............................................................................................................................ - 88 -

6.6 BIOS interface connecting to PC and upgrading ........................................................................... - 90 -

7. Help system ............................................................................................................................................. - 93 -

8. Using different languages ........................................................................................................................ - 94 -

Chapter IV: Instruction Programming System

............................................................. - 96 -

1. Description of programming symbols ..................................................................................................... - 96 -

2. Description of coordinates ....................................................................................................................... - 96 -

2.1 Relative coordinates ....................................................................................................................... - 96 -

2.2 Absolute coordinates ..................................................................................................................... - 97 -

3. G instruction description .......................................................................................................................... - 97 -

3.1. G92 reference point setting ........................................................................................................... - 98 -

3.2. G21/G20 metric/imperial system setting ...................................................................................... - 98 -

3.3. G00 space shift ............................................................................................................................. - 98 -

3.4. G01 straight line cutting ............................................................................................................... - 98 -

3.5. G02/G03 arc cutting ..................................................................................................................... - 99 -

3.6. G04 pause/delay instruction .......................................................................................................... - 99 -

3.7. G26, G27, G28 returning to reference point ............................................................................... - 100 -

3.8. G22/G80 circular processing ...................................................................................................... - 100 -

3.9. G81 workpiece counting ............................................................................................................. - 100 -

3.10.G91/G90 relative/absolute coordinate programming ................................................................. - 101 -

3.11. G41/G42/G40 ............................................................................................................................ - 101 -

4. Common M instructions ........................................................................................................................ - 101 -

Chapter V: Hardware

.................................................................................................... - 104 -

1. Dimensions ............................................................................................................................................ - 104 -

2. System I/O connection ........................................................................................................................... - 105 -

2.1 Rear cover view ........................................................................................................................... - 105 -

2.2 Electrical specifications ............................................................................................................... - 105 -

2.3 Electrical connection ................................................................................................................... - 107 -

3. Motor connection ................................................................................................................................... - 114 -

3.1 Differential drive connection ....................................................................................................... - 114 -

3.2 Common anode drive connection ................................................................................................ - 117 -

3.3 Panasonic servo drive connection ................................................................................................ - 119 -

4. Installation and testing points ................................................................................................................ - 119 -

4.1 Requirement of CNC system on pulse equivalent ....................................................................... - 119 -

4.2 Current adjustment for the drive .................................................................................................. - 120 -

4.3 Testing method of pulse equivalent ............................................................................................. - 120 -

4.4 Measures for anti-interference ..................................................................................................... - 120 -

Chapter VI: Troubleshooting

........................................................................................ - 122 -

1. Can’t read USB disk .............................................................................................................................. - 122 -

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

2. The cutting isn’t accurate ....................................................................................................................... - 122 -

3. The cutting quality of corners is low ..................................................................................................... - 122 -

4. The cut square becomes rectangle ......................................................................................................... - 122 -

5. The cut circle becomes ellipse ............................................................................................................... - 122 -

6. The diagonal has wave jitter while cutting circle .................................................................................. - 122 -

7. The motor doesn’t work or is similar to crash in auto mode ................................................................. - 123 -

8. The motor doesn’t work or is similar to crash in manual mode ............................................................. - 123 -

9. The processing code has returning reference instruction, but doesn’t return after running ................... - 123 -

10. The right angle of the cut square isn’t vertical ..................................................................................... - 123 -

11. Plasma is poor in anti-interference ...................................................................................................... - 123 -

12. Certain electromagnetic valve doesn’t work ........................................................................................ - 123 -

Appendix 2: Example of Editing Processing Graphics

............................................... - 126 -

1. Standard circle ....................................................................................................................................... - 126 -

2. Square .................................................................................................................................................... - 127 -

3. Triangle .................................................................................................................................................. - 128 -

4. Quincunx ............................................................................................................................................... - 129 -

5. Four graphics ......................................................................................................................................... - 130 -

Appendix 3: G Instruction Fact Sheet

.......................................................................... - 132 -

Appendix 4: M Instruction Fact Sheet

......................................................................... - 133 -

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Chapter I: Introduction

1. Function

HC4500 is the latest high performance flame/plasma CNC system developed by Adtech (Shenzhen)

CNC Technology Co., Ltd. Its control circuit uses ARM9 high speed microprocessor, super-large scale customized IC chip and multilayer PCB. The monitor is 7” color display, and uses SMT process. The hardware of this controller bases on the powerful R&D strength of Adtech for many years, and the software integrates features of many domestic and foreign manufacturers. This controller features high hardware stability, perfect and mature software performance. It is a trustful flame/plasma CNC system with high performance price ratio.

2. Features

1) Use ARM9 high speed microprocessor and super-large scale programmable device FPGA, and use real-time multitask control technology and hardware interpolation technology, featuring fast and stable motion, and faster program running and page refreshing

2) 7” true color display, friendly operation interface, simple operation, and various available interface languages

3) Reasonable structure, full optical coupling isolation control, and strong plasma anti-interference

4) 256MB super-large storage space for processing files meets the running and processing requirement of complicated programs, and processes the running of large programs easily

5) Control three step/servo motor simultaneously, allow two axes synchronization or developing third axis function according to actual requirement

6) Support both plasma and flame cutting, and the system software contains the perfect cutting process of them

7) Graphics library allows selecting hole and slice cutting

8) Graphics processing allows rotation, correction and X/Y mirror of graphics being processed

9) The graphics array makes the batch processing more convenient

10) Process control such as delay, preheating and perforation

11) Plasma arc testing, initial position, corner speed control, supporting height adjuster

12) Replace torch nozzle, displacement perforation, move parts, and adjust torch height freely

13) Breakpoint recovery, power failure protection while processing

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

14) Space running, board measuring, knife aligning, and backtracking

15) Slot compensation, backlash compensation for machine tools

16) Graphics display, real-time cutting track display

17) Integrate diagnosis function to help users eliminate machine failures quickly

18) Allow copying the processing files from CNC system to USB disk

19) The file names support Chinese, making users identify the saved files visually

20) The users can download latest update application to USD disk

21) Two modes are available for program input: transfer processing files with USB disk after CAD nesting and write G code manually on site

22) USB, RS232 serial communication control; read files in the USB disk directly, ensuring convenient operation on site

23) The help function makes primary users’ operation simpler

3. Application environment

Weather condition

Temperature Operating

Relative humidity

-5 ~50

Storage -30 ~70

Operating 20%~90% ( )

Atmospheric pressure

Power supply

Power consumption

86Kpa~106Kpa

DC 24V 50/60Hz

<10W

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Chapter II: Quick Guide

ADT-HC4500 flame/plasma CNC cutting system controls the flame or plasma torch for cutting on the machine tool. The system displays in progressive windows. In certain interface, you can press [F1] to [F6] to select a function, and press [ ] or [ ] to return to previous menu.

This chapter involves the general operation procedure of using this system, and helps you to learn using this system quickly. However, you need to read through this manual to understand every skill and detail.

After connecting the power supply, the system enters the main menu, which shows the greetings of the company as in the figure below:

Return / Auto /

Create CNC exquisite,

Library / Edit /

accomplish customers’ values

Parameter / Diagnosis / Upgrade /

Return

Fig. 2: Main Menu Interface

Press [F1] to [F6] to enter respective interface.

Press [F1] to enter automatic processing, manual, graphics display and processing interface.

Press [F2] to enter graphics library interface.

Press [F3] to enter processing file import, manual edit and copy interface.

Press [F4] to enter system parameter setting and adjustment interface.

Press [F5] to enter system diagnosis, version query and customized output port interface.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Press [F6] to enter system parameter reset, software update and help interface.

1. Get help info

In most menus, you can press [INS] to get the help information; for example, press [F1] (Auto) in the main menu to enter the Auto interface, and then press [INS] to get the help info about the Auto interface.

Main menu Press [F6] Upgrade interface Press [F6] (Help) to search for help info.

2. Restore default parameters

If the system parameters are adjusted improperly and cause speed and accuracy abnormal, the user can press [F6]

(Upgrade) [F1] (Reset) [F1] (Reset) [OK] to restore the default parameters.

(F1)

(F2)

Return /

Reset

(F1) Reset current parameters to default

(F2) Set current parameters to default

Save / Return Reset /

Fig. 2.2 Reset Parameters

Note: If the parameters weren’t saved when the product was delivered, the system can’t reset and will pop up the prompt dialog box.

Please refer to Chapter III: Detailed System Operation and Instructions (6.2) Reset.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

3. Graphics library

To facilitate the processing, reduce the workload and increase system usability, the system embodies 35 common processing part graphics and one test graphics. In the main menu interface, press [F2] (Graphics library) to enter the graphics library interface, and select the corresponding graphics parts in the library to process.

Operation mode: press [X+], [X-], [Y+], [Y-] to move the cursor, press [OK] to enter the graphics, modify the parameters and then import the graphics to process.

Return

Fig. 2.3 Graphics Library Interface

OK / Return

4. Copying processing file

Insert the USB disk copied with processing files to the USB interface in the front panel of the control system; in the main menu, press [F3] (Edit) [F3] (USB disk); if the USB disk is connected properly, the interface shows the file names saved in the USB disk, as in the figure below:

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Return /

Current directory:

New / Copy / Delete /

Fig. 2.4 Copy Processing Files

Return

Then, press [Y+][Y-] to select the processing file to copy, and press [F2] (Copy) or [OK] to copy; after copying, press any key to return to the main menu when the prompt pops up.

5. Importing processing file

In the main interface, press [F3] [F2] to enter file importing interface, as in the figure below:

Current directory:

Name / Size (byte) /

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Type

Return /

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Import / Delete / Copy / Copy all / Return

Fig. 2.5 File Importing Interface

In above interface, press [Y+][Y-] to select a processing file and then press [F2] or [OK] to confirm; the system enters processing code edit interface. Press to return to the main menu from the edit interface. Then, press

[F1] to enter the Auto interface and process with the selected file.

6. Adjusting cutting speed

In the main menu, press [F4] (Parameter) [F2] (Speed) to enter speed setting interface, in which you can set the start speed, acceleration, manual speed and automatic processing speed.

Parameter Description Unit

Start speed Start speed of X/Y axis mm/min

Acceleration The speed added every time from start speed to top speed of X/Y axis mm/min

Manual speed X/Y axis speed, G00 and reference returning speed during manual running mm/min

Processing speed

G01,G02,G03 speed of X/Y axis when the program is running mm/min

Speed Setting Interface

Start speed

Acceleration

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Return / System / Speed /

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Manual speed

Processing speed

Adjust / Control / Precision / Store /

Return

2.6.1 Speed Setting Interface

Press [X+], [X-], [Y+], [Y-] to move the cursor to select, and press the number keys in the left to enter the value.

After setting the speed, press [F6] (Store) to save the modified parameters.

Press to return to the main menu, and then press [F1] to enter the automatic processing interface:

Auto /

GLOBAL

Return /

Speed: /

Demonstrate /

Torch up /

Torch down /

Current coordinates

Slot compensation

Cutting Control

Height control

Prompt:

Working state:

Manual / Back /

Stopped /

Process / point / Return

Plasma

Return reference /

2.6.2 Automatic Processing Interface

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Program name:

Break

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

The processing speed depends on the “Processing speed limit” in Speed Setting interface and “Speed percentage” in Auto interface.

Actual processing speed = Processing speed × Speed percentage in Auto interface

Note: The speed percentage is adjusted with [F ]/[F ] on the panel or the [F] key.

7. Adjusting manual speed

In the main menu, press [F4] (Parameter) [F2] (Speed) to enter Speed Setting interface, which is shown in

“Adjusting Cutting Speed” in above section. Set the manual speed as setting the cutting speed, and press to return to the main menu.

In the main menu, press [F1] (Auto) [F2] (Manual) to enter the Manual interface:

G

X

Y

Shift

Manual /

/

Speed: /

G: switch Manual/Jog

Program name:

Torch up /

X

Y

X: Set coordinates of X axis

Y: Set coordinates of Y axis

Torch down /

Current coordinates:

Cutting Control

Height control

Z Shift: Set coordinates of Z axis Preheating delay

Return / Jog /

Working state:

Prompt:

Stopped /

Break point / Clear / Return reference /

Plasma

Return

2.7 Manual Interface

Actual processing speed = Processing speed × Speed percentage in Manual interface

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Note: The speed percentage is adjusted with [F ]/[F ] on the panel or the [F] key.

8. Controlling corner cutting quality

During flame cutting and plasma cutting, the speed should be controlled when cutting the corners. The acceleration/deceleration setting directly affects the quality of corner cutting, especially during the flame cutting, if the speed is too high, the flame may be off or can’t cut through the steel plate; if the speed is too low, the corner may be burnt to arc.

The acceleration/deceleration of the system is set in main menu [F4] (Parameter) [F2] (Speed) “Start speed” and “Acceleration” (as in the figure below). The specific definition follows:

Speed Setting Interface

Return /

Return

Start speed

Acceleration

Manual speed

Processing speed

System / Speed / Adjust / Control Precision / Store /

2.8 Speed Setting

1.

Start speed: The speed when the system starts running is the start speed, e.g. if the “Start speed” is set to 300, the system starts running at 0.3m speed. The setting of start speed should be adjusted according to the processing speed. The followings are the start speeds for reference, and the actual

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System data are adjusted according to field cutting effect:

Processing speed (mm/min) Start speed (mm/min)

100-200 100

200-500 200

500-700 300

700-800 500

800-1000 600

1000-1300 700

1600-2000 1000

2000-3000 1500

3000-4000 2000

Table 2.8.1

2.

Acceleration: the average increment that the processing speed is added from start speed to top speed; for example: if the start speed is 300, the acceleration is 100 and the top processing speed is 1000, then the processing speeds are 300, 400, 500…1000, added to top speed by 100.

The acceleration value is affected by Pulse Equivalent (in the main menu interface, press [F4] (Parameter)

[F5] (Precision)).

Pulse equivalent: the distance that the machine tool moves every time the control system sends a pulse

The followings are the pulse equivalent and acceleration for reference, and the actual data are adjusted according to field cutting effect:

Pulse equivalent Acceleration (mm/min)

0.001000-0.002000 10

0.002000-0.003000 20

0.003000-0.004000 30

0.004000-0.005000 40

0.005000-0.006000 50

0.006000-0.007000 60

0.007000-0.008000 70

0.008000-0.009000 80

0.009000-0.010000 90

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

0.010000-0.011000 100

0.011000-0.012000 110

0.012000-0.013000 120

Table 2.8.2

9. Adjusting preheating time while flame cutting

In the main menu interface, press [F4] (Parameter) [F4] (Control), and set the “Preheating delay” in the second line to desired time.

Flame Control Parameters

Edge perforation prompt:

Preheating delay:

Torch up delay:

Torch down delay:

Ignition delay:

Perforation torch up:

Perforation torch down:

Perforation delay:

Slot compensation:

Return / System / Speed /

OFF

Adjust / Control /

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Precision / Store /

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Return

2.9.1 Control Interface

While cutting in Auto interface, the system performs preheating before perforation. At this moment, the lower right of the interface shows the total preheating time and preheated time. In the bottom center, the system prompts:

“To memorize and stop preheating, press [G]; to stop preheating, press [Start]; to extend preheating, press

[Stop]”. According to the prompt, if you press [Start], the system stops preheating immediately and performs next motion; if you press [Stop], the system will extend the preheating time infinitely; if you press [G], preheating stops and the system automatically saves current preheating time as the preheating time later.

In the main menu interface, press [F1] (Auto):

Auto / Speed: /

Prompt:

GTo memorize and stop preheating, press [G]

To stop preheating, press [Start]

To extend preheating, press [Stop]

Ethyne control /

Preheating control /

Cutting Control /

Current coordinates

Program name

Torch up

Torch down

Height control

Slot compensation

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Return / point / Return

Demonstrate / Manual /

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Prompt:

Working state:

Back / Process /

Running /

Return reference /

Flame

Break

2.9.2 Auto Interface Preheating

10. Power failure treatment

To avoid material waste caused by sudden power failure, the system integrates power failure protection function.

If the power fails during processing, the system will automatically save the processing track before the power failure as a break point; when the power resumes, if you want to restore the coordinates before power failure, you can press [F1] (Auto) [F6] (Break point) in the main menu (or [F1] (Auto) [F4] (Break point)).

Note: When the power fails, do not move the nozzle, and do not set the coordinates when the power resumes, or else the memorized coordinates will be wrong.

11. Break point setting

If you want to return to the automatic processing interface after exiting (press [F1] (Auto) in the main menu interface), you need to restore the coordinates when the motion stops. You can press Pause while automatic processing, and then press [F6] (Break point), and the system will save current processing track (nozzle position) as a break point, which will be saved permanently, even when the machine is shut down. When you enter the

Auto interface next time, the coordinates will be the saved break point if the current program isn’t changed.

To restart after power failure, you can press [F6] (Break point) in Auto interface to restore the break point and press [Start] to resume processing.

12. Replacing torch nozzle

While processing, if the torch nozzle is damaged, please follow the procedure below to replace the nozzle:

in the main menu interface press [F1] (Auto), while processing press [Stop] press [X+], [X-],

[Y+], [Y-] respectively to move the torch to the position that can replace the nozzle press [Start] select popup dialog box (as in Fig. 2.12), and select corresponding operation item press [OK] and the coordinates automatically move to program interruption position and continue the processing according to selected item.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Auto /

Prompt:

Speed:

Cut after idle stroke return

Stop after idle stroke return

Cut and return directly

Continue at current position

/ Program name

Torch up /

Torch down /

Current coordinates

Slot compensation

Cutting Control

Height control

Prompt:

Stopped / Working state: Plasma

Return / Demonstrate / Manual / Back / Process / Return reference / Break point / Return

2.12 Replacing Nozzle

13. Shift and punch

A

- 21 -

B

B

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Fig. 1 Fig. 2

As in Fig. 1, the outer rectangle is steel plate and the inner rectangle is the workpiece to be cut. Suppose cutting from point A, if the steel plate being processed if too thick, it requires rather long time for perforating; however, it will save the preheating time to cut from point B, i.e. edge of the steel plate. The specific procedure follows:

during automatic processing press [Stop] press X/Y to move torch to the edge of the steel plate

press [Start] select corresponding operation item in the popup dialog box press [OK] and the coordinates move the program interruption position automatically and continue the processing according to the selected item.

14. Moving workpiece

1# workpiece

2# workpiece

2# workpiece

1# workpiece

Fig. 1 Fig. 2

To save steel during processing, you can shift the track for certain distance in every direction while cutting graphics and then process, as in the figure above: the outer rectangle indicates the steel plate and the inner rectangle indicates the graphics to be cut. After cutting “1# workpiece”, it will cause great waste to cut “2# workpiece” directly because they have certain distance. At this moment, you can move the track to appropriate position as shown in Fig. 2. The operation follows:

After cutting “1# workpiece”, press [Stop] [X+], [X-], [Y+], [Y-] to move torch to appropriate position.

15. Selecting line/point

This function allows select and process the any line of G code of the graphics being processed.

In the main menu interface, press [F1] (Auto) [F4] (Graphics) [F4] (Process) [F2] (Select line) to enter the following interface to select the positioning mode:

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

1.

2.

Current state: Turning / Program name:

Please select the positioning mode for line selecting:

1Current point

2Origin

Return /

Press OK after selecting

Please enter the target line No.:

Turn / Select line / Select point / Array /

Fig. 2.15 Selecting Positioning Mode

Restore / Return

Current point: The torch doesn’t move, and the coordinates change to the value of this line directly

Origin: The torch moves from current position to the coordinates of selected line.

Press [Y+], [Y-] to change the positioning mode for line selecting, and press [OK] to select line No. (see Fig.

2.15.2 below).

Press number keys to enter the line No. and then press [OK]. For fine adjustment, press [X+], [X-] to select next line No.

16. Array

While cutting, it is usually required to repeat cutting single graphics on a large steel plate, and the array function will make it easier.

In the main menu interface, press [F1] (Auto) [F4] (Graphics) [F4] (Process) [F5] (Array) to enter array parameter setting interface.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Return /

Current state : Array /

Please enter the parameters:

Program name:

1.

2.

3.

4.

1Line No.

2Row No.

3 Line space

4Row space

5.

6.

5Plate width

6Plate height

Y. Staggered X X. Vertical Y

Width: Height:

Turn Restore / / Select line / Select point / Array /

Fig. 2.16.1 Before Array (Processing Interface)

Return

The default offset is the size covered by the picture element, i.e. height and width of single graphics; adjust these two values to make the array more reasonable.

Press the number keys to enter the parameter value, press [Y+], [Y-] to select a parameter, enter the valid parameter, and then press [OK] to select array direction.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Current state: Array / Program name

Please enter the parameters:

1.

2.

3.

4.

1 Line No.

2Row No.

3Line space

4Row space

5.

6.

5Plate width

6Plate height

Select array direction and then press [OK]

Return /

Width: Height:

Turn / Select line / Select point / Array / Restore / Return

Fig. 2.16.2 Array Parameter Setting

Press [X+], [X-], [Y+], [Y-] to move cursor to the direction for array, select the direction and then press [OK] to complete all array steps and start array processing.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Current state: Array / Program name

Please enter the parameters:

2

1 1Line No.

2Row No.

5

6

3

4

X. Vertical Y

3 Line space

4Row space

5Plate width

6Plate height

X Y. Staggered

Restore / Return / Turn / Select line / Select point /

Fig. 2.16.3 Graphics after Array

During array, please pay attention to the following notice:

Array / Return

1) After array, all the processing states won’t be saved, e.g. pause coordinates, etc.

2) After array, press [Return] to check whether the size is suitable for the steel plate in the processing interface; press [F6] (Restore) for re-array.

17. Mirror

Mirror is to symmetrize the graphics to be cut by X or Y axis to get a new processing file.

In the main menu interface, press [F1] (Auto) [F4] (Graphics) [F4] (Process) [F1] (Turn), and then

- 26 -

ADT-HC4500 Flame/Plasma Cutting Machine CNC System press [F1] (X mirror) or [F2] (Y mirror) or [F3] (XY mirror), as in the figure below:

/

Current state: Turn /

Current graphics size

X mirror / Y

Height

Width

Program name

Y mirror/ XY XY mirror / Return /X

Return

Rotate /

Fig. 2.17.1 Before X Mirror

Correct / Restore

Current state: X X mirror /

Current graphics size

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Program name

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Height

Width

Return / X

Return

X mirror /Y Y mirror/XY XY mirror / Rotate / Correct / Restore /

Fig. 2.17.2 After X Mirror

18. Rotate

While cutting, the position and angle of steel plate should coincide with XY axis of the cutter; during the actual processing, offset is inevitable, and XY axis on the steel plate shifts the moving angle relative to the XY axis of the machine tool.

This system can correct the steel plate automatically through the rotation function, so that the user doesn’t need to move the steel plate or cutter. The operation follows: in the main menu interface, press [F1] (Auto) [F4]

(Graphics) [F4] (Process) [F1] (Turn) [F4] (Rotate), and enter the rotation angle to rotate the graphics. By default, the positive angle is counterclockwise, and the negative angle is clockwise.

/

Current state: Rotate /

Please enter the rotation angle:

X mirror / Y

Program name

Y mirror/ XY XY mirror / Rotate / Return / X

Return

Fig. 2.18 Rotate

Correct / Restore

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

19. Correct

If the rotation angle isn’t determined while correcting, we can get the rotation angle through the correction function.

First, a reference axis is required for correction, and the graphics rotate for certain angle around this axis.

In the main menu interface, press [F1] (Auto) [F4] (Graphics) [F4] (Process) [F1] (Turn) [F5]

(Correct) to pop up the Correct interface.

X

Y

Current state: Correct / Program name

Please select the reference axis for correction:

1.

2.

3.

X

Y

1 Axis X

2Axis Y

X+, X-, Y+ Please press X+, X-, Y+ or Y- to move

X offset:

Y offset:

Angle:

Return /X

Press [OK] after moving

X mirror /Y Y mirror/ XY XY mirror /

Return

First, press [Y+][Y-] to select the reference axis for correction.

Rotate / Correct / Restore /

If axis X is the reference axis: the offset angle of the steel plate is the angle between axis X of the steel

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plate and axis X of reference coordinates.

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

If axis Y is the reference axis: the offset angle of the steel plate is the angle between axis Y of the steel plate and axis Y of reference coordinates.

After selecting, press [OK] to confirm.

Press [X+][X-][Y+][Y-] to move the torch, and the system will calculate the angle automatically. The following correction principle will describe how to move the torch and calculate the correct angle.

Current state: Correct / Program name

Please select the reference axis for correction:

1 X 1Axis X

2 Y 2Axis Y

Please press X+, X-, Y+ or Y- to move X+, X-, Y+ Y-

X offset: X

Y Y offset:

Angle:

Return /X

Press [OK] after moving

X mirror / Y Y mirror/XY XY mirror /

Return

Fig. 2.19.1 Correct

Rotate /

The following correction principle is to correct with axis X as the reference.

The correction principle with axis X as the reference axis follows:

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Correct / Restore /

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

A

Fig. 1 Fig. 2

1) In Fig. 1 above, the bigger frame (real line) is the steel plate, the smaller frame (broken line) is the graphics to be cut, and point A is the start position of the torch. If cutting according to the position in Fig.

1, certain part of the graphics can’t be cut; if cutting according to Fig. 2, move the start point to the center of the steel plate and cut; in this way, the steel plate can’t be utilized reasonably and will cause waste.

2) At this moment, calculate the inclination of the steel plate without moving it, and then incline the processing graphics for corresponding angle to utilize the steel plate effectively.

Steel plate correcting method follows:

Original position of torch / Position after moving

1) As in the figure above, point A is the start point of torch; just move the torch to any point in the base side of the steel plate to calculate the inclination of the plate, press [X+] and then [Y-], or press [Y-] and then [X+], and then press [OK].

2) At this moment, the graphics displayed by the controller will be rotated for certain angle, and the

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System relationship between the graphics to be processed and the steel plate follows:

3) If the steel plate inclines to the left as in the figure below, the correcting method follows:

Original position of torch / Position after moving

Press [X+] and then press [Y+], or press [Y+] and then [X+], and then press [OK]. The relationship between the graphics to be processed and the steel plate follows:

20. Selecting cutter point

In the Auto interface, press [F4] (Graphics) to enter graphics display and processing graphics tracking interface.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

In pause state, press [G], and the start point moves to the lower left of the graphics automatically; press [G] again, and the start point moves to the lower right. Press it repeatedly, and the start point appears in the four corners of the graphics in sequence. You can select appropriate corner as the start point.

Auto / Speed: /

Ethyne control /

Preheating control /

Cutting Control /

Current coordinates

Slot compensation

Preheating delay

Prompt:

Program name

Torch up

Torch down

Height control

Working state:

Back / Process /

Stopped /

Return reference /

Flame

Break Return / Demonstrate / Manual / point / Return

Fig. 2.20 Locate the Start Point to the Lower Right of the Graphics

With this function, the program will reset automatically.

After selecting the alignment point, press Start to move the torch from alignment point to the original start of the program, and then start processing.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Chapter III: Detailed System Operation and Instructions

1. Auto

In the main menu interface, press [F1] (Auto) to enter automatic processing interface, as shown below:

Auto / Speed: /

Return /

Break point /

Ethyne control /

Preheating control /

Cutting Control /

Current coordinates

Torch up

Torch down

Height control

Prompt:

Working state:

Demonstrate /

Stopped /

Manual / Back /

Flame

Process /

Return

Slot compensation

Preheating delay

Fig. 3.1 Flame mode

Program name

Return reference /

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Auto /

GLOBAL

Torch up /

Torch down /

Speed: /

Cutting Control

Height control

Current coordinates

Slot compensation

Prompt:

Working state:

Return /

Stopped /

Demonstrate / Manual /

Plasma

Back / Process / point / Return

Fig. 3.1 Plasma mode

Fig. 3.1 Flame mode interface description:

Speed percentage, which is adjusted with [F ], [F ];

Program name:

Return reference / Break

Current moving speed;

Name of processing file;

ON/OFF state of electronic valves;

Current coordinates of X, Y, Z;

Slot radius compensation of current torch;

Oxygen preheating time for perforating during flame cutting;

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Current function, mode and state of the system;

Cutter model;

Current working state of the system;

Code run by current processing program;

Tracking of current processing graphics;

The differences between plasma and flame processing interface are that plasma doesn’t have preheating time and certain electronic valves are different.

1.1 Program running description

In the Auto interface shown in Fig. 3.1

and Fig. 3.1

above, press [Start] button to run current program. Press

[Start], and the torch starts perforating in the steel plate in any cutting mode (M07 is the perforating instruction by default), and cuts after perforating; cuts off the oxygen after cutting. Please refer to Chapter 4.4 for the specific content of M07 perforating instruction.

If you press Pause while cutting, the interface shown in Fig. 3.1.1 will appear. [F2] turns into [Forward] from

[Manual]; if you press [F2][ Forward], the machine will move forward along the track; if you press [ ] or [ ],

[Forward] turns into [Manual].

Auto /

Torch up /

Speed: /

Cutting Control

Torch down / Height control

Current coordinates

- 36 -

Program name:

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Slot compensation

Prompt:

Working state:

Return /

Paused /

Demonstrate / Manual /

Plasma forward/ Back / reference / Break point / Return

Fig. 3.1.1 Pause during Automatic Processing

Treatment while pause (shift perforating and torch replacing function):

Process / Return

Auto / Speed: /

Prompt:

Cut after idle stroke return

Stop after idle stroke return

Cut and return directly

Continue at current position

Program name

Torch up /

Torch down /

Current coordinates

Slot compensation

Prompt:

Cutting Control

Height control

Working state: Stopped / Plasma

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Return / Demonstrate / Manual /

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Back / Process / Return reference / Break point / Return

Fig. 3.1.1.2 Pause Treatment

While cutting, if you press [Pause], the following treatment is available according to whether the torch is moved manually:

1) If the torch isn’t moved manually after pause, you can press the [Start] button directly to make the controller start perforating and continue to run the program.

2) If someone moves the torch out of the track of the processing file when the program paused, you can press the [Start] button to pop up the interface shown in Fig. .

[1]. The controller runs idle and returns to the pause position of the processing program, starts cutting cycle and then runs processing program.

[2]. The controller runs idle, returns to the pause position of the processing program and then stops.

[3]. The controller starts cutting at current position, returns to the pause position of the processing program and then runs processing program. For these three functions, press [Y+] or [Y-] to move cursor “ ” up/down to select, and press [OK] to perform the function after selecting.

[4]. Continue running program code on the offset position, but do not return to the track position when it paused.

Press [ESC], the controller cancels returning and waits in current position for the user deciding whether continue processing or not.

3) After selecting, the perforating instruction will perform automatically according to program state; you can press Pause to stop performing M07 instruction.

1.2 Submenu description of Auto interface

1.2.1 Run idle

(Auto) [F1] (Run idle): The system only runs X, Y tracks, the switches for preheating oxygen, ethyne, cutting oxygen, starting arc and corner won’t be turned on, used to forecast whether the track and steel plate size are proper.

The run idle speed is the maximum manual speed, which isn’t controlled by the percentage.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

1.2.2 Manual

In the main menu, press [F1] (Auto) [F2] (Manual) to enter Manual interface:

X

Y

Shift

G

X

Y

Z

/

Manual / Speed: /

G: switch Manual/Jog

Program name:

Ethyne control / Torch up

X: Set coordinates of X axis

Y: Set coordinates of Y axis

Preheating control /

Cutting Control /

Shift: Set coordinates of Z axis Current coordinates:

Preheating delay:

Prompt: Manual

Working state: Stopped /

Return / Jog Return Break point / Clear / Return reference /

Fig. 3.1.2.2 Flame Manual Interface

Torch down

Height control

Flame

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

G

X

Y

Shift

Manual /

X

Y

/

Speed: /

G: switch Manual/Jog

X: Set coordinates of X axis

Y: Set coordinates of Y axis

Program name:

Torch up /

Torch down/

Current coordinates:

Cutting Control

Height control

Z Shift: Set coordinates of Z axis Preheating delay:

Return / Jog /

Working state:

Prompt:

Stopped /

Break point / Clear / Return reference /

Plasma

Return

Fig. 3.1.2.2 Plasma Manual Interface

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1.2.2.1 Jog

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

G

X

Y

Shift

Manual /

/

Speed: /

G: switch Manual/Jog

X

Y

Z

X: Set coordinates of X axis

Y: Set coordinates of Y axis

Shift: Set coordinates of Z axis

Program name:

Ethyne control /

Preheating control /

Cutting Control /

Torch up

Torch down

Height control

Current coordinates:

Preheating delay:

Prompt:

Working state: Stopped / Enter value:

Return / Jog / Break point / Clear / Return reference /

Flame

Return

Fig. 3.1.2.2.1 Jog Setting Interface

In Fig. 3.1.2.2 Manual interface above, press [F1] (Jog) to have the interface above; at this moment, “Jog” is highlighted, and “Input value L=” in the bottom of the screen; press number keys to enter the length

(unit: mm) of jogging. After that, press [X+], [X-], [Y+] or [Y-], and the corresponding motor moves the entered length. The plasma has the same function (the figure is omitted).

If “Jog” isn’t highlighted, press and release [X+], [X-], [Y+] or [Y-], and every axis performs continuous motion; when you press [X+], [X-], [Y+], [Y-] again or press [Stop], the system will decelerate and stop motion.

If you press [G], the system will switch between Manual and Jog. In jog state, if you press and hold [X+],

- 41 -

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

[X-], [Y+], [Y-], the respective axis performs continuous motion; when you release [X+], [X-], [Y+], [Y-], the system will decelerate and stop motion.

1.2.2.2 Breaking point

G

X down

Y Y

Height control

Shift

Manual /

/

Speed: /

G: switch Manual/Jog

Program name:

Ethyne control /

X X: Set coordinates of X axis

Y: Set coordinates of Y axis

Z Shift: Set coordinates of Z axis

Preheating delay:

Preheating control /

Torch up

Cutting Control /

Current coordinates:

Torch

Prompt:

Working state:

Start from power failure memory

Stopped / Flame

Return / Jog / Break point / Clear / Return reference / Return

Fig. 3.1.2.2.2 Break Point Interface

It has the same function as [F6] (Break point) in Auto interface. Please refer to Section 1.2.7 Break point in this chapter.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

1.2.2.3 Clear

In the manual interface, press [F5] to clear the parameters in memory; if you press [X] or [Y] [F5] (Clear)

[OK], the X, Y coordinates of the entire line will be cleared; to clear the last digit only, press [DEL] on the panel.

1.2.2.4 Returning reference point

In the manual interface, press [F6] to return X, Y coordinates in the manual interface to the reference coordinates.

1.2.2.5 X/Y coordinates setting

In the manual interface, press [X], [Y] on the panel to modify or clear X, Y values.

Press [X], [Y] to show current coordinates in the lower left of the interface, e.g. “Enter X: X=+00123.456”; at this moment, you can press [DEL] to clear the coordinates, press [F5] (Clear) to clear the entire line; press [OK] after setting above values.

1.2.3 Backward

In Auto manual, this function is used to back the plate along original track if it isn’t cut through. Follow the procedures below:

During automatic processing, press [Stop] to stop running press [F3] (Back) to backing function while backing, press [Stop] when it reaches desired position press [F1] (Run idle) to move forward if it backed in excess press [Start] again when the system is stable, and the system runs M07 perforating instruction again and processes according to the program.

The plate only can be backed to previous perforating hole.

1.2.4 Forward

In Auto interface, if you press [Stop] to stop running while processing, run idle or backing, the “Manual” menu will turn into “Forward”; if you press [F2] at this moment, the system goes forward at actual processing speed and doesn’t run M switch instruction, equivalent to running idle at processing speed.

1.2.5 Graphics processing function

In the graphics interface as in Fig. 3.1.2.5, press [F4] (Process) to enter graphics processing interface, as in

- 43 -

the figure below

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Please select corresponding graphics processing function

Program name

Current graphics size

Width

Height

Select point / Return / Turn / Select line / Array /

Fig. 3.1.2.5.1 Graphics Processing Interface

Restore /

/

Return

1.2.5.1.1 Turn

In above processing interface, press [F1] (Turn) to enter the interface.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Return / X

Current state: Turn /

Current graphics size

Height

Width

Program name

X mirror /Y Y mirror /XY XY mirror /

Restore / Return

Rotate /

Fig. 3.1.2.5.1.1 Graphics Processing Interface

Correct /

1.2.5.1.2 X/Y mirror

Please refer to Chapter II Section 17: Mirror.

1.2.5.1.3 Rotate

Please refer to Chapter II Section 18: Rotate.

1.2.5.1.4 Correct

Please refer to Chapter II Section 19: Correct.

1.2.5.1.5 Reset

In the Rotate interface, press [F6] to restore current graphics to the one before processing immediately.

1.2.5.1.6 Selecting line

Please refer to Chapter II, Section 15: Selecting Line.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

1.2.5.1.7 Selecting point

In the processing interface shown in Fig. 3.1.2.5.1, press [F3] (Select point) to enter point selecting.

1.

2.

Current state: Select point / Current point: /

Please select the point selecting mode

1Change coordinates directly

Move torch automatically

Press [OK] after selecting

Please enter the target perforating point:

Turn / Select line / Select point / Return /

Return

Fig. 3.1.2.5.2.7 Select Point

Press [Y+][Y-] to change the mode of selecting perforating point.

Array /

Program name

Restore /

Changing coordinates directly indicates that the torch doesn’t move, and the coordinates change to the perforating point coordinates directly;

Moving torch automatically indicates that the torch moves to the perforating point from current position.

As shown in the figure after selecting the perforating mode, select the position of any M07 perforating point to process during the graphics processing, enter the perforating point and press [OK]; for fine adjustment, press [X+][X-] to select next perforating point.

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1.2.5.1.8 Array

Please refer to Chapter II Section 16: Array.

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

1.2.5.1.9 Restore

In processing and turn interface, press [F6] (Restore) to restore the graphics after array, selecting point and line to the graphics before being imported.

1.2.6 Returning reference point

In the Auto interface, press [F5] to return the torch to the origin at current manual speed; during automatic running, press the [Stop] key first and then press [F5] when the system is stable.

1.2.7 Breaking point

The main functions of breaking point follow:

1) When the power resumes from failure, search for the coordinates before power failure

2) Set a point memory in current track to replace torch nozzle

3) Set a point memory in current track for displacing and perforating

Manual /

Ethyne control /

Speed:

Torch up

Preheating control / Torch down

Cutting Control / Height control

- 47 -

/ Program name:

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Current coordinates:

Slot compensation:

Preheating delay:

Prompt:

Working state:

Start from power failure memory

Stopped / Flame

Manual/ back / process / Return / point / Return

Demonstrate / Return reference / Break

3.1.2.7 Start from Power Failure Memory

If the automatic processing is paused manually, press [F6] (Break point), and the system will save current track

(torch position) as a break point automatically. This break point will be saved permanently even the machine is turned off. When the machine is restarted or enters auto mode again, you can press [F6] (Break point) in Auto interface to restore the break point if only current program isn’t changed; when the break point is found, press

[Start] again, and the system continues processing from the break point; plasma has the same function.

1.3 Basic operation

1) I/O

Flame: Before the machine processing, you can select strong current key manually to control ignition, ethyne, preheating oxygen, cutting oxygen, or torch up/down/stop. Note: when you press the ignition key, if the ethyne isn’t turned on, please open the ethyne valve first and then turn on the ignition switch, and delay for an ignition delay (see Parameter – Control – Ignition Delay) to turn off the ignition switch; press [Perforate] to perform a preheating and perforating process (see Section 3,

Point 4: M07 Fixed Preheating and Perforating Cycle); press [General Switch] to turn off the IO outputs.

Plasma: Before the machine processing, you can select the strong current arc switch (cutting oxygen

(switch) of flame) to control the start arc; if initial positioning has been set, the system starts initial positioning; if the system is installed with and has enabled the height adjustment system, the system will send a start arc signal to the height adjustment system; if no height adjustment system is installed, the system will turn on the start arc switch; press [Perforate] to perform a start arc and perforating process (see Section 3, Point 4: M07 Start Arc Perforating Cycle); press [General Switch] to turn off the outputs.

2) Press [F ] and [F ] to increase or decrease the rate of moving speed; in standby state, press and

- 48 -

ADT-HC4500 Flame/Plasma Cutting Machine CNC System hold this key to increase or decrease the speed continuously; if during processing, press the key to increase or decrease the speed percentage by 1 every time.

3) Press [Pgup/S ] and [Pgdn/S ], which are composite key. Press [Pgup/S ] (or [Pgdn/S ]) to move the torch upwards (or downwards); while editing, press the keys to turn pages.

4) Press [F] to switch the speed rate quickly; if the rate is 50%--100%, press [F] to switch the speed rate to 5%; if the rate is 1%--50%, press [F] to switch the speed rate to 80%.

5) In graphics interface: press the number keys to zoom in the graphics: 0 – resume original size of the graphics; 1—9: zoom in the graphics; 1—zoom in the graphics for one time; 2—zoom in the graphics for two times…… and so on. For example: press [2] to zoom in the graphics for two times; press [0] to resume the original size; press [2] twice consecutively to zoom in the graphics for 2*2=4 times. Others are same.

6) [INS] key: Activate the help of current interface.

2. Graphics library

2.1 Simple operation instruction

In the main interface, press [F2] to enter the graphics library interface (as shown in Fig. 2.1). In this interface,

35 graphics are available. You can press [Y+], [Y-], [X+], [X-] to select the graphics and press [OK] to enter the settings.

Return /

- 49 -

OK / Return

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Fig. 2.1

We will take “Circle” as an example for description. Move the blue frame to the circle and press [OK] to enter the graphics.

Graphics Library Parameters Settings

Part type: piece

Radius

Lead-in wire

Lead-out wire

X :Place shit X

Y:Place shift Y

Return / Preview / Import / Return

Fig. 2.3

By setting the parameters, the user can get different processing graphics.

Part type: Select to cut into pieces or holes; for pieces, the part inside the graphics frame is the desired workpiece; for holes, the part outside the graphics frame is the desired workpiece.

Lead-in/out wire: Lead-in wire (arc) is the wire (arc) reserved to prevent over-burning of perforating point.

Lead-out wire (arc) is used for plasma cutting process, during which the lead-out wire (arc) will cause arc breaking. The lead-in/out wire (arc) for holes cutting is inside the graphics, while the lead-in/out wire (arc) for pieces cutting is outside the graphics.

Space shift wire : the run idle distance from processing start to perforating point.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

The parameter settings of the graphics library are limited: the circle radius shouldn’t exceed the radius of outer arc, or the height from circle center to base side of the trapezium; base side length of the trapezium shouldn’t be smaller than two times of top arc radius. If the parameters exceed the range, they can’t form a correct graphics combination. After setting the parameters, press [F5] to preview. If the parameters exceed the range, the system will prompt and restore the original parameters. If the parameters do not have mistake, you can press [F6] Import to enter the Auto interface. At this moment, the processing file in the system has changed into the selected graphics library file.

While setting parameters, press [DEL] to delete the last digit of current last parameter, press number keys to enter the values, press [Cancel] to clear the parameters, and press [Y+], [Y-] to select setting parameters.

3. Edit

In the main interface, press [F3] to enter Fig. 3.1 Edit Menu Option Window, which displays the code of current processing file. The code is read-only. If there are more than one page, press [pgup ][pgdn ] to turn pages.

Return / New / Import /U USB disk /

Fig. 3.1 Edit Menu Option Window

Custom / Return

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3.1 Submenu description

3.1.1 New

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Input method: digital 123

Please type the file name:

Return Return / Save /

Fig. 3.1.1 New File Interface

In Fig. 3.1 edit interface, press [F1] to enter new file interface as shown in Fig. 3.1.1. At this moment, you can press the number keys directly to edit the file name, and press [F5] to save, or press [shift] to switch the input method. ABC and pinyin are available.

The operation of pinyin method follows:

1.

Press [OK] to select current character

2.

Press [Cancel] to delete all current characters

3.

Press [shift] to switch the input method

4.

Press [DEL] to delete the last character

5.

Press [Y+], [Y-] to select characters up/down

6.

Press [X+], [X-] to turn pages

7.

The letters on the panel are defined as below

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Delete

Switch input method / OK / Cancel

Up

Down / Page-up / Page-down

After entering, press [OK]; if the file name already exists in the system, press [OK], and the system will prompt, as shown in Fig. 3.1.1.2 below, or else enter the file edit interface, as in Fig. 3.1.1.3;

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Input method: digital 123

Prompt

The file exists. Overwrite?

OK /

Return /

Cancel

Save / Return

Fig. 3.1.1.2 File Name Already Exists in the System

In this prompt interface, press [OK] to overwrite the original file and enter the interface shown in Fig.

3.1.1.2, or press [Cancel], and the system returns to the interface shown in Fig. 3.1.1.

Return / Graphics / Test / Save / Add line /

Fig. 3.1.1.3 Edit New File Interface

Delete line / Return

After creating a new processing file, you can edit desired processing file code. Please refer to “3.2 Edit

Processing File” for the specific operation of editing the code.

3.1.2 Import

1) In Fig. 3.1 Edit Menu Option Window, press [F2] to enter file importing interface, as shown below:

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Current directory:

Name / Size (byte) /

Return / Import /

Type

Copy / Delete / Copy all /

Fig. 3.1.2 File Importing Interface

Return

In above interface, press [F ][F ] to select a processing file, and then press [F2] or [OK] to select, and then enter the processing code edit interface. Please refer to “3.2 Edit Processing File” for file editing.

2) [INS] key: Activate the help of current interface.

3.1.2.1 Copy

In Fig. 3.1.2 File Importing interface, press [F5] “Copy” to copy current selected processing file from the controller to USB disk; press [F6] “Copy all” to copy all processing files from the controller to the USB disk.

Prompt: To exit when copying all files, press and hold the Cancel key until exit the copy interface (as shown in

Fig. 3.1.2).

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Current directory:

Copying data.

Return / New /

Please wait……

Copy / Delete / Return

Fig. 3.1.2.1 File Copy Function

3.1.2.2 Delete

In processing file importing interface, you can select to delete the files in system directory. The system will ask you to confirm, you can press [OK] --- Delete; press [Cancel] --- Do not delete

Current directory:

Name / Size ( byte) / Type

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Prompt

OK /

Return /

Delete this file?

Cancel

Import / Delete / Copy / Copy all /

Fig. 3.1.2.2 Delete Interface

Return

3.1.3 USB disk

In Fig. 3.1 Edit Menu Option Window, press [F3] to enter USB connection. If the USB disk isn’t connected properly or is incompatible with the system, the system will pop up the interface below:

Current directory:

U Can’t find USB disk.

Return / New /

Press any key to return

Delete / Return Copy /

Fig. 3.1.3 USB disk isn’t connected successfully

If the USB disk is connected successfully, the interface will show the file names saved in the USB disk after initializing, as shown below:

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Current directory:

Return / New / Copy / Delete / Return

Fig. 3.1.3.1 USB disk is connected successfully

Press [Y+][Y-] to select the processing file to copy, and then press [F2] (Copy) or [OK]. After that, the system will prompt “Copy data successfully. Press any key to return”.

3.1.4 Definition

Return / Clear / Add line / Delete line /

3.1.4 Definition Interface

In Fig. 3.1 Edit Menu Option Window, press [F4] to enter the definition interface.

Save / Return

1) In this interface, press [F1] to customize M07 instruction, and the default perforating flow is:

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Flame:

Fixed ignition cycle M52

Fixed torch down cycle M71

Fixed preheating cycle M74

Fixed perforating torch up cycle M72

Cutting oxygen on M12

Plasma:

Fixed perforating torch down cycle M73

A. When height adjustment system is integrated:

Height adjustment on M22

Start arc M12

Wait for arc voltage test signal (IN0)

When arc starts, the height adjuster initializes positioning automatically (height adjust with initial positioning), perforates, delays, and sends a successful arc voltage test signal to the controller.

B. When height adjustment system isn’t integrated:

Start arc, start arc delay M12

Perforating, perforating delay

Actions after starting

The user can customize the function of M07 according to actual requirements.

2) [F2] is to customize M08 instruction, and the default M08 is to turn off the cutting oxygen, and the flow is:

Flame:

Cutting oxygen off M13

Fixed torch up cycle M70

Plasma:

Turn off arc M13

Turn off height control M23

The use can customize M08 to M80 (turn off all outputs) according to requirements. When performing M08, all valves will be turned off to save gas.

3) [F3]: Clear the data of current line

4) [F4]: Add a line below current line

5) [F5]: Delete current line

6) [F6]: Saved the edited content

7) [INS] key: Activate the help of current interface.

Note: After customizing M07, M08 instructions, please change [F1] (Configure) in [F4] (Parameter) into

“Custom”.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

3.2 Editing processing files

In Fig. 3.1 Edit Menu Option Window, if you create a new file or import a file successfully, the system will enter the edit interface automatically, and then you can edit the processing file, as shown below:

Return / Graphics / Test / Save / Add line /

Fig. 3.2 Processing File Edit Interface

Delete line / Return

3.2.1 Graphics

In above Processing File Edit Interface, press [F1] Graphics, and the interface shows the graphics of current code for reference.

3.2.2 Checking

In Fig. 3.2 Processing File Edit Interface, press [F2] to check whether the code of processing file has error after entering the code of processing file or importing the code of nesting software; if yes, the line with error will be highlighted and the bottom prompts the error type; if not, it shows that the coding is correct, as shown below:

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Return /

Encoding completes.

Graphics / Test /

Code entered correctly.

Save / Add line / Delete line / Return

Fig. 3.2.1.2 Code Error Check Interface

If the check code has error, the cursor will stay in the line with error. You can press [OK] to modify the error, and then press [F2] to check the processing file. The system will pop up the dialog box below:

Prompt

Return /

To re-check the code,

To continue the checking,

Graphics / press OK press Cancel

Test / Save / Add line /

Fig. 3.2.1.2.1 Code Re-check Interface

Delete line / Return

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

In above interface, press [OK] to re-check from the first line, or press [Cancel] to check from the cursor.

3.2.3 Save

Return / Graphics /

Press OK to save,

Test /

Prompt

Save in another file name?

Save /

3.2.1.3 Saving Files

or press Cancel to exit

Add line / Delete line / Return

After entering processing code or checking the code, press [F3] to save before exiting, or the system can’t memorize current processing file. When you press [F3], the system will ask whether save as another file (as in

Fig. 3.2.1.3); press [Cancel] to overwrite the original file; press [OK] to enter a file name and then press [F5] to save the file.

If you do not need to save current processing file, you can press [ ] or [ ] directly to return to the main interface.

3.2.4 Add/delete line

Add line: While editing processing file, press [F4] or [OK] to add a line of code below the cursor.

Delete line: While editing processing file, press [F5] to delete the line of code where the cursor locates.

3.3 Basic operation

1) The panel has two types of keys, composite keys and single function keys. For composite keys, you can

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System press it to execute the lower functions on the keys, or press [Shift] and the composite keys to execute the upper functions. This function is only available in program edit state.

2) When cursor moves up/down, you can locate the cursor at the line end of the program automatically, and press to move the cursor for one line every time.

3) Page up/down: Press [Pagup / S ] or [Pagdn / S ] to turn the page up or down.

4) The line number in the processing program is generated automatically.

5) Press [DEL] on the panel to delete a character where the cursor locates.

6) Press [INS] on the panel to insert a space in the line.

4. Parameters

In the main interface, press [F4] to enter parameter settings, as shown below:

Return / System / Speed /

Please select the parameter to set:

Adjust / Control / Precision /

Return

Fig. 4 System Parameters Setting Interface

4.1 System configuration

In above system parameter setting interface, press [F1] to enter the setting interface:

Save /

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Return / Configure /

M07

M08

System Configuration Interface

M07 instruction: Default

M08 instruction:

Model: Flame

Default

System:

Language:

Metric

Chinese

Adjust height / Advance /

Fig. 4.1 Configuration Interface

Flame / Save / Return

M07 , M08 instruction : The user can select Default or Custom for M07, M08 preheating perforating instruction. Please refer to section 3 “Definition”.

Language: Select language from available options.

Model: Two cutting processes are available, i.e. flame and plasma.

System: This instruction only allows switching metric and imperial system before entering auto mode or checking program.

Operating mode: Press [Y+], [Y-] to move cursor up/down, press [X+], [X-] to change the mode, and press

[F6] to save the parameters.

4.1.1 Height adjustment

In above system parameter setting interface, press [F2] to enter height adjustment interface:

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Return / Configure /

Plasma Height Adjustment Interface

Allow height adjustment: On

Initial positioning:

Arc voltage test

Adjust height /

Off

Off

Advance / Flame / Save / Return

Allow height adjustment: When the system is installed with arc voltage height adjustment device, this controls when to turn on/off arc voltage height adjustment.

Initial positioning : The torch performs a fixed rising height after touching the steel plate.

Arc voltage test : The plasma power supply feeds back a signal for start arc. If it is successful, the system executes running track; if not, it stops track running.

Operating mode: Press [Y+], [Y-] to move cursor up/down, press [X+], [X-] to change the mode, and then press [F6] or [OK].

4.1.2 Flame step height adjustment

In parameter setting interface, press [F4] Flame to enter flame step height adjustment interface:

Press number keys to enter the parameter values, and press [Y+] [Y-] to select parameters.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Z

Z

Z

Z

Z

Flame Step Height Adjustment Setting

Allow Z axis height adjustment: Off

Z axis pulse equivalent

Z axis start speed

Z axis acceleration

Z axis maximum speed:

Torch up/down distance

Perforating up/down distance:

Return / Configure / Adjust height / Advance / Flame /

Fig. 4.1.2 Flame Step Height Adjustment

Save / Return

Parameter description:

1) Allow Z axis height adjustment: If the state is on, connect to axis Z of the system to adjust the torch height while flame cutting.

2) Z axis pulse equivalent: Z axis precision setting; please refer to section 4.5.1 (Pulse equivalent setting)

3) Z axis start speed: Please refer to section 4.2.1 (Speed setting)

4) Z axis acceleration: Please refer to section 4.2.1 (Speed setting)

5) Z axis end speed: Please refer to section 4.2.1 (Speed setting)

6) Torch up/down distance: The distance dropping to preheating height (cutting) for the first time while cutting (the distance that torch rises from cutting height to initial height)

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

7) Perforating up/down distance: the distance that torch rises from cutting height to safe height while perforating (the distance that torch rises from safe height to cutting height), preventing high temperature solution entering the nozzle.

Note: If not in flame height adjustment, Z axis is synchronous to Y axis. Y, Z can be used for bilateral drive.

After entering the parameters, press [F6] to save.

4.2 Speed

In Fig. 4 system parameter setting interface, press [F2] to show the interface below, in which you can set the speed, manual speed, acceleration and deceleration.

Return / System /

Speed Setting Interface

Start speed

Acceleration

Manual speed

Speed /

Processing speed

Adjust / Control /

Return

Fig. 4.2 Speed Parameter Setting

Precision / Store /

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

4.2.1 Speed setting

Start speed

Acceleration

Manual speed

Start speed of axis X/Y mm/min

The speed value of axis X/Y added every time from start speed to mm/min maximum speed

Axis X/Y speed during manual running, G00 and reference returning mm/min speed

Processing speed Axis X/Y speed when program is running, G01, G02, G03 speed mm/min

Table 4.2.1

Note:

During actual cutting, the speed should be controlled when cutting the corners. If the speed is too high, the flame may be off or can’t cut through the steel plate; if the speed is too low, the corner may be burnt to arc.

Therefore, the “Start speed” and “Acceleration” in “Speed” settings should be adjusted repeatedly to the optimum state.

Reference:

Processing speed

500mm/min

500mm/min

Pulse equivalent Start

0.008000

0.001000

300

300

Acceleration

80-100 (the adjustment of this value should be stressed)

5-15 (the adjustment of this value should be stressed)

Table 4.2.2

4.3 Adjustment

In Fig. 4 system parameter setting interface, press [F3] to the interface below, in which you can set the limit coordinates, origin coordinates and reverse clearance.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Return /

Parameter Setting Interface

Soft positive limit

Soft negative limit

Machine tool origin

System / Speed /

Reverse clearance

Adjust / Control /

Store / Return

Fig. 4.3Parameter Setting Interface

Precision /

4.3.1 Adjustment setting

Soft positive limit

Positive limit of the system; if current position is larger than mm this value, the system will stop automatically

Soft negative limit

Negative limit of the system; if current position is smaller mm than this value, the system will stop automatically

Origin position of the machine tool mm Machine tool origin

Reverse clearance (X)

Clearance compensation for axis X during reverse direction mm change

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Reverse clearance (Y)

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Clearance compensation for axis Y during reverse direction mm change

Table 4.3.1

4.4 Control

In Fig. 4 system parameter setting interface, press [F4] to show the interface below, in which you can set X, Y motor speed, preheating and torch up/down time during automatic processing.

Return /

Flame Control Parameter Interface

Edge perforating prompt: Off

Preheating delay

Torch up delay

Torch down delay

Ignition delay

Perforating torch up

Perforating torch down

System / Speed /

Perforating delay

Slot compensation

Control / Adjust /

Return

Fig. 4.4.1

Flame

Precision /

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Store /

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Return / System / Speed /

Plasma Control Parameter Interface

Start arc delay

Torch up delay

Torch down delay

Preheating delay

Corner speed ratio

Positioning up time

Slot compensation

Preheating up delay

Corner arc radius

Corner down speed

Adjust / Control /

Return

Precision / Store /

Fig. 4.4.2

Plasma

Parameter Description Unit

Edge perforating Enable perforating prompt while perforating prompt

Preheating delay The preheating time while perforating steel plate, which 0.01 sec

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can be adjusted

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Torch up delay Used before G00 transferring position to raise the torch to 0.01 sec

Torch down delay an appropriate height, preventing the torch and steel plate from colliding

Counter action of torch up delay lowers the torch to an appropriate height; after transferring G00 and before

0.01 sec processing, the torch must be lowered; the dropping time of torch is shorter than rising time due to gravity.

Ignition delay The time that high voltage ignition coil electrified while igniting

0.01 sec

Perforating torch In the fixed cycle of preheating perforating, when the 0.01 sec up preheating ends, torch rises quickly and perforating torch delays. At this moment, cutting oxygen turns on, torch starts dropping, perforating torch down delays. Torch rising before turning on cutting oxygen will prevent the steel chip blocking the torch nozzle while turning on cutting oxygen

Perforating torch In the fixed cycle of preheating perforating, torch drops, down

0.01 sec and the fixed cycle ends after the perforating torch down delay. The dropping time of torch is shorter than rising time due to gravity.

Start arc delay After arc switch is started, a delay is required before 0.01 sec processing (plasma processing)

Perforating delay

Height adjustment control

After arc switch is started, a continuous start arc time is required to avoid unsuccessful arc start

If the speed is smaller than this parameter during G01,

G02, G03 code motion, height adjustment is turned off

(plasma processing)

Positioning up Set initial positioning up time during plasma processing time

0.01 sec

%

0.01 sec

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Slot compensation

Preheating up delay

Corner speed ratio

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Flame/plasma radius compensation mm

(Plasma) Torch up time while perforating delay 0.01 sec

%

Corner arc radius

Corner down speed

(Plasma) When the processing speed percentage drops to this value, height adjustment control signal is turned off; when the processing speed percentage rises to this value, height adjustment control signal is turned on

(Plasma) Set the critical value of arc radius when processing arc

The speed drops if the arc radius is smaller than this value

(Plasma) Set the speed dropping to this percentage if the radius is smaller than corner arc radius when processing arc

Speed = F × Processing speed percentage × corner descending speed

Table 4.4 mm

%

4.5 Precision

In Fig. 4 system parameter setting interface, press [F5] to show the interface below, in which you can set the distance (mm) of X, Y axis moving every pulse. The value affects the precision of the track directly.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Return / System /

X

Y

N

Speed /

Pulse Equivalent Setting Interface

X axis pulse equivalent

/

Y axis pulse equivalent

Note: The unit is N·mm/min.

Control / Precision / Adjust /

Return

Fig. 4.5 Precision Parameter Interface

Store /

4.5.1 Pulse equivalent settings

1) In the main interface, press [F4] and then press [F5] to enter precision setting interface, and set the

X, Y pulse equivalent to 0.010000 (at this moment, the control system sends a pulse, and the motor moves 0.01MM); after setting, press [F6] to save and exit the main interface.

2) Press [F1] and then press [F2] to enter the manual interface, and then press [F1] to have “Jog increment: L=+00000.000”,

Enter desired jogging length, and suppose that the jogging unit is 1000MM

3) Press [X+], [X-] or [Y+], [Y-] to start jogging; suppose that the actual moving distance is 578MM,

Calculation formula: (578 × 0.01) ÷ 1000 = 5.78 ÷ 1000 = 0.005780

Actual moving distance

Pulse equivalent of current system

Actual jogging data

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

1) Return to the main interface, press [F4] and then [F5] to enter precision setting interface, enter

0.005780 into X, Y axis pulse equivalent coefficient.

Note: Generally, the pulse equivalent of X, Y axis has a little error. Please set respectively.

4.6 Storage

After modifying every submenu in “Parameter”, please press [F6] to save before exiting, or else the modified values won’t be saved.

5. Diagnosis

In the main interface, press [F5] to enter the diagnosis interface, as shown in Fig. 2.6:

Return / Diagnosis /

Prompt

Please select desired option in the menu below.

Definition / Upgrade /

Fig. 5 Diagnosis Main Interface

Version / Return

5.1 Submenu description

1) Diagnosis interface

In the Diagnosis interface shown in Fig. 5, press [F1] to enter the Diagnosis interface as shown in Fig.

5.1.1;

Operation instructions:

Press [F1] to test the forward rotation of X axis

Press [F2] to test the reverse rotation of X axis

Press [F3] to test the forward rotation of Y axis

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Press [F4] to test the reverse rotation of X axis

Press [F5] to stop current rotation of X/Y axis

Press [X+] [X-] [Y+] [Y-] to move output cursor, and press [OK] to output related switching signal.

If there is input signal, the red circle below pin mark corresponding input diagnosis will turn into yellow.

With this function, you can check whether the I/O port is normal.

X

Diagnosis Interface

X forward moving

Return / Stop /

Fig. 5.1.1 Diagnosis Test Window

Return

2) Defining reserved I/O interface

In Fig. 5 Diagnosis interface, press [F2] to show output function customizing interface, and press

[X+][X-][Y+][Y-] to set. As in Fig. 5.1.2, “Default” is the default output of the system, while “Standby” is the standby output connected to the system. Please refer to Chapter 5, 2.3 Electrical Connection for the definition of output.

Note: The “Standby” output is used only when the default output optical coupling has failure, while

“Default” output is used under normal condition.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Select the output port to set

Ignition control: Default

Preheating oxygen control: Default

Ethyne control: Default

Cutting oxygen control: Default

Torch up control: Default

Torch down control: Default

Return / Return

Flame

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Select the output port to set

Start arc control: Default

Corner control: Default

Perforating torch up control: Default

Perforating torch down control: Default

Return Return /

Plasma

Fig. 5.1.2 Customizing Output Port

4) In the Diagnosis interface shown in Fig. 5, press [F5] to show the latest update of the system.

5) In the Diagnosis interface shown in Fig. 5, press [F6] to show current version info. Fig. 5.1.3 shows the version info of HC4500.

Current version:

4500 V0.1.0

If you have any suggestion or inconvenience, please contact us, and we will do our best to improve.

Thanks!

July 19, 2010

Return /

Fig. 5.1.3 HC4500 Version Display

Return

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

6. Upgrade

This function is used by the used to upgrade the software. In the main interface, press [F6] to enter the upgrade option window, as shown in Fig. 6:

Return /

Upgrade Interface

F1 System parameter reset (F1)

(F2) U

(F5)

Reset / U USB disk /

F2 Upgrade via USB disk

F5 Upgrade via PC

Restart / PC / Help /

Fig. 6 .1 System Upgrade Option Window

6.1 Submenu description

Press [F1] to restore the default parameters

Press [F2] to connect to USB disk

[F3] is reserved

Press [F4] to restart the control system

Press [F5] to connect to computer

Press [F6] to enter the help system

Press [INS] to activate the help of current interface.

Return

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

6.2 Reset

In Fig. 6.1 Upgrade Interface, press [F1] to enter system parameter reset/save interface.

F1

F2

Back /

Reset

(F1) Reset current parameters to default

(F2) Set current parameters to default

Save / Back Reset /

Fig. 6.2.1 Parameter Reset/Save Interface

In this interface, the system will ask the user to reset or set to default. To reset, press [F1], and the system prompts after resetting, as in Fig. 6.2.3; if you press [F1], the system enters the prompt interface, as in Fig. 6.2.4, or press

[Cancel] to return to previous interface.

Note: If the system parameters haven’t been saved, the system won’t restore the parameters, as shown in

Fig. 6.2.2.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Prompt

Reset current parameters to default?

OK Cancel

Save / Return / Reset /

Fig. 6.2.2 Can’t reset the parameters

Return

Return / Reset /

Prompt

Reset parameters successfully. Please restart.

Save / Return

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

In system parameter reset/save interface, you need to enter the valid password to save the parameters; if you don’t want to save, press [ ] or [ ] to return.

Prompt

Please type the password

Reset /

OK Cancel

Save / Return /

Fig. 6.2.4 Resetting Validation Interface

In above interface, type the valid password to have the interface below:

Return

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Return /

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Prompt

Set current parameters as default?

OK / Cancel

Reset / Save / Return

In Default Setting Prompt Interface, press [OK] to set current parameters as default, and the parameters will be reset to this default value. After saving, the system pops up a prompt interface, as in Fig. 6.2.6. If you don’t want to set current parameters as default, please press [Cancel] and [ ] or [ ] to return.

Prompt

Save parameters as default successfully

Return / Reset / Save / Return

Fig. 6.2.6 Prompt interface after saving parameters as default successfully

6.3 Upgrading through USB disk

1) USB disk isn’t connected successfully

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Current directory

Can’t find USB disk. Press any key to return U

Return / New / Copy / Delete / Return

Fig. 6.3.1 USB disk isn’t connected successfully

Copy the latest program to USB disk, and insert the disk into USB interface. In the main interface, press

[F6] to enter the upgrade interface, and press [F2] to show the interface in Fig. 6.3.1 if the USB disk isn’t connected successfully. Press any key to return to the main interface.

2) USB disk is connected successfully

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Current directory

Multiple copies copy

Return / copy

Reset /U USB disk / Restart / PC /

Fig. 6.3.2 USB disk is connected successfully

Help / Return

If the USB disk is connected successfully, press [Y+], [Y-] in the directory to move cursor to

“2440TEST.BIN” and [OK] to show the interface below:

Return /

Current directory

Downloading program file. Please wait

PC / Help / Reset / U USB disk / Restart /

Fig. 6.3.3 Upgrading

Return

If the selected file isn’t system upgrade file, the system will prompt automatically, as in Fig. 6.3.4:

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Return /

Current directory

This isn’t system file. Upgrade fails

PC / Help / Reset /U USB disk / Restart /

Fig. 6.3.4 Upgrade fails

Return

If the selected file is appropriate, the interface after downloading the program is shown below:

Current directory

BIOS F3 BIOS

After downloading the program, please press and hold F3 for one second and press Cancel to enter BIOS

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System update interface and burn the latest program into BIOS chip.

Return / Restart / OK /

Fig. 6.3.5 Upgrade completes

Return

At this moment, press [F3] to restart, press [Cancel] after one second to enter the interface shown in Fig.

6.6.1, or turn off the power supply, press and hold [Cancel] for several seconds, and connect the power supply to enter the interface shown in Fig. 6.6.1. Then, update the BIOS in the program burning method described in Chapter 6.6.

6.4 Connecting to PC and upgrading

In the main interface, press [F6] and then press [F5] to connect to PC:

Return /

Upgrade Interface

F1 System parameter reset (F1)

F2 U

F5

Reset / U USB disk /

(F2) Upgrade via USB disk

(F5) Upgrade via PC

Restart / PC / Help / Return

Fig. 6.5.1 Connecting to PC

Connect PC and the controller with a USB cable (shown below), press [F5] to connect to PC, and click “My

Computer” to show the controller on PC as a 256MB USB disk. Click “Mobile disk” and copy the latest software to folder “ADT” and overwrite original “2440TEST.BIN”. After that, turn off the power supply, press and hold

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

[Cancel] and connect the power to burn the latest program into BIOS chip. Refer to 6.6 for specific operation.

6.5 Burning program

After transmitting the latest software to the controller, you need to save the software in the BIOS of the controller, making the controller be able to execute the latest software. Operation procedure: turn off the controller, press and hold [Cancel] on the panel and connect the power to have the interface below:

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Current date: January 13, 2006; Current time: 11:00:00

0 – System setting 0----

1 – BIOS setting 1----BIOS

2 – USB disk setting 2---U

3 – System self test 3---

4 – Start mode 4---

5 – LCD selection 5---

6 – Language 6---

Press number keys to perform operations, press [ESC] to return ESC

6.6.1 BIOS Password Interface

Press [1] to enter BIOS setting interface:

Current date: January 13, 2006; Current time: 11:00:00

Please select the section to update:

0---BIOS 0 – BIOS section

1--1 – Program section

2-----16

3---24

2 – 16-dot matrix section

3 – 24-dot matrix section

ESC Press number keys to perform operations, press [ESC] to return

6.6.2 BIOS Setting Interface

Press [1] to select “1. Program section” and press [OK]; the system asks “Confirm to write-in? [y/n]”. Press [y]

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System and the system will find the file to update, and prompt “NAND Flash programming completes” after that. Please cut off the power supply and restart the controller.

After updating the program, check whether the start mode is “Normal”, as shown below:

Current date: January 13, 2006;

0— 0 – Normal

Current time: 11:00:00

1---U 1 – USB

Current start mode: Normal

ESC Press number keys to perform operations, press [ESC] to return

6.6.3 Start mode

If current start mode isn’t “Normal”, please press [0] to switch to “Normal”.

6.6 BIOS interface connecting to PC and upgrading

In PC, decompress the program file.

Connect PC to the control system with the cable.

Operation procedure: turn off the power supply first, press and hold [Cancel] on the panel and connect the power supply, as shown below:

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Current date: January 13, 2006;

0----

Current time: 11:00:00

0 – System setting

1---BIOS

2---U

1 – BIOS setting

2 – USB disk setting

3----

4----

3 – System self test

4 – Start mode

ESC

5---5 – LCD selection

6 – Language 6---

Press number keys to perform operations, press [ESC] to return

6.6.4 BIOS Password Interface

In above interface, press [2] to enter USB disk setting interface:

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Current date: January 13, 2006;

0----USB

Current time: 11:00:00

0 – USB communication

1----

2---U

U 1 – Format USB disk

2 – Copy data in USB disk

3----

(ESC)

YAFFS2 3 – Format YAFFS2 section

Press number keys to perform operations, press [ESC] to return

6.6.5 BIOS USB Disk Interface

Press [0] to select USB communication, the prompt will prompt “USB transmitting……”

Please find the control system in the connected PC. The control system is indicated by a disk symbol in PC as

USB disk.

Please copy the decompressed folders “ADT”, “PRG” and “HELP” (to copy English, please rename help to help), and then copy them to the control system, and press [Cancel] to exit the communication connection.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Current date: January 13, 2006; Current time: 11:00:00

Please select the section to update:

0----BIOS 0 – BIOS section

1--1 – Program section

2----16

3----24

2 – 16-dot matrix section

3 – 24-dot matrix section

ESC Press number keys to perform operations, press [ESC] to return

6.6.6 Entering setting interface of BIOS

Press [Y+], [Y-] to move cursor to “B. BIOS setting” and press [OK]. Then, press [X+], [X-] to move cursor to “2. Update program” and press [OK]. When the system prompts “Confirm to update? Y/N”, please press [OK].

The system will prompt that file is found and updating, and prompts “update completes; please restart the machine” after updating; please cut off the power supply and then restart the controller.

7. Help system

To help you to operate the system, we provide the help system:

1) In the main interface, press [INS] to activate the help system of current interface, which provides basic operation instructions and prompts.

2) In the upgrade interface, press [F6] to enter the help system, as shown in Fig. 7.1. With this help system, you can look for basic help topics by entering desired content and pressing [F5]. The system will highlight the first item; if you don’t enter the content for search, the system will show

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System the entire help file.

Note: The help involves G code, M code and commonly used instructions that are easily to be forgotten.

3) Press [pgup ] [pgdn ] to turn pages, and press [ ] or [ ] to exit the help system and return to current interface.

Input method: 123

Please type the content to search:

Return Return / Search /

Fig. 7.1 Help System

8. Using different languages

1. ADTLIB graphics library: The default ADTLIB folder already contains Chinese and English graphics library.

2. Help file only supports ANSI language.

3. Please rename the LOGO picture to LOGOC.BMP in Chinese format, and rename to LOGO.BMP in other languages.

4. Multi-languages in HC4500 system: (default: Chinese and English)

Please follow the CONFIG2.INI, CONFIG3. INI files and the instructions provided by us or translated by customers and import the configuration file into the ADT directory of the controller. The files named

CONFIG2.INI and CONFIG3.INI in the directory are configuration files in other languages required by

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System customers.

When selecting languages in parameter configuration interface, if the required language isn’t in the ADT folder or the folder is empty, the controller will be in Chinese by default.

Notes for HC4500 language configuration file translation:

1. Please copy the configuration file, and open the copied file with Notepad;

2. If it is in Chinese and one character is two bytes, please name it to config2.ini,

If it is English and one character is one byte, please name it to config3.INI.

3. Please translate the content following '=' in the configuration file to Chinese, and keep others unchanged.

Note:

1. Character ';' is the end of configuration, and followed by note;

2. The '=' symbol shouldn’t exist in notes and configuration values;

3. Do not change the parameter sequence in every interface, and do not use '[]' in notes;

4. To add new parameters, please add to the end of the interface;

5. Due to the small screen of the controller, please control the character quantity when translating the parameters;

6. Please keep the content in '[]' unchanged;

7. If the equal mark isn’t followed by any content, which is preserved length of previous line, you can write the excessive part of previous line after translated.

For example: (Chinese info)

[1]=Adtech (Shenzhen) CNC Technology Co., Ltd.; (

≤

60 Byte)

[2]=;

[3]= …;

After translated:

[1]=ADTECH CNC TECHNOLOGY;

[2]= CO., LTD (SHENZHEN);

[3]= …;

5. If you have any question, please refer to the translation document or contact the supplier.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Chapter IV: Instruction Programming System

1. Description of programming symbols

Every motion of the CNC processing follows specified procedure, every processing program consists of several instructions, every instruction consists of several function words, and every function word is started with letter and followed by parameter value.

Definition of function words:

G Preparation function

M Auxiliary function

L Cycle times or delay time

X X axis coordinates: relative coordinates under G91 (default), absolute coordinates under G90

Y Y axis coordinates: relative coordinates under G91 (default), absolute coordinates under G90

I When processing arc, circle center coordinates minus X axis start value

J When processing arc, circle center coordinates minus Y axis start value

R Arc radius

2. Description of coordinates

2.1 Relative coordinates

In the coordinates system, if the position of current coordinates is calculated from previous coordinates’ position, it is called as relative coordinates, as in the figure below:

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

B

C

D

A

Fig. 2.1

As in the figure above, if calculated with relative coordinates, the coordinates of the entire graphics will be:

1. A is the origin, and the coordinates are X0, Y0;

2. B relative to A: X50, Y50;

3. C relative to B: X50, Y50;

4. D relative to C: Y-50;

5. D relative to B: X-50;

2.2 Absolute coordinates

In the coordinates system, if the position of current coordinates is calculated from origin coordinates’ position, it is called as absolute coordinates; as in Fig. 2.1 the coordinates of entire graphics calculated absolute coordinates will be:

1.

A is the origin, and the coordinates are X0, Y0;

2.

B relative to A: X50, Y50;

3.

C relative to A: X100, Y100;

4.

D relative to A: X100, Y50;

5.

D relative to B: X50, Y50;

3. G instruction description

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

3.1. G92 reference point setting

When setting program running, the coordinates of processing start (reference point) must be put at the start of the program.

Format: G92 X0 Y0

If G92 isn’t followed by X, Y, the current coordinates of X, Y will be the reference point. Generally, if the origin of machine tool is used for positioning, G92 won’t be followed by X, Y.

3.2. G21/G20 metric/imperial system setting

Set the length unit (default: metric) of program processing

G20: imperial (unit: inch)

G21: metric (unit: mm)

Format: G21

This instruction sets the length unit (mm) of processing. It is usually written in the second line of the program

(unless temporary change is required), i.e. next line of G92. The instruction isn’t followed by any content, and will persist until next G20 or G21.

3.3. G00 space shift

This instruction can return the torch to specified position quickly, and the system moves from start to end in linear.

The processing is at run idle speed, i.e. maximum manual speed, and isn’t controlled by percentage.

Format: G00 Xn Yn

For example: G92 X0 Y0

G00 X75 Y75

M02

Current position of torch

Expected position of torch

3.4. G01 straight line cutting

This instruction can feed the torch to specified position in linear and single axis or two axes linear interpolation is allowed as cutting instruction.

Format: G01 Xn Yn

For example:

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

G92 X0 Y0

G00 X100 Y50

G01 X30 Y90

M02

Current position of torch

Expected position of torch

3.5. G02/G03 arc cutting

This instruction is used to cut a circle or arc, while circles include G02 (clockwise) and G03 (counterclockwise)

Format: G02 [03] In

For example (G02):

G92 X0 Y0

G00 X55 Y55

G02 I35

M02

For example (G03):

G92 X0 Y0

G00 X55 Y55

G03 I35

M02

Current position of torch

Expected position of torch

Note:

I and J are the increment of circle center relative to the start in X, Y axes direction. To simplify the manual programming of processing file, type I50 directly to program a circle with 100MM diameter; type I75 directly to program a circle with 150MM diameter.

3.6. G04 pause/delay instruction

This instruction is used to set the delay. When executing this instruction, the program delays the time (unit: sec) specified by L.

Format: G04 Ln

For example: G04 L3.6 (delay: 3.6sec).

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

If G04 isn’t followed by Ln, the system will be delayed without day after executing G04 until you press [Start] to stop the delay.

3.7. G26, G27, G28 returning to reference point

This instruction can return the torch to reference point automatically. The processing is at run idle speed, i.e. maximum manual speed, and isn’t controlled by percentage.

Format:

G26 X axis returns to reference point

G27 Y axis returns to reference point

G28 X and Y axes return to reference point

For example: G28 (X, Y axes return to reference point at the same time, which is like G00)

3.8. G22/G80 circular processing

This instruction is used for cycle processing, and G22 is the start of cycle and specifies cycle times L. G80 is the end of cycle. G22 and latest G80 downwards constitute a cycle.

Format: G22 Ln_ (L specified cycle times)

Cycle

G80 (cycle ends)

For example: 0000 G92 X100 Y100

0001: G22 L10000 ——cycle starts

0002: G00 X50 Y50

0003: G01 X80 Y80

0004: G80 ——cycle ends

0005: M02

3.9. G81 workpiece counting

This instruction is the total workpieces memorized and processed by the system automatically.

Format: G81

For example: 0000 G92 X0 Y0

0001: G22 L3——cycle starts

0002: G01 X50 Y50

0003: G81——Count

0004: G80——cycle ends

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

0005: M02

3.10. G91/G90 relative/absolute coordinate programming

Relative coordinates under G91 (default), absolute coordinates under G90

Format: G91

G01 X100

---

3.11. G41/G42/G40

Set the slot compensation, which is set before steel plate perforating and cutting, and canceled by M08 instruction

G41 Left compensation

G42 Right compensation

G40 Cancel compensation

4. Common M instructions

1) Commonest M instructions:

The user only needs to be familiar with the function of M07, M08 and M02. M07 is the fixed cycle of preheating perforating; after track processing and executing M08, the system will turn off related air valve, and M02 processing ends finally. The specific code functions follow

M07 Fixed cycle of preheating perforating; the operation procedure follows:

Flame:

1.

Ethyne valve open M10;

2.

Ignition open M20;

3.

Torch down M16;

4.

Preheating valve opens, starts preheating M24;

5.

Perforating torch up M14;

6.

Cutting oxygen valve open M12;

7.

Perforating torch down M16;

8.

Perforating action completes, performs next action

Plasma:

A. When height adjustment system is on:

1. Enable height adjustment (corner) M22

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

2. Start arc M12

3. Wait for arc voltage test signal (IN0)

When arc starts, the height adjuster initializes the positioning automatically (height adjuster with initial positioning, which is disabled in parameters); perforates, delays, and sends a successful arc voltage test signal to the controller. The control system starts next action when detects the arc voltage signal.

B. When height adjustment system and initial positioning are disabled:

1. Start arc, start arc delay M12

2. Perforating, perforating delay

3. Torch down

3. Start cutting

M08 Turn off fixed cutting cycle, and the operation sequence follows:

Flame:

1.

Turn off cutting oxygen valve;

2.

Torch up

Plasma:

1. Turn off arc M13

2. Turn off height control M23 (torch up if height control and initial positioning are not enabled)

M02 Program end instruction

2) Other M instructions:

M10/M11 Ethyne valve switch, M10 (ON), M11 (OFF)

M12/M13 Cutting oxygen valve switch, M12 (ON), M13 (OFF)

M14/M15 Torch up switch, M14 (ON), M15 (OFF)

M20/M21 Ignition switch, M20 (ON), M21 (OFF)

M24/M25 Preheating oxygen valve switch, M24 (ON), M25 (OFF)

M52 Fixed ignition cycle (controlled by time in “Control” interface)

M70 Fixed torch up cycle (controlled by time in “Control” interface)

M71 Fixed torch down cycle (controlled by time in “Control” interface)

M72 Fixed perforating torch up cycle (controlled by time in “Control” interface)

M73 Fixed perforating torch down cycle (controlled by time in “Control” interface)

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

M74 Fixed preheating cycle (controlled by time in “Control” interface)

M80 General switch; all outputs will be turned off after performing M80

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1. Dimensions

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Chapter V: Hardware

Fig. 1.1 Front Appearance Dimensions

Fig. 2.1 Side Appearance Dimensions

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

USB

Digital output

Motor

Digital input

USB communication / Serial port

Fig. 2.1 Rear Appearance Dimensions

Note: The length above is in “mm”;

2. System I/O connection

2.1 Rear cover view

Digital output

Motor

- 105 -

USB

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Digital input

USB communication / Serial port

2.2 Electrical specifications

Switching quantity input

Channel: 32, all optic coupling isolation

Input voltage: 12-24V DC

High level>4.5V

Low level<1.0V

Isolation voltage: 2500V DC

Count input:

Channel: main axis ABZ phase code input, all optic coupling isolation

Maximum counting frequency: 2MHz

Input voltage: 5-24V DC

High level >4.5V

Low level <1.0V

Isolation voltage: 2500V DC

Pulse output:

Channel: 3 pulses, 3 directions, all optic coupling isolation

Output type: 5V differential output

Output mode: pulse + direction or pulse + pulse

Switching quantity output:

Output Channel: 16, all optic coupling isolation

Output type: NPN collector open-circuit, 12-24V DC, maximum current: 100mA

RS-232 baud rate (bps):

1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

2.3 Electrical connection

2.2.1 Motor control interface——15-port socket (male)

XS3

1

9

2

10

3

11

4

12

5

13

6

14

7

15

8

XDR+

XDR-

XPU+

XPU-

YDR+

YDR-

YPU+

YPU-

ZDR+

ZDR-

ZPU+

ZPU-

PU_COM

5V-

5V-

5

13

6

14

7

Wire No. D e f i n i t i o n

1 XDR+ X direction signal +

9

2

10

XDR-

XPU+

XPU-

X direction signal -

X pulse signal +

X pulse signal -

3

11

4

12

YDR+

YDR-

YPU+

YPU-

Y direction signal +

Y direction signal -

Y pulse signal +

Y pulse signal -

15

F u n c t i o n

ZDR+

ZDR-

ZPU+

Z direction signal +

Z direction signal -

Z pulse signal +

ZPU- Z pulse signal -

PU_COM Positive end of internal 5V power supply; can’t connect to external power supply

(used for signal end input drive)

5V- Negative end of internal 5V power supply; can’t connect to external power

- 107 -

8 5V- supply

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Negative end of internal 5V power supply; can’t connect to external power supply

Wiring mode of pulse output signal:

Æ

Differential mode:

This mode is recommended for step drives with independent pulse and direction input and most servo drives to get better anti-interference.

Step motor drive

Servo motor drive

Æ

Single end mode:

Suitable for step drives that pulse is connected to anode of direction

Step motor drive

Note: Not suitable for step drives that pulse is connected to cathode of direction

PU_COM and 5V- are specially designed for step drives or servo drives whose control signals are not differential.

The drives are connected in common anode or common cathode. If the control signals of the drive are connected

- 108 -

ADT-HC4500 Flame/Plasma Cutting Machine CNC System in differential mode, PU_COM and 5V- do not need to be connected.

Please note that PU_COM shouldn’t be used for any other purpose except non-differential connection of drive pulse, or else the controller may be damaged.

Note: Neither two of PU+, PU-, DR+ and DR- can be connected, or else the pulse interface will be damaged.

2.2.2 Output control interface——25-port socket (male)

Wire No. Definition Function

Arc voltage signal test (AVT) (connect only when arc voltage should be tested during

1 IN0 plasma cutting)

Original positioning signal test (ORI) (as Z axis negative limit signal during step

2 IN1 height adjustment of X axis)

Manual/auto switch (reserved) (HAD) (as Z axis negative limit signal during step

3 IN2 height adjustment of X axis)

4 IN3 External pause key (PAU)

5 IN4 External hand control box X – positive control (X+)

6

7

8

9

10

IN5

IN6

IN7

IN8

IN9

External hand control box Y – positive control (Y+)

External hand control box acceleration key (SP+)

External hand control box torch up control key (UP)

X axis positive limit (>X+)

X axis negative limit (X-<)

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

14

15

16

17

18

19

20

21

IN10

IN11

IN12

IN13

IN14

IN15

IN16

IN17

Y axis positive limit (>Y+)

Y axis negative limit (Y-<)

External emergency stop key (STP)

External start key (STA)

External hand control box X – positive control (X-)

External hand control box Y – positive control (Y-)

External hand control box deceleration key (SP-)

External hand control box torch down control key (DOW)

Wiring mode of input signal:

Optical coupling input

DICOM terminal is connected to positive end of internal power supply, and the input signal is connected to respective terminal.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

2.2.3 Output control interface——25-port socket (female)

Wire No. D e f i n i t i o n

1 OUT0

F u n c t i o n

Flame cutting ethyne valve control, M10 (ON), M11 (OFF)

2

3

OUT1

OUT2

Torch up control, M14 (ON), M15 (OFF)

Flame cutting ignition control, M20 (ON), M21 (OFF)

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Wiring mode of output signal:

The output is collector open circuit. If the external load is inductance load, e.g. relay, a freewheeling diode should be connected, as shown below:

EXTCOM or DOUTnGND

EXTCOM terminal is connected to negative end of internal power supply, and output signal is connected to respective terminal.

The power voltage should be lower than 24V and shouldn’t exceed 30V. Do not connect the anode and cathode reversely or short circuit the load, or else the module will be damaged.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

2.2.4 Serial communication interface—— 9-port socket (male)

XS9

1

6

2

7

3

8

4

9

5

Wire No. D e f i n i t i o n

NC

NC

TXD

NC

RXD

NC

NC

NC

GND

F u n c t i o n

2

3

T X D

R X D

Tr a n s mi t d a t a ( d e d i c a t e d f o r s o f t w a r e e n g i n e e r )

R e c e i v e d a t a ( d e d i c a t e d f o r s o f t w a r e e n g i n e e r )

Wiring mode of communication signal:

Controller

RS-232

PC

RS-232 communication mode

Note: IN20 panel — stop; IN21 panel — start

IN22 null; IN23 null

- 113 -

2.2.5 Power connection of SX8

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

2.2.6 Standard USB interface of SX11

3. Motor connection

3.1 Differential drive connection

The following diagram is the controller connected to ADT Q2BYG404MA drive:

Q2BYG404MA drive

Controller XS3 plug

XS3

1

9

2

10

3

11

4

12

5

13

6

14

7

15

8

XDR+

XDR-

XPU+

XPU-

YDR+

YDR-

YPU+

YPU-

ZDR+

ZDR-

ZPU+

ZPU-

PU_COM

5V-

5V-

+

PU

+

DR

+

MF

V+

V-

AC

BC

A+

The following diagram is ADT Q2BYG404MA drive connected to 56BYGH630C step motor

- 114 -

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Q2BYG404MA drive

+

PU

+

DR

+

MF

V+

V-

AC

BC

A+

A-

B+

B-

Wh

Blac

Red

Gre

Blue

Yell

5V motor locked

DC power

18-40V

DC power

56BYGH630C

Step motor

The following diagram is ADT Q2BYG404MA drive connected to 56BYGH630EJP step motor

- 115 -

Q2BYG404MA drive

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

+

PU

+

DR

+

MF

V+

V-

AC

BC

A+

A-

B+

B-

Wh

Blac

Red

Oran

Coffee

Yell

5V motor locked

DC power

18-40V

DC power

56BYGH630EJP

Step motor

The following diagram is ADT Q2BYG404MA drive connected to 85BYGH830A step motor

- 116 -

+

PU

+

DR

+

MF

V+

V-

AC

BC

A+

A-

B+

B-

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Q2BYG404MA drive

5V motor locked

DC power

18-40V

DC power

Yellow/blue

Purple/brown

Red

Black

White

Green

85BYGH830A

Step motor

Remark:

1) Please adjust the drive subsections and current dip switch properly during operating. It is recommended to adjust the drive into 64 subsections, and adjust the current to 1.2 times of motor current.

2) The unlocked power supply after electrified 5V DC power supply. For 12V DC power, please connect a

1K resistor to MF pin in serial and the power is higher than 1/4W; for 24V DC power, please connect a

2K resistor to MF pin in serial and the power is higher than 1/4W.

3.2 Common anode drive connection

Controller XS3 plug

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

XS3

1

9

2

10

3

4

11

5

12

8

13

6

14

7

15

X axis drive

XDR+

XDR-

XPU+

XPU-

YDR+

YDR-

YPU+

YPU-

ZDR+

ZDR-

ZPU+

ZPU-

PU_COM

DIR+

CP+

OPTO

EN+

EN-

V+

V-

A+

5V-

A-

5V-

B+

B-

Step motor

Motor locked

DC power

DC power

- 118 -

3.3 Panasonic servo drive connection

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Controller XS3 plug

XS3

5

12

6

13

7

14

8

15

1

9

3

2

10

4

11

5V-

5V-

XDR+

XDR-

XPU+

XPU-

YDR+

YDR-

YPU+

YPU-

ZDR+

ZDR-

ZPU+

ZPU-

PU_COM

Servo motor

4. Installation and testing points

X axis drive

CN1/F5 SING1

CN1/F6 SING2

CN1/F3 SING1

CN1/F4 SING2

4.1 Requirement of CNC system on pulse equivalent

To improve the machine precision, please adjust the pulse equivalent of the CNC system to 0.004000—0.006000, as below:

1) If step motor is used, please adjust the subsections of the drive to desired value; the bigger the drive subsections, the lower pulse equivalent and the higher the precision. For example, if the step drive is divided into 32 subsections, the pulse equivalent is 0.008000; if divided into 64 subsections, the pulse equivalent is 0.004000, and the precision is improved for one time.

2) If servo motor is used, you can get desired value by adjusting the electronic gear ratio of the drive.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

3) However, if the pulse equivalent is too low, e.g. 0.001000, the processing speed of the system will be reduced although the precision is high. Therefore, low pulse equivalent isn’t recommended.

4.2 Current adjustment for the drive

Please adjust the current according to the driver manual of the manufacturer. If you use the step motor drive

Q2BYG404MA+56BYGH630C provided by Adtech, please adjust the drive current to 1.2 times of motor current.

4.3 Testing method of pulse equivalent

Please refer to Chapter II — Quick Guide —1. Parameter Settings — 1.5 Precision Setting (Page 18)

4.4 Measures for anti-interference

Please follow the method below to take the measures for anti-interference:

1) The PE end of 24V power input port of the CNC system, i.e. the grounding end, should be grounded.

Connect to earth wire of machine shell

2) A magnetic ring should be added to 24V power input wire of the CNC system, as shown below:

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Fig. 5.5.4

Note: Do not reel PE end i.e. earth wire into the magnetic ring.

3) A magnetic ring should be added to the end of X, Y axis signal output wire, as shown below:

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Chapter VI: Troubleshooting

1. Can’t read USB disk

A: Insert the USB disk into the controller, but the disk can’t be read. To solve this problem, you can modify the

“File system” of USB disk with computer and then format the disk. The specific operation: insert the USB disk into the computer open “My Computer” find mobile USB disk right click the mouse click “Format

(A)” change the format in “File system” from “FAT32” to “FAT” click “Start” to format the disk, copy the processing file to USB disk and then check whether the disk is readable; if not, please replace the USB disk.

The capacity of the USB disk shouldn’t exceed 2GB.

2. The cutting isn’t accurate

A: 1. Check whether the pulse equivalent in the precision is modified, or re-correct the pulse equivalent.

2. Check the level of the machine, and check whether the nozzle is vertical to the steel plate.

3. The cutting quality of corners is low

A: Please check whether the start speed and acceleration are set appropriately.

4. The cut square becomes rectangle

A: Please check whether the pulse equivalent is appropriate and whether the precision of X, Y axes during single axis motion is appropriate; if both are appropriate, please check whether the roller and rail of the machine are damaged.

5. The cut circle becomes ellipse

A: Please check whether the pulse equivalent is appropriate and whether the precision of X, Y axes during single axis motion is appropriate; if both are appropriate, please check whether the roller and rail of the machine are damaged.

6. The diagonal has wave jitter while cutting circle

A: Please adjust the reverse clearance in “Adjustment” of “Parameters”.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

7. The motor doesn’t work or is similar to crash in auto mode

A: Please check whether “Auto speed limit” is set to appropriate speed and whether the manual processing percentage is too low.

This will occur if the manual speed is set to 0.

8. The motor doesn’t work or is similar to crash in manual mode

A: Please check whether “Manual speed limit” is set to appropriate speed and whether the manual percentage is too low.

This will occur if the manual speed is set to 0.

9. The processing code has returning reference instruction, but doesn’t return after running

A: Please check whether “Manual speed limit” is set to appropriate speed and whether the manual percentage is too low.

10. The right angle of the cut square isn’t vertical

A: Re-adjust the start speed and acceleration in “Speed” of “Parameters”.

11. Plasma is poor in anti-interference

A: Check whether the grounding is proper or isolate the high frequency of external power supply filter.

12. Certain electromagnetic valve doesn’t work

A: Check whether the problem is caused by system damage, relay or electromagnetic valve damage in the methods below.

1) Replace with an electromagnetic valve of same specifications to check whether the electromagnetic valve is damaged, or press [Ignition][Preheating oxygen][Ethyne][Cutting oxygen] in the automatic processing interface to output a signal manually, and then check whether the input end of the electromagnetic valve has voltage signal with a multimeter.

2) If the input end of the electromagnetic valve doesn’t have voltage signal, open the case and check whether the input end of the relay has voltage signal in the same method to check whether the relay is intact.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

3) If the relay doesn’t have input voltage signal, the interior of output end of the CNC system is damaged.

Please replace the reversed output according to the procedure below.

4) Open the case, and then open the output ports, as shown below:

5) Find corresponding reserved output pins according to the table below:

Ignition 3

Preheating oxygen 17

7

18

Ethyne 1 5

14 19 Cutting oxygen/start arc

Torch up

Torch down

2

15

6

20

Corner speed ratio 4 8

(height adjustment)

6) Weld the pins in the figure below from default pins to reserved pins according to above wire connection.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

7) After installation, connect the power supply of the system, press [F5] (Diagnosis) [F2] (Define) in the start-up interface, press [Y ], [Y ] to select up/down, press [X ], [X ] to select the state, and then press Save to change corresponding port to reserved.

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Appendix 2: Example of Editing Processing Graphics

In the main interface, press [F3] to enter the edit interface, and then press [F1] to create a new processing file, enter the file name, press [OK] to enter file edit interface. Take cutting the figure below as an example (the dashed and arrows are the motion direction, the real line is the cutting track, and “ ” is the cutting start):

Remark: Absolute coordinates are not used commonly and won’t be introduced. The following example is relative coordinates.

1. Standard circle

The graphics program follows:

Relative coordinate programming and graphics code description:

0000: G 92 X 0 Y 0——Reference point setting;

0001: G22 L3——L indicates processing cycle setting; 3 indicates 3 cycles;

0002: G41——Left compensation

0003: M07——Preheating and perforating function. Prompt: Please set the time parameters in [Parameter] – [Control] properly;

0004: G 01 X 75 Y 75——Perforating lead;

0005: G 02 I 30 J 0——Clockwise circle processing;

0006: M08——Turn off cutting oxygen valve;

0007: G 00 X -75 Y-75——Space shift to the origin at top manual speed;

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2. Square

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

0007: G81——Counting instruction; the system counts once automatically every cycle;

0009: G40——Compensation ends

0010: G28——Return to reference point

0011: G80——Cycle ends;

0012: M02——Processing ends

Relative coordinate programming and graphics code description:

0000: G 92 X 0 0

0001: G41——Left compensation

0002: M07——Perforating action;

0003: G01 X50 Y50——Perforating lead;

0004: Y50——First edge; if the above instruction is G01, G01 and X0 of this instruction can be emitted to make the manual code editing convenient.

0005: X50——Second edge;

0006: Y-50——Third edge;

0007: X-50——Fourth edge;

0008: M08——Turn off cutting oxygen;

0009: G40——Compensation ends

0010: G28——Return to reference point at the top speed;

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3. Triangle

0011: M02——Processing ends

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Relative coordinate programming

0000: G 92 X 0 0

0001: G21

0002: G41

0003: M07

0004: G01 X50 Y50

0005: X50 Y50

0006: Y-50

0007: X-50

0008: G40

0009: M08

0010: G28

0011: M02

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4. Quincunx

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Relative coordinate programming

0000: G 92 X 0 0

0001: G21

0002: G41

0003: M07

0004: G00 X75 Y75

0005: G02 Y100 I0 J50

0006: X100 I50 J0

0007: Y-100 I0 J-50

0008: X-100 I-50 J0

0009: G40

0010: M08

0011: G28

0012: M02

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5. Four graphics

Relative coordinate programming

0000: G92X0Y0

0001: G21

0002: G22 L1

0003: G41

0004: M07

0005: G0 X50

0006: G1 Y200

0007: X200

0008: Y-200

0009: X-200

0010: M08

0011: G00 Y400

0012: M07

0013: G1 Y50

0014: G2 X50 Y50 I50 J0

0015: G1 X100

0016: G2 X50 Y-50 I0 J-50

0017: G1 Y-100

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

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0018: G2 X-50 Y-50 I-50 J0

ADT-HC4500 Flame/Plasma Cutting Machine CNC System

0019: G1 X-100

0020: G2 X-50 Y50 I0 J50

0021: G1 Y50

0022: M08

0023: G00 X400 Y50

0024: M07

0025: G2 X100 Y0 I50 J0

0026: Y-100 I0 J-50

0027: X-100 I-50 J0

0028: Y100 I0 J50

0029: G00 X-50 Y-350

0030: G2 X0 Y0 I100 J0

0031: M08

0032: G28

0033: G81

0034: G80

0035: M02

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Appendix 3: G Instruction Fact Sheet

1

3

G00

G02

Quick positioning (run idle)

Clockwise circle processing

8

9

10

6

7

12

G26

G27

G28

G22

G80

G40

X axis returns to reference point

Y axis returns to reference point

Both X axis and Y axis return to reference point

Cycle starts (must be used together with G80)

Cycle ends (must be used together with G80)

Cancel slot compensation

15 G92 Processing reference point setting

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ADT-HC4500 Flame/Plasma Cutting Machine CNC System

Appendix 4: M Instruction Fact Sheet

S/N Instruction name

1 M02 Program ends

2 M07

Description

Start fixed cycle of preheating perforating

3 M08

4 M10/M11

Turn off the fixed cycle of cutting oxygen (plasma arc)

Ethyne valve switch, M10 (ON), M11 (OFF)

5 M12/M13

6 M14/M15

7 M20/M21

8 M24/M25

9 M52

10 M70

11 M71

12 M72

13 M73

14 M74

15 M16

16 M80

Cutting oxygen valve switch (plasma arc switch), M12 (ON), M13

(OFF)

Torch up switch, M14 (ON), M15 (OFF)

Ignition switch, M20 (ON), M21 (OFF)

Preheating oxygen valve switch, M24 (ON), M25 (OFF)

Fixed ignition cycle (controlled by time in “Control” interface)

Fixed torch up cycle (controlled by time in “Control” interface)

Fixed torch down cycle (controlled by time in “Control” interface)

Fixed perforating torch up cycle (controlled by time in “Control” interface)

Fixed perforating torch down cycle (controlled by time in “Control” interface)

Fixed preheating cycle (controlled by time in “Control” interface)

Torch down switch, M16 (ON), M17 (OFF)

General switch,; all outputs will be turned off after performing M80

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