ICNC Technical Manual 2006 - Draft

All versions of the controls Document version 2.
TECHNICAL MANUAL
ProMotion® iCNC® 2006-09-06/JP/MW

All versions of the controls Document version 2.0
Contents
1. PROMOTION® ICNC® MECHANICAL DIMENSIONS .......................................5
2. INTERNAL KEY COMPONENTS ........................................................................1
2.1. INTERNAL POWER SUPPLY ........................................................................................................ 1
2.2. PC-INT CARD STACK..................................................................................................................... 2
2.3. FRONT PANEL PUSH BUTTON CARD ....................................................................................... 2
2.4. CPU BOARDS .................................................................................................................................... 2

2.4.1. CPU CONNECTIONS .................................................................................................................... 2
2.5. CONNECTIONS TO BOARDS........................................................................................................ 3

2.5.1. BASIC CONNECTIONS IN A STANDARD SYSTEM................................................................ 3
2.5.2. BASIC INTERNAL WIRING ........................................................................................................ 4
2.5.3. VARIOUS MACHINE INTERFACES........................................................................................... 5
3. PCB’S IN DETAIL................................................................................................6
3.1. MAIN CPU BOARD OPTIONS ....................................................................................................... 6
3.2. SECONDARY CPU BOARD.......................................................................................................... 10
3.3. PROCESSOR CARD (INNER CARD - CARD STACK) ............................................................ 12

3.3.1. J4 SIGNALS.................................................................................................................................. 12
3.3.2. JUMPERS ..................................................................................................................................... 12
3.3.2.1. Card Address, J1, Default Connections ............................................................................... 12
3.3.2.2. Clock Select for Counter, J2, Default Connection............................................................... 12
3.3.2.3. +12 V to Signals A+ and B+ (when closed), Default Open................................................. 12
3.3.3. LEDs.............................................................................................................................................. 13
3.4. D/A CARD (OUTER CARD – CARD STACK)............................................................................ 13

3.4.1. J1 SIGNALS.................................................................................................................................. 13
3.4.2. J6 SIGNALS.................................................................................................................................. 13
3.4.3. JUMPERS ..................................................................................................................................... 14
3.4.3.1. Bypass of 1 kΩ serial resistor in output (default closed) ..................................................... 14
3.4.3.2. Reference voltage, 3-2 internal(default), 2-1 external ......................................................... 14
3.4.3.3. Modification of output polarity (3-2 pos. (default), 2-1 negat.)........................................... 14
3.4.4. TRIMMERS .................................................................................................................................. 14
3.4.4.1. Zero Adjustment .................................................................................................................. 14
3.4.4.2. Maximum Output Voltage ................................................................................................... 14
3.4.5. LEDs.............................................................................................................................................. 14
3.5. FET CARD (CENTER CARD – CARD STACK) ........................................................................ 15

3.5.1. J2 SIGNALS.................................................................................................................................. 15
3.5.2. J3 SIGNALS.................................................................................................................................. 16
3.5.3. LEDs.............................................................................................................................................. 16

3.5.3.1. Output LEDs ........................................................................................................................ 16

3.5.3.2. Input LEDs........................................................................................................................... 16
3.6. FRONT PANEL CARD (PARA 2) ................................................................................................. 17

3.6.1. Connector J 11:.............................................................................................................................. 17
4. MACHINE INTERFACES...................................................................................18
4.1. CONNECTOR CARD ..................................................................................................................... 18

4.1.1. FJ2 SIGNALS ............................................................................................................................... 18
4.1.2. FJ3 SIGNALS ............................................................................................................................... 19
4.1.3. PJ4 SIGNALS ............................................................................................................................... 19
4.1.4. DJ1 SIGNALS (to D/A card) ........................................................................................................ 19
4.1.5. DJ6 SIGNALS (to D/A card) ........................................................................................................ 19
4.1.6. JX6 SIGNALS (for optional built-in servo amplifier) .................................................................. 19
4.1.7. JP1 SIGNALS (to enable switch).................................................................................................. 19
4.1.8. SWBYPAS JUMPER (to JP1 connector)...................................................................................... 20
4.1.9. OUTACTIVATE JUMPER (to JP1 connector) ............................................................................ 20
4.1.10. JP3 (normally not used) ............................................................................................................ 20
4.1.11. JP2 and (J11) SIGNALS (from switch card / relay card) ......................................................... 20
4.1.12. J10 (screw connector for ExtVin and EncVcc from optional built-in power sources) ............. 20
4.1.13. JPGND (normally left open)..................................................................................................... 20
4.1.14. RELAYBYPASS...................................................................................................................... 20
4.1.15. JPFIELD for selecting Drive Enable functioning..................................................................... 20
4.1.16. I/O CONNECTOR J4 (37 pin male AMP) ............................................................................... 21
4.1.16.1. Outputs................................................................................................................................. 22
4.1.16.2. Inputs ................................................................................................................................... 22
4.1.17. DRIVE CONNECTOR J5 (24 pin male AMP) ........................................................................ 23
4.1.18. ENCODER CONNECTORS J1, J2, J3 (9 pin male AMP) ...................................................... 24
4.1.18.1. Complementary Encoders (recommended) .......................................................................... 24
4.1.18.2. Single Ended Grounding Encoders ...................................................................................... 24
4.2. SMALL RELAY CARD .................................................................................................................. 25

4.2.1. J10 SIGNALS................................................................................................................................ 25
4.3. SINGLE PLASMA INTERFACE .................................................................................................. 26

4.3.1. I/O CONNECTOR J25 (37 pin female AMP)............................................................................... 27
4.3.2. J16 LIMITS / MOTION CONNECTOR....................................................................................... 28
4.3.3. OTHER CONNECTORS .............................................................................................................. 28
4.4. SIX STATION RELAY INTERFACE........................................................................................... 28

4.4.1. RELAY CARD CONNECTOR J9 (37 pin male AMP)............................................................... 30
4.5. FOUR GAS, TWO PLASMA AND ONE MARKER INTERFACE........................................... 31

4.5.1. PLASMA STATION CONNECTORS J25-Plasma 1 & J23-Plasma 2 (37
pin female AMP) ......................................................................................................................................... 33
4.5.2. OXY-FUEL STATION CONNECTORS J18, J19, J20 and J21 (37 pin female AMP) ...... 34
4.5.3. MAIN GAS SUPPLY CONNECTOR J17 (14 pin female AMP)............... 35
4.5.4. J16 LIMITS / MOTION CONNECTOR....................................................................................... 35
4.5.5. MARKER CONNECTOR J24 (9 pin female AMP) ................................................................... 35
4.5.6. OTHER CONNECTORS .............................................................................................................. 36
4.6. 8 STATION INTERFACE W. AUTOMATIC SPACING ........................................................... 36

4.6.1. MAIN GAS SUPPLY CONNECTOR J17 (14 pin female AMP)............... 39

4.6.2. J16 LIMITS CONNECTOR.......................................................................................................... 39

4.6.3. STATION #1 CONNECTOR J18 (37 pin female AMP).......................................................... 40
4.6.4. STATION CONNECTORS J19, J20, 21, 22, 23, and J24 (37 pin female AMP)................ 41
4.6.5. STATION #8 CONNECTOR J25 (37 pin female AMP)............................................................ 42
5. SUPPLY VOLTAGES , CONNECTORS AND WIRING GUIDANCE................. 43
5.1. SUPPLY VOLTAGES NEEDED.................................................................................................... 43

5.1.1. CONTROLLER POWER SUPPLY 115/230 VAC ...................................................................... 43
5.1.2. DC +/-15V SUPPLY FOR SERVO SPEED SIGNALS ............................................................... 43
5.1.3. DC +24 V SUPPLY FOR INTERNAL LOGIC............................................................................ 43
5.1.4. DC +5V SUPPLY FOR PULSE ENCODERS.............................................................................. 43
5.2. STANDARD DEVICE CONNECTORS ........................................................................................ 43
6. INSTALLING AND SETTING UP PROMOTION ICNC CONTROLLERS............1
6.1. CHECKING THE BASICS............................................................................................................... 1
6.2. MOTION............................................................................................................................................. 2
6.2.1. DRIVE CONFIGURATION ........................................................................................................... 2
6.2.2. SERVO DRIVE & ENCODER POLARITY .................................................................................. 3
6.2.3. ENCODER VALUES ..................................................................................................................... 4
6.2.4. DRIFT ADJUSTMENT AND SPEED OUTPUT VOLTAGES..................................................... 5
6.2.5. SPEED TESTS AND MOTION PARAMETERS .......................................................................... 7
6.3. SETTING THE PROGRAMMABLE I/O ..................................................................................... 11

6.3.1. INPUTS / OUTPUTS .................................................................................................................... 12
6.4. OTHER SETUPS ............................................................................................................................. 18
6.5. BACKING UP & RESTORING SYSTEM.................................................................................... 23
6.6. TESTING THE OUTPUTS AND INPUTS.................................................................................... 24
6.7. ROBOTIC PARAMETERS, C:\ROBO\PROG\ROBOPRM1.DAT........................................... 25

1. PROMOTION® iCNC® MECHANICAL

DIMENSIONS
400 mm
430 mm
497 mm
TOTAL WEIGHT ABOUT 35 kg
BOTTOM VIEW
4 x M6 Nuts welded inside.

430 mm
Center to center distances are:
Width = 345 mm
Depth = 320 mm
Dist. from back edge 21 mm

4-1
2. INTERNAL KEY COMPONENTS
2.1. INTERNAL POWER SUPPLY

All power to the system comes in through the Power Card. The card is available in two
versions, one for 100/115VAC and another for 230VAC main power input voltage. This card
delivers incoming AC-power to a standard PC-Power Source, as well as to other devices. It
also makes the internally needed 24VDC, +/-15VDC for speed signals and 5VDC for
encoders.
Screw connectors are:

J1 AC-IN J2 To Power Switch
J3 To PC-Power Source J4 To Emergency Stop Switch
J5 To Transformer J6, J7 Spare AC Outputs
8VAC AC-input to make 5VDC 15-0-15VAC AC-input to make +/- 15VDC
19VAC AC-input to make 24VDC
LEDs close to upper edge of the card indicate +5V, +/-15V and +24V existence.
LEDs close to the bottom edge of the card indicate the existence of +5V and +12V from the
PC-Power Source.

4-2
2.2. PC-INT CARD STACK

PC-INT card stack provides the interface between the machine control computer and
other electronics needed to operate the machine. It consists of 3 separate cards;
Processor Card, FET-Card and D/A-Card.
All three cards sit on the PC-104 bus of the second CPU. Processor Card reads the
pulse encoder inputs and communicates with the Front Panel Push Button Card; FET-
Card handles the digital inputs and outputs; D/A-Card gives the +/-10VDC speed
commands to drive servo amplifiers.
2.3. FRONT PANEL PUSH BUTTON CARD

Front panel push buttons, indicator lights and Speed Potentiometer are on this card.
Additionally, it handles the 6 station select outputs.
2.4. CPU BOARDS
2.4.1. CPU CONNECTIONS
MAIN CPU BOARD

Com 2
Com 1 FLAT PANEL SCREEN
SECOND CPU BOARD USB-PORT
HARD DRIVE
OPTIONAL FLOPPY DRIVE

PC-INT CARDS
KEYBOARD
MOUSE
DIFFERENT ETHERNET CONNECTOR

MACHINE
INTERFACE OPTIONAL second USB-PORT
OPTIONS

4-3
2.5. CONNECTIONS TO BOARDS
2.5.1. BASIC CONNECTIONS IN A STANDARD SYSTEM
MAIN SECOND PROCESSOR D/A FET

CPU BOARD CPU BOARD CARD CARD CARD
COM2
PC 104
COM1
J3 J9 J9 J1
J 13 J4 J1 J6 J2 J3
PC POWER
J 14 J 13 PJ 4 DJ 1 DJ 6 FJ 2 FJ 3
FRONT PANEL CARD
MACHINE INTERFACE
J 11
JOYSTICK JP 2
SPEED POT.

4-4
2.5.2. BASIC INTERNAL WIRING

4-5
2.5.3. VARIOUS MACHINE INTERFACES
ProMotion Controllers may be equipped with many different machine interfaces.
CONNECTOR CARD provides industrial grade connectors to connect the PC-INT

Card stack signals to external electronics. This is the simplest machine interface
available.
RELAYS AND SWITCHES can be added to the system in various versions. There are
interface packages for: Single plasma cutting machines; 4-oxy 2-plasma 1-marker; 6
oxy and 8 oxy torch combination machines, and even systems with automatic torch
spacing capability. Details of these interfaces are contained in separate documents.
BUILT IN AC AND DC SERVO SYSTEMS are also available in both 2- and 3-axis
configurations. DC-servo systems are 6 Amp continuous / 12 Amp peak, and can be
configured for 70, 30 and 20 VDC Buss voltages. Digital AC Servo Amplifiers provide
more than 1kW power for each axis. Details of these are contained in separate
documents.

4-6
3. PCB’S IN DETAIL
3.1. MAIN CPU BOARD OPTIONS

GX1LCD/PLUS 300 MHz
786 LCD/S Intel Pentium® III 700 MHz

4-7
886LCD-M/mlTX 1.3 GHz

4-8
HS-862VXL 533 MHz

4-9
LV-675 w. M-processor 1.3 GHz

4-10
3.2. SECONDARY CPU BOARD
GX1LCD 300/200 MHz

4-11
HS-862VXL 533 MHz

4-12
3.3. PROCESSOR CARD (INNER CARD - CARD STACK)
J4 TO BACK WALL
CONNECTOR
CARD PJ4
(ENCODERS)
3.3.1. J4 SIGNALS
1. +EncVccX 7. Y2EncA+ 13. Y1EncA+
2. EncGNDX 8. Y2EncA- 14. EncGNDY
3. XencA+ 9. Y2EncB+ 15. +EncVccY
4. XencA- 10. Y1EncB- 16. Y2EncB-
5. XencB+ 11. Y1EncB+
6. XencB- 12. Y1EncA-
3.3.2. JUMPERS
3.3.2.1.Card Address, J1, Default Connections

1,2,3,4,5 closed 6,7 open 8 not connected
3.3.2.2.Clock Select for Counter, J2, Default Connection

1-2 closed
3.3.2.3.+12 V to Signals A+ and B+ (when closed), Default Open

X/A+ and X/B+ Y1/A+ and Y1/B+ Y2/A+ and Y2/B+
J15/J14 J16/17 J5/J6

4-13
3.3.3. LEDs
D1 (red) +12V supply for x encoder is on (JP6/JP7 back wall connector)
D6 (red) +12V supply for y encoders is on (JP4/JP5 back wall connector)
D2 and D3 (green) Functioning of encoder channel A and channel B of x channel
D4 and D5 (green) Functioning of encoder channel A and channel B of y1 channel
D7 and D8 (green) Functioning of encoder channel A and channel B of y2 channel
3.4. D/A CARD (OUTER CARD – CARD STACK)
J6 TO BACK WALL
CONNECTOR
CARD DJ6
(DRIVE SIGNALS)
J1 TO BACK WALL
CONNECTOR
CARD DJ1
(±15 VDC SUPPLY)
3.4.1. J1 SIGNALS
1. +15Vinput 5. SysOn+ 9. –15Vinput
2. AGND 6. SysOn- 10. AGND
3. –15Vinput 7. +15Vinput
4. AGND 8. AGND
3.4.2. J6 SIGNALS
1. XextRef 5. AGND 9. Y1SpeedOut
2. Y2ExtRef 6. Y2SpeedOut 10. Y2SpeedIn
3. XSpeedOut 7. Y1ExtRef
4. XSpeedIn 8. Y1SpeedIn

4-14
3.4.3. JUMPERS
3.4.3.1.Bypass of 1 kΩ serial resistor in output (default closed)

X Y1 Y2
J7 J8 J10
3.4.3.2.Reference voltage, 3-2 internal(default), 2-1 external

X Y1 Y2
J2 J4 J11
3.4.3.3.Modification of output polarity (3-2 pos. (default), 2-1 negat.)

X Y1 Y2
J3 J5 J12
3.4.4. TRIMMERS
3.4.4.1.Zero Adjustment
X Y1 Y2
Linearity TR3 TR6 TR9
Symmetry TR4 TR7 TR10
Zero TR5 TR8 TR11
3.4.4.2.Maximum Output Voltage

X Y1 Y2
TR1 TR2 TR12
3.4.5. LEDs
D1 (red) +15 V supply OK
D2 (green) -15 V supply OK
D14 (red) System on
D17, D23, D27 (red) Positive output signal for X, Y1, Y2
D18, D24, D28 (green) Negative output signal for X, Y1, Y2
D7, D11, D31 (red) Positive reference voltage for X, Y1, Y2
D8, D12, D32 (green) Negative reference voltage for X, Y1, Y2

4-15
3.5. FET CARD (CENTER CARD – CARD STACK)
J2 TO BACK WALL
CONNECTOR
CARD FJ2
(OUTPUTS)
J3 TO BACK WALL
CONNECTOR
CARD FJ3
(INPUTS)
3.5.1. J2 SIGNALS
1. NC 12. NC 23. Out 05
2. Out 00 13. NC 24. Out 13
3. NC 14. Out 03 25. Out 06
4. NC 15. NC 26. Out 14
5. NC 16. Out 08 27. Out 07
6. Out 01 17. Out 09 28. Out 15
7. NC 18. Out 10 29. Ext GND
8. NC 19. NC 30. Ext GND
9. NC 20. Out 11 31. ExtVin
10. Out 02 21. Out 04 32. ExtVin
11. NC 22. Out 12 33/34. NC

4-16
3.5.2. J3 SIGNALS
1. In 00 8. In 07 15. +12V Out
2. In 01 9. In 08 16. ExtGND
3. In 02 10. In 09 17. In 14+
4. In 03 11. In 10 18. In 14-
5. In 04 12. In 11 19. In 15+
6. In 05 13. In 12 20. In 15-
7. In 06 14. In 13
3.5.3. LEDs
3.5.3.1.Output LEDs
Output 00 01 02 03 04 05 06 07
LED D35 D37 D39 D41 D43 D45 D47 D49
Output 08 09 10 11 12 13 14 15
LED D51 D60 D61 D62 D63 D64 D65 D66
3.5.3.2.Input LEDs
Input 00 01 02 03 04 05 06 07
LED D3 D4 D7 D8 D11 D12 D15 D16
Input 08 9 10 11 12 13 14 15
LED D19 D20 D23 D24 D27 D28 D31 D32

4-17
3.6. FRONT PANEL CARD (PARA 2)
J 14 PC POWER J 13 (SERIAL) TO PROCESSOR CARD
J11 TO JOYSTICK, SPEED POT. AND SWITCH CARD
There are two slightly different versions of this card. The picture above is the earlier
version, used with systems containing a separately mounted joystick. The newer
version integrates push buttons in place of the joystick. On this newer version, all push
button switches, lights and 4 directional “joystick” buttons are located on the same
card. This makes the card a little bit longer overall and forces the relocation of the J13
connector to the right hand side edge of the card, vertically mounted. These are the
only differences between both card versions.
3.6.1. Connector J 11:

JOYSTICK: Directions: Pins 1, 2, 3, 4 (all 5v) and pin 5 (gnd)
MOUSE: Aux1 pin 9 and 10 (gnd) Aux2 pin 12 and 11 (gnd)
SPEED POT. Pins 8 (+5v), 7 and 6 (gnd).
SWITCH CARD: Station select outputs 1-6: Pins 14, 15, 16, 17, 18, 19
+12V: Pins 13 and 20

4-18
4. MACHINE INTERFACES
4.1. CONNECTOR CARD

This card is used on controllers without internal servo drive systems.
The view shown is from ”inside the box”. Input/Output
Connector
J4
Drive
Connector
J5
Encoder
Connectors
J1, J2, J3
4.1.1. FJ2 SIGNALS

1. NC 12. Ext GND 23. Out 05
2. Out 00 13. NC 24. Out 13
3. NC 14. Out 03 25. Out 06
4. NC 15. NC 26. Out 14
5. NC 16. Out 08 27. Out 07
6. Out 01 17. Out 09 28. Out 15
7. NC 18. Out 10 29. Ext GND
8. NC 19. NC 30. Ext GND
9. NC 20. Out 11 31. ExtVin
10. Out 02 21. Out 04 32. ExtVin
11. Ext GND 22. Out 12 33/34. ExtVin

4-19
4.1.2. FJ3 SIGNALS

1. In 00 8. In 07 15. +12V Out
2. In 01 9. In 08 16. ExtGND
3. In 02 10. In 09 17. In 14+(XencZ+)
4. In 03 11. In 10 18. In 14-(XencZ-)
5. In 04 12. In 11 19. In 15+(Y1EncZ+)
6. In 05 13. In 12 20. In 15-(Y1EncZ-)
7. In 06 14. In 13
4.1.3. PJ4 SIGNALS

1. +EncVccX 7. Y2EncA+ 13. Y1EncA+
2. EncGNDX 8. Y2EncA- 14. EncGNDY
3. XencA+ 9. Y2EncB+ 15. +EncVccY
4. XencA- 10. Y1EncB- 16. Y2EncB-
5. XencB+ 11. Y1EncB+
6. XencB- 12. Y1EncA-
4.1.4. DJ1 SIGNALS (to D/A card)

1. +15V 5. Enable (drive relays) 9. –15V
2. AGND 6. ExtGND 10. AGND
3. –15V 7. +15V
4. AGND 8. AGND
4.1.5. DJ6 SIGNALS (to D/A card)

1. XExtRef 5. AGND 9. Y1SpeedOut
2. Y2ExtRef 6. Y2SpeedOut 10. Y2SpeedIn
3. XSpeedOut 7. Y1ExtRef
4. XSpeedIn 8. Y1SpeedIn
4.1.6. JX6 SIGNALS (for optional built-in servo amplifier)

1. XSpeedOut 5. AGND 9. Enable Com
2. Y1SpeedOut 6. +15V 10. Y2SpeedOut
3. Enable1 7. -15V
4. Enable2 8. AGND
4.1.7. JP1 SIGNALS (to enable switch)

1. +12V 2. Enable 3. Enable
4. Enable to D/A card relays
Switch must have 2 dry contacts to close pin 1 to 4 and pin 2 to 3.

4-20
4.1.8. SWBYPAS JUMPER (to JP1 connector)

Makes it possible to jumper JP1 pin 2 and pin 3 together on this card.
4.1.9. OUTACTIVATE JUMPER (to JP1 connector)

Makes it possible to jumper JP1 pin 1 and pin 4 together on this card.
4.1.10.JP3 (normally not used)

1. Y2EncZ+ 2. Y2EncZ-
4.1.11. JP2 and (J11) SIGNALS (from switch card / relay card)
1.(5) Select station 1 2.(6) Select station 2 3.(7) Select station 3
4.(8) Select station 4 5.(9) Select station 5 6.(10) Select station 6
4.1.12. J10 (screw connector for ExtVin and EncVcc from optional
built-in power sources)
1. EncVcc+ 2. ExtGND 3. ExtVcc+
4. ExtGND
4.1.13. JPGND (normally left open)

Makes it possible to jumper the encoder power GND to ExtGND.
4.1.14. RELAYBYPASS
Makes it possible to bypass the enable relay driven by software Out 14.
4.1.15. JPFIELD for selecting Drive Enable functioning

1. (top left) Connects to Enable Com in JX6 and J5 through the Enable relay
2. (bottom left) ExtGND
3. (top right) Connects to Enable switch connector JP1 pin 3 (enable com)
4. (bottom Right) Internal +12VDC
- Default setting is pins 1 and 3 (one jumper horizontally on top). If set

this way the enable is a dry contact between pins Enable Com and
Enable Hot in JX6 and J5 connectors.
- If setting is pins 1 and 2 together and 3 and 4 together (jumpers
vertically in left and right), Enable Com becomes ExtGND and
Enable Hot will be +12VDC in JX6 and J5 connectors.

4-21
4.1.16. I/O CONNECTOR J4 (37 pin male AMP)

J4 pin Name Default Function Remarks
1 Output 00 Close/Torch Station Lock Grounds any voltage
+5-24VDC to 21 Ext
GND
2 Output 01 Oxy/Cut On As above
3 Output 02 Gas/Preheat As above
4 Output 03 Gas/Torch Up As above
5 Output 04 Gas/Torch Down As above
6 Output 05 Gas/Preheat Ignition As above
7 Output 06 Marking As above
8 Output 07 IHS Start As above
9 Output 08 Select Plasma 2 As above
10 Output 09 Plasma/Cut On As above
11 Output 10 Spare As above
12 Output 11 Plasma/Torch Up As above
13 Output 12 Plasma/Torch Down As above
14 Output 13 Open/Torch Station Lock As above
15 Output 14 Drive Enable As above
16 Output 15 Torch Hold As above
17 Select 1 Station Select * No station select is
18 Select 2 Station Select * available if the relays
19 Select 3 Station Select * and switch option is
20 Select 4 Station Select * not installed
21 Ext GND External Ground From Power Card 24V
22 Ext Vin +24VDC From Power Card
23 Ext Enc Vcc+ Encoder power (+) Note JPGND position
on connector card
24 Input 00 +12VDC out of ExtVin if Becomes active when
not grounded outside grounded to 21 ExtGND
25 Input 01 As above
28 Input 04 Main Arc OK As above
29 Input 05 IHS Ready As above
32 Input 08 Torch Spacing Limit 1 As above
33 Input 09 Torch Spacing Limit 2 As above
34 Input 10 Torch is Down As above
35 Input 11 External Stop As above

4-22
4.1.16.1.Outputs
There is a total of 22 outputs: Out0…Out15, Select1...Select4, and Select5 and Select6 in J5.
Please note that none of the station select signals is available if the switch and relay option is
not installed.
Electrically the output circuit is a grounding circuit: the controller activates an output by
closing the circuit between the output line and external ground (21)
Voltage for OUT outputs can be

5...28 V DC, max 2 A.
Notes:
• Pins 21/22 give out the non-regulated supply voltage (24V DC) from the Power Card.
• Pin 21 (Ext. Gnd) is common for all I/O voltages and IN and OUT signals.
• Pin 23 can be used for supplying encoder power from an external source in case the
internally made 5V from the Power Card is not suitable. NOTE: When connecting this way,
the supply from the Power Card must be eliminated and the Encoder Ground must be
connected to ExtGND with the jumper JPGND on Connector Card. Voltages from 5 to 15
VDC can be used.
• Select Outputs are only available with optional Switch Card.
• When the controller is off all output circuits are open.
EXAMPLE OUTPUT 0 EXAMPLE INPUT 0

SUPPLY
5...28 VDC
+ -
J4/1 J4/24
RELAY
J4/21 J4/21
4.1.16.2.Inputs
There is a total of 14 inputs: In0...In13.
The inputs are used to provide information to the controller about the cutting process.
Most of them can be freely used for any purpose to interrupt delays, however some
inputs are fixed to a pre-selected function:
Input 8 Torch spacing limit 1
Input 9 Torch spacing limit 2
Input 11 External stop
Electrically the input circuit is a grounding circuit: the input is activated when the
circuit between the input line and ext. ground (21) is closed. The voltage on input lines
is +12V.

4-23
4.1.17.DRIVE CONNECTOR J5 (24 pin male AMP)

J5 Default Function Remarks
1 +15V From Power Card for speed outputs
2 AGND From Power Card for speed outputs
3 -15 V From Power Card for speed outputs
4 AGND Drive system reference GND
5 Enable Dry contacts for drive enable inside CNC
6 Enable Dry contacts for drive enable inside CNC
7 X out Speed signal to servo amplifier
8 X in From tracer, or jumper to AGND
10 X ext. Ref. Normally not used
12 Y1 out Speed signal to servo amplifier
13 Y1 in From tracer, or jumper to AGND
15 Y1 ext. Ref. Normally not used
17 Y2 out Speed signal to servo amplifier
18 Y2 in Normally jumper to AGND
20 Y2 ext. Ref. Normally not used
22 Select 5 Station select, grounds incoming 5-24VDC to
J4/21 Ext GND. SEE NOTE IN J4 CHART
23 Select 6 Station select, grounds incoming 5-24VDC to
J4/21 Ext GND. SEE NOTE IN J4 CHART
24 Not Used
The drive connector has lines for the external supply of +/- 12 or 15VDC and ground.
This supply is used for generating the control signals for servo system signals(x-signal
out, y1-signal out, y2-signal out), but normally these voltages are made internally.
The Y2 channel is used on larger machines to control the second servomotor in the
y-axis. This eliminates the need of any synchronizing mechanism (Digital Sync).
The Y2 channel can also be used for controlling the rotation of a beveling head
(optional software feature) however cannot control both Y2 (slave) and bevel head
simultaneously.
External reference voltages are used e.g. if the external servo amplifiers need AC
signals instead of DC for the speed signal.
If the controller is not on, or the enable switch is off, the speed inputs and outputs are
connected to each other (7+8, 12+13, 17+18). If the alternate (optical) drive system is
not used, add a jumper from pins 8,13,18 (X,Y1,Y2 In) to AGND.
This connector also contains outputs Select5 and Select6 which are available only with
the optional Switch Card / Relay Card.

4-24
4.1.18.ENCODER CONNECTORS J1, J2, J3 (9 pin male AMP)
Encoder voltage can vary from 5 to 15 VDC. By default the Power card provides a
floating voltage of 5V for the best noise immunity. If an external voltage is used,
jumper JPGND on the connector card must be set to connect the Encoder GND to
ExtGnd. In this case encoder supply voltage is connected either to Connector Card J10-
1 (+) J10-2 (-) inside the controller or to J4 connector pins 23 (+) and 21 (gnd) or
directly to any of J1/J2/J3 pins 1 and 2.
4.1.18.1.Complementary Encoders (recommended)

STANDARD CONNECTION, COMPLEMENTARY ENCODER
Ext. Vcc GND
A+
A-
B+
B-
(Z+)
(Z-)
4.1.18.2.Single Ended Grounding Encoders

If single ended grounding encoders are used, connect supply voltage to the A+,B+ (and
Z+) channels.
GND Vcc 5-15 V
VCC N/C 1
GND N/C 2
CHA+ 3
CHA- 4 A- (A+ N/C)
CHB+ 5
CHB- 6 B- (B+ N/C)
CHZ+ 7
CHZ- 8 Z- (Z+ N/C)
GND N/C 9

4-25
4.2. SMALL RELAY CARD

This relay card is used together with the Connector Card above. It provides dry
contacts for all the basic devices needed in an Oxy-Fuel / Plasma machine including a
marking device. There is also an optional Delay Piggy-Back Card capable of creating
4-step piercing for Oxy-Fuel. This card also includes a connector for the addition of
on/off/auto switches in the front panel for Low Preheat, High Preheat, Cutting Oxygen,
Ignition, IHS, Plasma and Marker. If the switches are not used, jumpers must be
installed to simulate these switches being in the Auto position
4.2.1. J10 SIGNALS

1. Plasma Start Supply 9. Marker 17. Ext Stop 1
2. Plasma Start 10. Hi Preheat 18. Ext Stop 2
3. Ign. Supply voltage 11. IHS 19. Main Arc 1
4. Ignition 12. Preheat supply 20. Main Arc 2
5. Cutting Oxygen Vent 13. NC 21. Cut Oxy Supply
6. Cutting Oxygen 14. Hold Supply 22. Cutting Oxygen 2
7. Low Preheat 15. Hold 23. Cutting Oxygen 3
8. Marker Supply 16. IHS Supply 24. Cutting Oxygen 4

4-26
4.3. SINGLE PLASMA INTERFACE

This interface card is used with built-in servo systems or with a separate J5 connector
card for external servo systems. This card also requires a Switch Card specifically
designed to work along with this interface to provide front panel switches for Drive
Enable, IHS Manual/Auto, Torch Up/Down, Floating Head and Plasma On/Off/Auto.

4-27
4.3.1. I/O CONNECTOR J25 (37 pin female AMP)

J4 pin Function Remarks
1 115 VAC line Out
2 115 VAC neutral Out
3 PE Ground Out
4 THD (Torch Height Disable/Hold) Signal Dry contact closure from CNC
5 Floating Head Down 115 VAC line Out
6 Floating Head Down 115 VAC neutral Out
7 Floating Head Down PE Ground Out
8 Not Used
9 THD (Torch Height Disable/Hold) Common Dry contact closure from CNC
10 Torch Down 115 VAC line Out
11 Torch Up/Down 115 VAC neutral Out
12 Torch Up/Down PE Ground Out (also note pin 16)
13 Collision Sense Input Common In
14 +24 VDC Supply max 2A Out
15 Plasma Enable Signal (NO contact in RL5) Dry contact closure from CNC
16 Torch Up 115 VAC line Out (also note pins 10-12)
17 IHS in Manual Mode Signal Out +24 VDC if front panel
switch is in manual position
18 Keying Pin
19 Keying Pin
20 User DC-Common for supply DC-Common Out
21 Collision Sense Input Signal In (needs NC contact to pin 13)
22 Plasma Enable Common (NO contact in RL5) Dry contact closure from CNC
23 +37 VDC Output max. 3.3A Out
24 37 VDC Common Out
25 Torch Up Sense Input Common Input
26 Torch Up Sense Input Signal Input
27 Spare Common ExtGND
28 Not Used
29 Plasma Enable Signal 24VDC Output
30 Plasma Enable Common signal in pin 29 Output
31 Not Used
32 Arc Transfer Input Signal Dry Contact Input from Plasma
33 Arc Transfer Input Common Input
34 +24 VDC Output Output
35 ExtGnd for 24 VDC Output in pin 34 Output
36 Torch Down Input Common Input
37 Torch Down Input Signal Dry Contact Input

4-28
4.3.2. J16 LIMITS / MOTION CONNECTOR

1. Limit Switch Input (In0). Actual signal to indicate Limit Switch trip. Fail-
safe NC or activated through limit switches placed in serial circuit.
2. Jumpers to pin 3 internally. Connect NC switch to pins 1 and 2.
3. Connect another NC switch to pins 3 and 4.
4. ExtGnd
5. Not Used
6. Not Used
7. Motion Vout (+24VDC in systems w. Built-in AC-amplifiers)
8. Motion GND
9. Not used
4.3.3. OTHER CONNECTORS

All connectors (FJ2, FJ3, PJ4, DJ1 and DJ6) for signals to PC-INT card stack are
identical to those with same names described in Chapter 4.1. Connector Card.
Additionally, the encoder connectors J1, J2 and J3 are also identical.
4.4. SIX STATION RELAY INTERFACE

This relay card is used together with the Connector Card (4.1.) above. It provides dry
contacts for all the basic devices needed in an Oxy-Fuel / Plasma machine including a
marking device. There is also an optional Delay Piggy-Back Card capable of creating
4-step piercing for Oxy-Fuel. This interface is used with external or built-in servo
systems. This card also requires Switch Cards specifically designed to work along with
this interface and to provide front panel switches.

4-29

4-30
4.4.1. RELAY CARD CONNECTOR J9

(37 pin male AMP)
J9 pin Name Explanation
1 Ext Vin OUT ONLY + 24 V DC max. 1A, same as J4/22
2 Gas Cut 1 on Relay Output
3 Gas Cut Supply Any voltage up to 230VAC or 24VDC
4 Vent Relay Output
5 Lo Preheat Supply Any voltage up to 230VAC or 24VDC
6 Lo Preheat Relay Output
7 Hi Preheat Supply Any voltage up to 230VAC or 24VDC
8 Hi Preheat Relay Output
9 Vent Supply Any voltage up to 230VAC or 24VDC
10 Plasma on Supply Any voltage up to 230VAC or 24VDC
11 Plasma on Relay Output
12 Ignition Relay Output
13 Ignition Supply Any voltage up to 230VAC or 24VDC
14 Torch 4 down Relay Output
15 Torch 5 up Relay Output
21 Torch 6 up (Plasma) Relay Output
23 Marking on Relay Output
24 Marking on Supply Any voltage up to 230VAC or 24VDC
27 Torch 6 down (Plasma) Relay Output
28 Torch up/down Common Any voltage up to 230VAC or 24VDC
29 Gas Cut 2 on, delayed by time 1 Relay Output
30 Gas cut 3 on, delayed by time 2 Relay Output
31 Gas Cut 4 on, delayed by time 3 Relay Output
32 Ext. Plasma up Command Drives relay in socket on relay card (default
relay coil is 110VAC)
33 Ext Plasma down Command Drives relay in socket on relay card
34 Ext Plasma up/down Common Drives relay in socket on relay card
35 Ext. GND for Ext Vin Same as J4/21
36 Not used
37 Not used
With pins 32 and 33 you can activate plasma up and plasma down signals with an
external device (e.g. AVC). The relays in sockets use a 110VAC coil as the default.
Additionally, jumpers JP1 and JP2 on the switch card are for connecting the plasma
up/down signals to torch 6 up/down.

4-31
4.5. FOUR GAS, TWO PLASMA AND ONE MARKER

INTERFACE
This interface is used with built-in servo systems or with a separate J5 connector card
for external servo systems. This card also requires Switch Cards specifically designed
to work along with this interface and to provide front panel switches.

4-32

4-33
4.5.1. PLASMA STATION CONNECTORS J25-

Plasma 1 & J23-Plasma 2 (37 pin female AMP)
Pin Function Remarks
1 115 VAC line Out
2 115 VAC neutral Out
3 PE Ground Out
4 THD (hold) Signal Dry contact closure from CNC
5 Floating Head Down 115 VAC line Out
6 Floating Head Down 115 VAC neutral Out
7 Floating Head Down PE Ground Out
8 Not Used
9 THD (hold) Common Dry contact closure from CNC
10 Torch Down 115 VAC line Out
11 Torch Up/Down 115 VAC neutral Out
12 Torch Up/Down PE Ground Out (note also pin 16)
13 Collision Sense Input Common In
14 +24 VDC Supply max 2A DC Supply Out (note pin 20)
15 Plasma Enable Signal (NO contact in RL104) Dry contact closure from CNC
16 Torch Up 115 VAC line Out (note also pins 10-12)
17 IHS in Manual Mode Signal Out +24 VDC if front panel
switch is in manual position
18 Keying Pin
19 Keying Pin
20 User DC-Common for supply DC-Common Out
21 Collision Sense Input Signal In (needs NC contact to pin 13)
Note: J23 must have a jumper
between pins 13 & 21 if only 1
plasma w. safety mount is in
use)
22 Plasma Enable Common (NO contact RL104) Dry contact closure from CNC
23 Not Used
24 Not Used
26 Not Used
28 Not Used
29 Plasma Enable Signal 24VDC Output
30 Plasma Enable Common for signal in pin 29 Output
31 Not Used
32 Arc Transfer Input Signal Dry Contact Input from Plasma
33 Arc Transfer Input Common Input
34 +24 VDC Output max. 2 A Output
35 ExtGnd for 24 VDC Output in pin 34 Output
36 Torch Down Input Common Input

4-34
37 Torch Down Input Signal Dry Contact Input
4.5.2. OXY-FUEL STATION CONNECTORS J18, J19, J20 and J21

(37 pin female AMP)
1 Torch Up Signal (NO dry contact to pin 35) Torch Up2 Output (DC-lifter)
2 Not Used
3 Not Used
4 Pulse Ignition 115VAC Line Output Line to Pulse Ignition Solenoid
5 Not Used
6 Not Used
7 Not Used
8 Ignition Fuel Solenoid 115AC Line Output Line to Std. Ignition Solenoid
9 Ignition Transformer 115AC Line Output Line to Ignition Transformer
10 Torch Up 115 VAC line Line Lifter Output Torch Up
11 Not Used
12 115 VAC Neutral Neutral to AC Torch Lifter
13 115 VAC Neutral Continuous 115VAC NEUTR.
14 115 VAC Neutral Neutral to Ignition Solenoid
15 115 VAC Neutral Neutral to PH Solenoid
16 115 VAC Line Continuous 115VAC LINE
17 PE GND PE GND to AC Torch Lifter
18 115 VAC Neutral Neutral to WS Solenoid
19 115 VAC Neutral Neutral to Ignition Transformer
20 115 VAC Neutral Neutral to Cut Oxygen Solenoid
21 PE GND PE GND to Ignition Solenoid
22 PE GND PE GND to PH Solenoid
23 Torch Down 115 VAC line Line Output Torch Down
24 PE GND Continuous 115VAC PE GND
25 PE GND PE GND to WS Solenoid
26 PE GND PE GND to Ignition Transformer
27 PE GND PE GND to Cut Oxy Solenoid
28 Preheat Local Solenoid Valve 115 VAC Line Line to PH Solenoid
29 Not Used
30 Not Used
31 Not Used
32 Not Used
33 Water Spray 115 VAC Line Output Line to WS Solenoid
34 Torch Down Signal (NO dry contact to pin 35) Torch Down2 Output (DC-lifter)
35 NO Relay Common for Up/Dowd (1 and 34) In any voltage within relay specs
36 Cut Oxygen Local Solenoid Valve 115 VAC Line to Cut Oxygen Solenoid
37 Not Used

4-35
4.5.3. MAIN GAS SUPPLY CONNECTOR J17

(14 pin female AMP)
3 115 VAC Line Low Preheat Line to LoPH Solenoid
5 115 VAC Neutral Neutral to LPH Solenoid
6 115 VAC Neutral to High Preheat Neutral to HiPH Solenoid
7 115 VAC Line to High Preheat Line to HiPH Solenoid
10 115 VAC Neutral to Ignition Neutral to Ignition System
11 115 VAC Line to Ignition Line to Ignition System
12 115 VAC Line to Cutting Oxygen Line to Cut Oxygen Solenoid
13 115 VAC Neutral to Cutting Oxygen Neutral to Cut Oxygen Solenoid
14 Not Used
4.5.4. J16 LIMITS / MOTION CONNECTOR

3. Connect an other NC switch to pins 3 and 4.
4. Jumpers to pin 5 internally.
6. ExtGnd
7. Motion Vout (+24VDC in systems w. Build-in AC-amplifiers)
8. Motion GND
9. Not used (Keying Pin)
4.5.5. MARKER CONNECTOR J24 (9 pin female AMP)

1 Not Used Keying Pin
2 115 VAC Line to Marker Down 115VAC Line to MD Solenoid
3 115 VAC Neutral to Marker Down 115VAC Neutr. to MD Solenoid
4 NO Dry Contact to Marker Device Marker Enable Signal
5 Common of NO Marker Relay Marker Enable Common
6 Marker Main Arc On Input (In4) from Marker NO Dry Contact in Marker Dev.
Device
7 Marker THD (Hold) Signal NO Dry Contact THD Signal to Marker
8 Marker THD (Hold) Common, Dry Contact THD Common to Marker
9 Marker Main Arc On Input Common (ExtGnd) NO Dry Contact in Marker Dev.

4-36
4.5.6. OTHER CONNECTORS

All connectors (FJ2, FJ3, PJ4, DJ1 and DJ6) for signals to PC-INT card stack are
identical to those with same names described in Chapter 4.1. Connector Card.
Additionally the encoder connectors J1, J2 and J3 are identical.
4.6. 8 STATION INTERFACE W. AUTOMATIC SPACING

This interface additionally supports one plasma and one marker device. It can be used
with built-in servo systems or with a separate J5 connector card for external servo
systems. This card also requires switch cards specifically designed to work along with
this interface and to provide front panel switches.
This interface can also be used without the Automatic Torch Spacing, in which case
there are no Clamping Switches or LEDs for clamping.

4-37
This picture shows the connector layout in an 8 torch system using external servo
drives (J5 connector). The same system is also available with built-in AC or DC servo
systems, 2 or 3 axis.

4-38
Both of these cards are installed to the controller back wall. The left-hand card in this
picture sits on top of the right-hand card. Short 10-pin ribbon cables on both sides of
the cards, combine them together electrically.

4-39
4.6.1. MAIN GAS SUPPLY CONNECTOR J17

(14 pin female AMP)
3 115 VAC Line Low Preheat Line to LoPH Solenoid
5 115 VAC Neutral Neutral to LPH Solenoid
6 115 VAC Neutral to High Preheat Neutral to HiPH Solenoid
7 115 VAC Line to High Preheat Line to HiPH Solenoid
10 115 VAC Neutral to Ignition Neutral to Ignition System
11 115 VAC Line to Ignition Line to Ignition System
12 115 VAC Line to Cutting Oxygen Line to Cut Oxygen Solenoid
13 115 VAC Neutral to Cutting Oxygen Neutral to Cut Oxygen Solenoid
14 115 VAC Line to Cut Oxygen Vent Line to Cut Oxy Vent Solenoid
4.6.2. J16 LIMITS CONNECTOR

4. Jumpers to pin 5 internally.
5. Connect an other NC switch to pins 5 and 6.
6. ExtGnd
7. Signal from NO Spacing Limit 1
8. Common for Spacing Limits 1 and 2 (ExtGND)
9. Signal from NO Spacing Limit 2

4-40
4.6.3. STATION #1 CONNECTOR J18 (37 pin female AMP)

2 Not Used
3 Not Used
5 Not Used
6 115 VAC Neutral Neutral Spare
7 115 VAC Neutral Neutral to Marker
8 Ignition Fuel Solenoid 115AC Line Output Line to std. Ignition Solenoid
11 PE GND PE GND Spare
29 Not Used
30 IHS ON Common, (NO dry contact to pin 31) IHS/AUTO HEIGHT ON com.
31 IHS ON Signal, (NO dry contact to pin 30) IHS/AUTO HEIGHT ON sig.
32 Not Used
33 Marker On 115 VAC Line Output Line to Marker 115VAC Relay
37 Not Used

4-41
4.6.4. STATION CONNECTORS J19, J20, 21, 22, 23, and J24
(37 pin female AMP)
2 Not Used
3 Not Used
5 Not Used
7 115 VAC Neutral Neutral to Clamp Solenoid
25 PE GND PE GND to Clamp Solenoid
29 Not Used
32 Not Used
33 Station Clamp 115 VAC Line Output Line to Clamp Solenoid
37 Not Used

4-42
4.6.5. STATION #8 CONNECTOR J25 (37 pin female AMP)

2 Plasma Signal #2 (NO dry contact to pin 5) Plasma Signal #2
3 Plasma Common #l (NO dry contact to pin 11) Plasma Common #1
5 Plasma Common #2 (NO dry contact to pin 2) Plasma Common #2
7 115 VAC Neutral Neutral to Clamp Solenoid
11 Plasma Signal #l (NO dry contact to pin 3) Plasma Signal #1
25 PE GND PE GND to Clamp Solenoid
29 Main Arc Sense Signal (In4) Main Arc Sense (NO contact in
plasma device, note pin 32)
32 Main Arc Sense Common (ExtGnd) Main Arc Sense (NO contact in
plasma device, note pin 29)
33 Station Clamp 115 VAC Line Output Line to Clamp Solenoid
37 +24 VDC Output 2A User Output +24V 2A

4-43
5. SUPPLY VOLTAGES , CONNECTORS

AND WIRING GUIDANCE
5.1. SUPPLY VOLTAGES NEEDED
5.1.1. CONTROLLER POWER SUPPLY 115/230 VAC

The controller needs either 115 VAC or 230 VAC (as ordered from the factory) to the
standard power inlet connector on the back wall. To change voltages, consult the
factory. Frequency can be 50 or 60Hz.
5.1.2. DC +/-15V SUPPLY FOR SERVO SPEED SIGNALS

The controller contains a built-in power source, making +/- 15V DC for the servo
speed signals. The actual +/- 10VDC speed signals are made on the D/A card out of
these voltages. The reference AGND for these voltages is not connected to chassis
ground inside the controller, instead the supply is floating for best noise immunity.
5.1.3. DC +24 V SUPPLY FOR INTERNAL LOGIC

24 VDC supply voltage for the internal logic is also floating and made internally on the
Power Card. DO NOT CONNECT the ExtGND to chassis ground without a very good
reason. This is especially important when using the Connector Card outputs for driving
external relays or other logics, since CE regulations do not accept a design where a
cable failure causing any of the signal cables to be grounded to chassis could activate
the external devices.
5.1.4. DC +5V SUPPLY FOR PULSE ENCODERS

5 VDC supply voltage for the encoders is also floating and made internally on the
Power Card. DO NOT CONNECT the EncGND to chassis ground without a very good
reason, otherwise encoder noise immunity may be compromised.
5.2. STANDARD DEVICE CONNECTORS

PS-2 Mouse Connector - for a standard mouse
PS-2 Keyboard Connector - for a standard keyboard
USB Device Connector - for a standard USB Memory Stick
RJ-45 Ethernet Connector - for a network cable

4-44
RS-232/422/485 Connector - for external serial devices like plasma and THC systems.
This port can also be used for transferring cutting programs (DNC), but we strongly
recommend using the network connection. (When using this connector for DNC, either
iLink or WinLink software needs to be installed on the Host PC. Consult factory for
additional information.)
Warning: DO NOT CONNECT the controller directly to a computer through the RJ45
or RS232 port! Connections must be made with fiber optic devices, wireless LAN,
short haul modems or other approved devices which provide galvanic isolation, due to
ground loops, electrical noise, or high frequency which can destroy electrical
components in the controller or host computer. Failure to follow these rules will VOID
THE WARRANTY!

5-1
6. INSTALLING AND SETTING UP

PROMOTION iCNC CONTROLLERS
6.1. CHECKING THE BASICS

- Make certain the cutting machine is in sound operating condition
- Complete the mechanical installation of the controller, encoders, rack, servo
amplifier and servo motors (if they are included in the retrofitting)
NOTE: On three channel systems using the Y2 channel, keep both Y1 & Y2 servo
motors disengaged from the rack so that testing can take place.
- Complete all interface wiring and route all applicable system cables.
- Make sure that the existing optical tracing system (if applicable) functions fine when
the J5 cable is connected, but power has not been switched on to the CNC-controller.
It is advisable to open the Machine Info screen from the “Info System Status” “View”
menu and to keep this screen open during the Machine Motion Set-Up procedure.
In order to run the set-up procedure, the application must be opened.

Open START > ALL PROGRAMS > PROMOTION >iCNC SETUP, or navigate to
C:ROBO\PROG\iCNCSETUP.EXE.
Because improper use of this program will easily cause the controller to stop working
properly, it is password protected. Only authorized people should have the password.
Without a password it is possible to run the program and view all the settings, but it is
not possible to change any settings.
!!! IMPORTANT – PLEASE COMPLETE ALL MOTION SET-UP, IN

SEQUENCE, BEFORE OPERATING THE CONTROLLER (Section 1.1 to 1.8)
- Please note that all supply voltages must be present for the system to work. See
section 5 for details.-

5-2
Click Enter Administrator Mode and enter the password rbtc
6.2. MOTION
6.2.1. DRIVE CONFIGURATION

Select 1. Motion > 1.1. Drive Configuration: choose 2 or 3 axis.
Changing the drive configuration to a 3-axis system, demands doing a Total Restart to
make the change valid. Follow the on-screen prompts and wait for the system to shut
down and to restart again. Note: Total Restart is located on the lower tray on the
Windows screen.

5-3
When the controller reboots, you will be prompted to transfer the newly modified
ROBOPRM1.DAT file to the background CPU. Select YES and give the password
rbtc to complete this action. When completed, restart ProMotion iCNC Setup as
explained above.
6.2.2. SERVO DRIVE & ENCODER POLARITY

- Set the Drive Enable Switch on the front of the controller to “ON”
- Make sure that power is ON to the servo amplifier system and that clutches (if any)
are engaged on two axis systems. Remember to keep the Y1 and Y2 pinions out of
the rack in three axis systems. In certain applications, you have to set the optical
tracing system to the trace state to enable driving simultaneously in both directions.
- Make sure that the controller is in basic status (no lights-on in any of the 10 push
buttons in front panel.)
Select 1.2. Drive and Encoder Polarities from iCNC Setup.
Note: Opening this dialog box opens the positioning loop and allows you to send out
speed signals to the drives by using Y+/Y-/X+/X- buttons and checks the actual
rotation of the drive pinion wheels. If rotation is incorrect, change the corresponding
polarity in the dialog box and check again.
After all polarities are correct, click the Drive Polarity OK check box.
Next, set the encoder polarity by pressing the Y+ direction for about 2 seconds. If the
polarity is incorrect, the software will automatically detect it, and change the setting
automatically. Repeat for the +X direction. Click OK when completed.
Note: You can also manually change the encoder polarities if you desire. Choose Set
polarities manually to do so, then OK when finished.

5-4
6.2.3. ENCODER VALUES

ProMotion iCNC Set-up has a routine which can automatically calculate your encoder
values. Select 1.3. Encoder Values from iCNC Setup.
Move the machine to the front of the rail or reference mark. Reset the encoder counters
by pressing the Reset counters button. Press the “Jog On/off” button to enter manual
mode (note: the manual mode button will flash on-off) 1) Using the joystick or
corresponding drive direction button, move the machine as long of a distance as is
possible. Measure the machine position from the end of the rail or reference mark,
using a metric tape measure if possible. Key this distance the machine actually moved,
into the Measured distance box as a metric value and click the Calculate encoder
value button. Repeat this procedure with the other axis from step 1 above for machines
with a different rack & pinion combination, or simply “copy and paste” the calculated
encoder value into the opposite Encoder values box and press Recalculate. Click Jog
On/off then click Apply and OK when done.
The encoder value corresponds with pulse edges per one meter of motion. The bigger
you set the encoder value the bigger it will make your programmed figures.
Example: If you drive a distance of one meter according to your encoder reading, and
the actual measured motion distance of the machine is 997 mm, you must divide your
current encoder value by 0.997 in order to make the machine cut parts to the correct
size.
Normal encoder values are in the 20,000 – 400,000 range with values of 8K to 500K
being the extreme limits.

5-5
6.2.4. DRIFT ADJUSTMENT AND SPEED OUTPUT VOLTAGES

Select 1.4. Drift Adjustment from iCNC Setup. This will open the positioning loop
and allow the machine to drift if the electrical settings are not perfect.
The following adjustments can be made with the Drive Enable switch in the Off
position
First adjust the maximum speed output voltage for each axis to the wanted level.
Normally it is a good practice to set these voltages to 9.00Vdc. These voltages can be
adjusted on the PCINT-DACard with potentiometers TR1 (for X), TR2 (for Y1) and
TR3 (for Y2) and measured on test points P1 (X), P4 (Y1) and P11 (Y2) using the
(left) negative leg of capacitor C6 as reference Ground.
For adjusting the zero outputs, measure the voltage for each of these outputs on the
appropriate test point (test point P3 for X, P6 for Y1 and P13 for Y2). All should be at
zero millivolts. If adjustment is needed, use potentiometers TR5 for X, TR8 for Y1 and
TR11 for Y2 and set to 0.000V.
J6 TO BACK WALL
CONNECTOR
CARD DJ6
(DRIVE SIGNALS)
J1 TO BACK WALL
CONNECTOR
CARD DJ1
(±15 VDC SUPPLY)
When completed, enable the drives (if not already enabled) and adjust the motion to
zero drift at your amplifiers for all axis. View machine motion through the position
counters and speed indicators in the Drift adjustment window.

5-6
It is advisable to press the ZERO push button on the controller before clicking OK.
Clicking OK in the Drift adjustment window will close the positioning loop and allow
you to resume positional control.
NOTE: IT IS NOT SAFE TO ENGAGE THE DRIVE UNITS OF A THREE

CHANNEL SYSTEM INTO THE RACK UNLESS THE PROCEDURE ABOVE
HAS BEEN FOLLOWED
Select 1.5. Max Speed Adjustment from iCNC Setup. This will again open up the
positioning loop, making it possible to see the true speeds for each axis, and will allow
the machine to drift if the electrical settings are not perfect.
Use the direction buttons to drive the machine with maximum speed in each direction.
You already adjusted the maximum speed outputs to the wanted voltage. This routine
allows you to look at the speed of each axis and fine tune them at the amplifier end to
the wanted value. Make sure this speed adjustment ends up being a little bit higher than
the wanted maximum speed of the machine, and that the speeds of different axis are as
close as possible to the same values.
NOTE: This is especially important with 3 axis machines. Set both Y1 & Y2 motors to
run at the same speed. Click Close when you are done.

5-7
6.2.5. SPEED TESTS AND MOTION PARAMETERS

The next step is 1.6. Max Speed Test. This test is elementary for proper operation of
the controller.
In most cases it is safe to do this test with the drives disengaged, because the majority
of the system inertia is normally within the drive motors, and the machine motion
friction is very small. If you can’t disengage the drives and your machine is small in
size but fast, you may want to reduce the test time to a smaller number. The default is
4 seconds (4 sec. for acceleration, 4 sec. for constant max speed and 4 sec. for
deceleration for a total of 12 sec). Changing this setting to 2 seconds would reduce the
space needed for the test dramatically.
Make sure the speed potentiometer is set to 100% for this test.
Set the Max settable speed for the machine to a slightly slower speed than found when
previously checking all four directions in step 1.5 above. Select Start test when you
are ready. When all four directions and speeds are set, press the ZERO push button on
the controller and select OK to complete the test.

5-8
Select 1.7. Min Speed Test from iCNC Setup.
Set the speed value (%) to something reasonable related to the nature of the machine.
Normally 123 mm/min (4-5 ipm) is a good test value. Use the Increase or Decrease
buttons until something close to this is reached.
Select Start test and be patient until you see the results posted in the Corrections
Speed boxes in all four directions. This may take several minutes. Since the speed
value is small, it may be difficult to see anything happening unless watching the motor
pinions, or viewing X-Y positional data in the Machine Info screen.
After the tested speeds appear, select Calculate low speed corrections. With optimum
drives and perfect adjustment, all the correction values will come in at 1. Press the
ZERO push button on the controller, then select OK when ready.

5-9
Select 1.8. Drive Parameters from iCNC Setup.
In this screen, you can set the most important motion related parameters and test
machine motion by running a test rosette pattern. Synchronization settings for 3 axis
systems are also included in this dialog.
- Max settable speed is the maximum desired machine speed. This can be
the same as set in 1.6. Max Speed Test, or maximum machine speed can be limited
- Max trial run speed is normally set equal to the Max settable speed
- Min settable speed is set to your lowest dependable speed. The system enters this
value in automatically after completing the Min speed test
- Parking speed is used for machine positioning and drift correction, either while
the machine is standing still, or positioning to a part location. High values will
cause oscillation; small values will make it impossible to properly position the
machine
- P-Gain (0 – 255) A critical gain setting controlling system responsiveness and
performance. If the encoders are driven directly off the motor shafts, a value of
190-210 works well in most cases. If the encoders are separately mounted and
measure off the machine carriage, this value may need to be dropped as low as 75
- 45° dampening can be increased from the default value of 100 if vibration is seen,
especially when driving at a 45° angle

5-10
- External stop slowdown time controls the reaction time between when an
external stop input is received, and when the controller halts motion
- Acceleration and Deceleration controls the accel/decel responsiveness when
positioning the machine. With fast plasma machines, a value of 25-35 mg is
normal. If the machine is mechanically very rigid, with near zero backslash and a
strong drive system, you might be able to use values as high as 50-100 mg. For
slow gas cutting machines, a value of 15 mg is normal. Both acceleration and
deceleration values are generally adjusted equally.
Note: One g (the value describing how fast an object accelerates when dropped to
a free fall on earth) is 9.81 m/s/s. Therefore 10 mg (milli-g) is 0.0981 m/s/s or 9.81
cm/s/s
- Centrifugal acceleration will limit the maximum speed of the machine when
driving on small radius arcs or approaching sharp corners. This must be set to a
value equal-to or less-than your acceleration or deceleration values, and can be set
as low as 3 mg
- Corner slowdown level works together with the Centrifugal acceleration when
calculating the maximum allowed speed for sharp corners. With value 1 the
system will slow down more and with value 3 less
- Corner angle w/o slowdown specifies the maximum corner angle to be driven
without any speed limitations. 15000 milli degrees is same as 15 degrees
The Y2 adjust screen is for setting parameters related to synchronization of the first
longitudinal drive (Y1-master) with the second longitudinal drive (Y2-slave) Please
try the Defaults first, most machines work well with them. Click the Defaults button
in the Y2 adjust screen.
- First step is a control value to be given when there is 1 increment difference in Y1

and Y2 positions. A control value of 1 equals maximum speed signal voltage
divided by 2047
- Static P-Gain gives corrections based only on the magnitude of difference
between Y1 and Y2. The correction is linear
- Static P2-Gain is like the P-gain but is not linear. It has it’s full value at the edge
of the adjust window, but with the Y1/Y2 difference being half of the adjust
window, the effect of this parameter is only one quarter
- Adjust window is given in μm (=1mm/1000). The default value is 2000 meaning
that the Y1-Y2 distance related values will reach maximum if the Y1-Y2
difference is 2mm or greater
- Dynamic P-Gain and Dynamic P2-Gain are related not only to the difference of
Y1-Y2 but also to the speed. They will have maximum effect at the edge of adjust
window if the machine is driving with maximum speed. In low speeds these values
have almost no effect to the Y2 correction
- Error limit will set the Y1-Y2 difference where the machine must be stopped.
The default value is 5000 μm (=5mm = 0.2”)
- Slowdown time is the time spent to stop the machine from full speed. Default is
50 msec = 0.05 seconds
First press Apply and then press Save to temporarily store the parameters before
running the test Rosette.

5-11
When running the test Rosette, it is necessary to watch actual machine motion, and
therefore you should have your drives engaged to the pinion rack.
Pressing the Test run button will allow you to run a test Rosette of desired size and
speed. The test starts when you click the Start button and press the MOVE AHEAD
push button on the controller’s front panel.
AFTER COMPLETING THIS SECTION, IT IS ADVISABLE TO DO A TOTAL

RESTART AND PASSWORD-SAVE THE CHANGES PERMANENTLY WHEN
PROMPTED.
6.3. SETTING THE PROGRAMMABLE I/O

With the most basic Machine Interface hook-up utilizing the J4 Connector (section 4.1)
simply connecting pins 2 (Out1) and 21 (Ext GND) would activate the CUT ON relay.
This allows the controller to have control over either Plasma or Oxy cut operations.
With more advanced Machine Interface hook-ups, the I/O becomes fully
programmable and can be setup utilizing various timing diagrams, delays and
interrupts.
Set the inputs / outputs according to your configuration. The outputs can be set
individually for each machine operation such as Plasma, Gas, Marking, etc. and
include:
- 4 different sequential delays before cutting (or marking)

- Cutting move delay and cutting movement
- 2 sequential ending delays
- Move delay before the next rapid movement and basic status

5-12
6.3.1. INPUTS / OUTPUTS
Select 2.1. General.
Wire your machine so that any problem indicators like limit switches and collision
sensors will cause an External Stop condition.
External stop polarity - Not Inverted is used with N/O devices, and Inverted is used
with N/C devices.
Limit switches - Not Inverted is used with N/O devices, and Inverted is used with
N/C devices.

5-13
Home switches inbits - Not Inverted is used with N/O devices, and Inverted is used
with N/C devices.
Activated outputs during program running – If you wanted to activate an outbit

while the program is running, e.g. keeping the high preheat on while cutting, check the
appropriate box.
Select 2.2. Plasma Cutting to configure your plasma settings.
Normally the outputs for plasma are defined in Tab 1. In this example, SD1 & SD2
(start delays 1 and 2) do nothing. The system starts to move the torch down in SD3
(Start Delay 3). When Inbit interrupt 10 indicates that the torch is down and in place,
the plasma will be started during SD 4 (Start Delay 4). Inbit interrupt 4 is used to
inform the controller that the main-arc has transferred and machine motion can begin
after running the Move Delay timer. After cutting the torch is driven up for the time in
ED1 (End Delay 1).

5-14
Notes:
1) The times for each of these delays will be entered in the Plasma section of
ProMotion Cut through Setup>Advanced Setup>Folder 6.
2) Remember to check that you do not have any disturbing outputs activated in Tab 0
or Tab 2.
Click Advanced to get the following screen.
External stop if main arc is not ok – the system can be setup to generate an External
Stop if the main arc input signal is lost while cutting by checking the Enabled box
Timeout – set this long enough to prevent an external stop condition from occurring if
cutting ends without a plate below the torch
Hold polarity - the polarity of the Torch Hold or Automatic Torch Height Control
Disable output signal
Hold activates below – when set to 100%, anytime the machine begins to slowdown
below 100%, the hold output is activated
Plasma prehold distance – controls the distance from the End-of-Cut when the hold
output is activated
Hold extension – delays the hold output from changing states after reaching 100% spd
Hold during Move Delay – forces a “hold” condition during move delay
Click the PreStop button to get here from the 2.2 Plasma cutting screen

5-15
Here you can activate the Plasma PreStop feature, select which one of your outputs
will be effected at Plasma PreStop and what the value will be (off/on) of that output at
the time of Plasma PreStop. The length of Plasma PreStop Distance will be determined
in the ProMotion Cut settings through Setup>Advanced Setup>Folder 6.
This can be set individually for each “plasma-cutting parameter set”
(material/thickness/tool)
Select 2.3. Gas Cutting to configure your gas cutting settings.
Normally the outputs for gas cutting are defined on Tab 0.
This screen is used to set up which outputs will be activated and in which order. In this
example the High Preheat and the IHS Start (used in this case to switch on the
capacitive height control system) outputs will be activated in SD1 (start delay 1)
immediately when getting to the piercing point. In most cases SD1 and SD2 would
probably not be used for anything, with the preheat time set in SD3. The system would
start lifting the torch in the beginning of SD4, wait the time of SD4 before switching on
the cutting oxygen and then after the Move Delay time, start the cutting motion.
Notes:
1) The times for each of these delays will be entered in the Gas section of ProMotion
Cut through Setup>Advanced Setup>Folder 6.

5-16
2) Pierce delays, etc. can be set individually for each “plasma-cutting parameter set”
(material/thickness/tool) in Advanced Setup also.
3) Remember to check that you do not have any disturbing outputs activated in Tab 1
or Tab 2.
AFTER COMPLETING THIS SECTION, IT IS ADVISABLE TO DO A TOTAL

RESTART AND PASSWORD-SAVE THE CHANGES PERMANENTLY WHEN
PROMPTED.
Select 2.4. Line Marking to configure your line marking settings.
In this example we have a plasma marker which only needs the start signal to lower the
marker and start the marking process. This happens when a main arc signal is received,
indicating motion can begin. Settings in this case are similar to plasma settings above.
The “Advanced” button also works the same way.
Select 2.5. Point Marking to configure your point marking settings.

5-17
In this example the plasma is used to create a point type mark on the plate. SD2 is used
to drive the torch down to a sensor connected to In5, plasma will be started within SD3
and the main arc signal will terminate SD3, which starts driving the torch up for the
time of SD4. For this feature only the first 4 delays are available, SD1-SD4.
Select 2.6. Out Bits to see the default meanings for each Out Bit. You also have the
ability to change the names of the Outputs when using the signals for different
purposes, like a water jet cutting system or router application.
Select 2.7. In Bits to see the default meanings of each In Bit. You also have the ability
to change the names of the Inputs when using the signals for different purposes like a
water jet cutting system or router application.

5-18
2.8. Wiring examples / 2.9. Connector layouts / 2.10. Signal names / 2.11.0 Power
requirements are reserved for future use.
6.4. OTHER SETUPS

Select 3.1. Homing / Limits

5-19
In this dialog you can set the automatic homing to home limit switches, and/or the
software limits for your machine to limit the allowed working area. The software limits
will become active AFTER setting the absolute Zero position either by using the
homing feature or by setting it manually in the ProMotion Cut Jogging dialog.
Select 3.2. Table Home Locations
Table Home Locations also need a valid absolute Zero to function properly. There is
no practical limitation to the maximum number of different Table Homes.
Select 5.1. General to configure other general settings.

5-20
Within this dialog you can:

- Change the behavior of the Stop/Backup push button on the controller front
panel to Enabled (latched) or disabled (un-latched) or the Timeout before
latching
- Change the Reduce speed potentiometer setting and control the percentage of
maximum speed while backing up
- Change the Speed increments for Gas or Plasma when using the Speed
Up/Speed Down push buttons on the controller front panel
- Change the latching time of the joystick when jogging
- Select the THC type to communicate with through a serial gate.
Select 5.2. Teach In to configure teach tracing options

5-21
- When doing a teach-trace the system is capable of automatically recognizing the

point where the figure closes and stops recording any more points. Closing
distance describes how close to the starting point you need to come before
allowing the system to close the figure
- Linear deviation is the maximum allowed error in combining lines together.
- Minimum line length prevents the system from building up any figure out of
extremely short lines
Select 5.3. Get serial number for identifying the hardware serial number in your
controller
Select 5.4. Simulation mode to set the controller into simulation mode for
demonstration purposes. This works in 2-axis mode only, and is password protected. In
this mode the system works normally, except the encoder input will be ignored and
simulated in the system allowing the controller to function in a demo mode. Contact
the factory for password instructions and warnings.

5-22
Selecting 5.5. Diagnostic Information allows you to save important system

information about your machine when encountering a problem. Generates a file which
is stored on the hard drive and can be retrieved from the folder C:\Robo\Diags\
This information can be useful when trying to diagnose a problem with the assistance
of factory personnel.
Selecting 5.6. Advanced Diagnostics starts the diagnostic testing of the controller
front panel push buttons. This tests both the light bulb and the push button for proper
operation. Pressing the Start Push button test will illuminate ALL front panel push
buttons. Pressing each push button one at a time, will turn the light off.

5-23
6.5. BACKING UP & RESTORING SYSTEM

Select 6.1. Backup Machine Settings to backup all critical controller parameters and
settings to the hard drive. This information should also be saved to a diskette or
network for safety. The folder will be automatically named with the current date. The
path information is C:\Robo\Backup\
Select 6.2. Restore Machine Settings to restore all critical controller parameters,
license files and parameter settings to the hard drive. You can also choose the backup
data location and dated folder.

5-24
6.6. TESTING THE OUTPUTS AND INPUTS

You can test the electrical function of outputs and inputs by using the Machine info
screen.
• Start the DIAGNOSTIC MODE by pressing and holding the MANUAL MODE
push button in for about 15-20 seconds, until it starts to blink
• Open the Machine info screen from “Info System Status” “View” menu
• Choose either the Outbits folder or Inbits folder
• For the Outbits folder, click on the desired output with the mouse changing it from
dark green to bright green and check for desired operation at either the appropriate
back panel receptacle or by checking operation at the device itself
•For the Inbits folder, externally force the condition to the “on-state” such as a limit
switch or torch breakaway, and visually check the appropriate box for a bright green
indicator

6.7. ROBOTIC PARAMETERS, C:\ROBO\PROG\ROBOPRM1.DAT 16.6.1997
LINE GENERAL X Y GENERAL ROTATING
0 ACCELERATION /mG MIN CTRL CRAWL (+DIR) MIN CTRL CRAWL (+DIR) 1 / BASIC ENC. RES..* 10^9 LINEAR GAIN
10...30...100 1…10 1…10 39062 100
1 ACCELER. FOR ARCS /mG MIN CTRL CRAWL (-DIR) MIN CTRL CRAWL (-DIR) BASIC ENCODER RESOL. P/M DEV. LIMIT FOR SQ. /mdeg
10...30...100 1…10 1…10 25600 100
2 DECELERATION /mG THEOR. CRAWL CTRL /40mm THEOR. CRAWL CTRL /40mm do not change SQUARE GAIN
-10...-20...-100 11682 11682 1 32
3 SPEED FEEDBACK MAX CTRL CRAWL MAX CTRL CRAWL X-ENC. VALUE MULTIPLYIER DEV. FOR SLOW.DOWN / mdeg
0 240 240 65534 180000
4 MIN ARC WITH NO SPEED FBACK MAX SPEED (- DIR.) mm/min MAX SPEED (- DIR.) mm/min X-ENC. VALUE DIVIDER (CONST) DEVIATION FOR STOP / mdeg
1000 -3150 -2950 19780 190000
5 SPEED MEASUR. INTERVAL /ms MAX SPEED CTRL VALUE MAX SPEED CTRL VALUE Y-ENC. VALUE MULTIPLYIER ZERO POSITION FROM Z / p
60 2047 2047 65534 -1250
6 LOOK AHEAD. ADD. /0.001mm ZERO-CONTROL STEP -X ZERO-CONTROL STEP -Y Y-ENC. VALUE DIVIDER (CONST) FULL CIRCLE IN PULSES
100…400…600 1...10 1...10 19780 999999
7 LOOK AHEAD LIN./0.001mm/m/min MAX SPEED (+ DIR.) mm/min MAX SPEED (+ DIR.) mm/min STORE INTERVAL ms do not change
500...1000...2000 3050 2960 10 999999
8 LOOK AHEAD .SQ./0.001mm MAX SPEED CTRL VALUE MAX SPEED CTRL VALUE MIN. SPEED (ARCS) mm/min do not change
10 2047 2047 80 999999
9 LOOK AHEAD/DEC.ADD /0.001mm ZERO-CONTROL STEP +X ZERO-CONTROL STEP +Y MIN SPEED (CORNERS) mm/min do not change
500 1...10 1...10 80 999999
10 LOOK AHEAD/DEC.LIN./0.001mm do not change do not change MAX CORNER FAULT INCREM. do not change
200 1 1 3 999999
11 LOOK AHEAD/DEC. SECUR.% do not change do not change PARKING SPEED (X,Y) mm/min do not change
100...140 1 1 40 999999
12 not in use do not change do not change JOY STICK HOLD TIME /ms do not change
3000 0 0 5000 999999
13 not in use do not change do not change SPEED RANGE, MIN mm/min do not change
3000 0 0 60 999999
14 not in use do not change do not change SPEED RANGE, MAX mm/min do not change
3000 0 0 2800 999999
15 not in use CRAWL / L.AHEAD SP. mm/min CRAWL / L.AHEAD SP. mm/min do not change MAX CORNER,NO SLOW / mdeg
-500 300 300 360000 15000
16 STOP ERROR FOR X-CRAWL / mm WA, OUTER L. (-DIR) / mm WA, OUTER L. (-DIR) / mm X-SP. TO HOME, odd act./mm/min do not change
5 1000 1000 500 999999
17 STOP ERROR FOR Y-CRAWL / mm WA, INNER L. (-DIR) / mm WA, INNER L. (-DIR) / mm X-SPEED HOME -> Z / mm/min MIN CORNER OofC SP. / mdeg
5 900 900 -50 (90000 no act.)…30000
18 not in use WA, INNER L. (+DIR) / mm WA, INNER L. (+DIR) / mm Y-SPEED TO HOME /mm/min DIST.from CORNER, OofC / mm
999999 1900 5900 500 10
19 MEM. ALLOC. WA, OUTER L. (+DIR) / mm WA, OUTER L. (+DIR) / mm Y-SPEED HOME -> Z / mm/min MAX SPEED OofC DIST/mm/min
999999 2000 6000 -50 2000
CALCULATING THE LOOK AHEADS: (ENCODER RESOLUTION=0,04 MM, MAX SPEED=3M/MIN) MIN STEPS=
ADD. 400*0,001 mm=0,4 mm 500*0.001mm=0.5 mm C=Cmin-(Cmax-Cmin)/(Vmax-Vmin)*Vmin
LIN. 1000*0.001mm*3=3mm 200*0.001mm*3=0.6 mm (positive values only)
SQ or SECUR. 10*0.001mm*3*3=0,09mm 140 % If the machine runs too long distance,
TOTAL LOOK AHEADS: ACCELERATION = 3,49 mm 1.4*(0.5+0.6+THEOR.VALUE) make the Multiplier smaller

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ProMotion® iCNC® 2006-09-06/JP/MW

2. INTERNAL KEY COMPONENTS ........................................................................1

2.1. INTERNAL POWER SUPPLY ........................................................................................................ 1

2.2. PC-INT CARD STACK..................................................................................................................... 2

2.3. FRONT PANEL PUSH BUTTON CARD ....................................................................................... 2

2.4. CPU BOARDS .................................................................................................................................... 2

2.5. CONNECTIONS TO BOARDS........................................................................................................ 3

3.1. MAIN CPU BOARD OPTIONS ....................................................................................................... 6

3.2. SECONDARY CPU BOARD.......................................................................................................... 10

3.3. PROCESSOR CARD (INNER CARD - CARD STACK) ............................................................ 12

3.4. D/A CARD (OUTER CARD – CARD STACK)............................................................................ 13

3.5. FET CARD (CENTER CARD – CARD STACK) ........................................................................ 15

ProMotion® iCNC® 2006-09-06/JP/MW

3.5.3.1. Output LEDs ........................................................................................................................ 16

3.6. FRONT PANEL CARD (PARA 2) ................................................................................................. 17

4.1. CONNECTOR CARD ..................................................................................................................... 18

4.2. SMALL RELAY CARD .................................................................................................................. 25

4.3. SINGLE PLASMA INTERFACE .................................................................................................. 26

4.4. SIX STATION RELAY INTERFACE........................................................................................... 28

4.5. FOUR GAS, TWO PLASMA AND ONE MARKER INTERFACE........................................... 31

4.6. 8 STATION INTERFACE W. AUTOMATIC SPACING ........................................................... 36

ProMotion® iCNC® 2006-09-06/JP/MW

4.6.2. J16 LIMITS CONNECTOR.......................................................................................................... 39

5. SUPPLY VOLTAGES , CONNECTORS AND WIRING GUIDANCE................. 43

5.1. SUPPLY VOLTAGES NEEDED.................................................................................................... 43

5.2. STANDARD DEVICE CONNECTORS ........................................................................................ 43

6. INSTALLING AND SETTING UP PROMOTION ICNC CONTROLLERS............1

6.1. CHECKING THE BASICS............................................................................................................... 1

6.3. SETTING THE PROGRAMMABLE I/O ..................................................................................... 11

6.4. OTHER SETUPS ............................................................................................................................. 18

6.5. BACKING UP & RESTORING SYSTEM.................................................................................... 23

6.6. TESTING THE OUTPUTS AND INPUTS.................................................................................... 24

6.7. ROBOTIC PARAMETERS, C:\ROBO\PROG\ROBOPRM1.DAT........................................... 25

ProMotion® iCNC® 2006-09-06/JP/MW

1. PROMOTION® iCNC® MECHANICAL

TOTAL WEIGHT ABOUT 35 kg

4 x M6 Nuts welded inside.

Dist. from back edge 21 mm

ProMotion® iCNC® 2006-09-06/JP/MW

2. INTERNAL KEY COMPONENTS

2.1. INTERNAL POWER SUPPLY

Screw connectors are:

ProMotion® iCNC® 2006-09-6/JP/MW

2.2. PC-INT CARD STACK

2.3. FRONT PANEL PUSH BUTTON CARD

2.4. CPU BOARDS

2.4.1. CPU CONNECTIONS

MAIN CPU BOARD

Com 1 FLAT PANEL SCREEN

SECOND CPU BOARD USB-PORT

OPTIONAL FLOPPY DRIVE

DIFFERENT ETHERNET CONNECTOR

ProMotion® iCNC® 2006-09-6/JP/MW

2.5. CONNECTIONS TO BOARDS

2.5.1. BASIC CONNECTIONS IN A STANDARD SYSTEM

MAIN SECOND PROCESSOR D/A FET

FRONT PANEL CARD

ProMotion® iCNC® 2006-09-6/JP/MW

2.5.2. BASIC INTERNAL WIRING

ProMotion® iCNC® 2006-09-6/JP/MW

2.5.3. VARIOUS MACHINE INTERFACES

ProMotion Controllers may be equipped with many different machine interfaces.