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39

Installation and Operations Guide

Illustration

Step 20: Connect CNC cable to AVHC (optional)

If the AVHC is installed, the AVHC Controller will connect both to the plasma cutter raw arc
voltage terminals, its CNC interface cable (two wire pairs), and to the CNC Controller. In addi-
tion, the lifter station motor cable runs to the AVHC Controller.

Qty

Part

Description

Part #

1

MPMP with cables
routed to CNC Con-
troller

From Step 13

1

AVHC controller

(03-0001-001A (25’)

or 03-0001-003A (50’)

or 03-0001-005A (75’)

(optional purchase)

1

CNC interface cable

(Supplied with plasma

cutter)

1

Signal cable package

(Supplied with AVHC)

Required parts /
components

Instructions

• Connect plasma cutter wires to the AVHC Controller, and also

from the AVHC Controller to the CNC Controller. Connect the lifter
station motor cable to the AVHC Controller. Connect the magnetic
breakaway cable to the CNC Controller input.

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Summary of Contents for MASTERPIPE Mini Profiler

Page 1: ...MASTERPIPE Mini Profiler Installation and Operations Guide February 11 2014 Copyright 2013 2014 by Vernon Tool Company ...

Page 2: ...pany All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this manual whether such error results from negligence accident or any other cause Publication Date February 11 2014 Document 2014MPMP1...

Page 3: ...iii Installation and Operations Guide MASTERPIPE Mini Profiler MPMP Base machine and single add on section cutting 8 I D pipe ...

Page 4: ...l drive unit 27 Step 9 Add hard stops 28 Step 10 Install optional AVHC torch mount 29 Step 11 Install optional oxy fuel torch mount 30 Step 12 Install optional oxy fuel relay 31 Step 13 Install cradles and catch trays 32 Step 14 Install optional small pipe cradles 33 Step 15 Route cables through cable carrier 34 Step 16 Connect motor cable to chuck motor 35 Step 17 Connect air lines 36 Step 18 Con...

Page 5: ...alling the Driver software 56 Manually installing the device drivers if necessary 58 Configure the computer s power saving feature 60 Driver software configuration setup files 62 Driver software panels 64 Control panel descriptions 66 Coordinates DRO panel 68 Connection status 70 G code panel 72 Viewport panel 74 Output panel 76 Driver software basic operations 78 Jog motion testing 80 Output line...

Page 6: ...er s cost No defective goods are to be returned without written authorization of seller The sole purpose of the stipulated exclusive remedy shall be to provide the Buyer with free repair and replacement of defective Goods in the manner provided herein This exclusive remedy shall not be deemed to have failed of its essential purpose so long as the Seller is willing and able to repair or replace def...

Page 7: ... with written notice of any claim for shortage overcharge or damage of Goods within ten 10 days from invoice date such Goods shall be deemed finally inspected checked and accepted by Buyer and no allowances shall be made thereafter In absence of shipping and packaging instructions Seller shall use its own discretion in the choice of carrier and method of packing Seller shall not be responsible for...

Page 8: ... promise that you will get out of it what you put in Operating any machinery is a skill and does have a learning curve The first and perhaps most important item I want to give you today is the Torchmate Technical Support Hotline 866 571 1066 ext 3 This num ber is toll free for those within the United States For those outside the United States use the following number 775 673 2200 ext 3 There is a ...

Page 9: ...1 Safety Guide Safety Information ...

Page 10: ...erforming any service or repairs When the power source is operating voltages in excess of 250 volts are produced This creates the potential for serious electrical shock possibly even fatal 1 3 Insulate yourself from work and ground using dry insulation Wear dry gloves and clothing Take extra care when the work place is moist or damp 1 4 Always be sure the work cable makes a good electrical connect...

Page 11: ...e arc nor expose themselves to the arc rays or to hot spatter or metal 3 FUMES AND GASES can be dangerous 3 1 Plasma cutting or gouging may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When cutting or gouging keep your head out of the fumes Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone 3 2 Use an air suppl...

Page 12: ... chemicals known to the State of California to cause birth defects 3 10 Some dust created by routing sawing grinding drilling and other construction activities contains chemicals known to cause cancer birth defects or other reproductive harm Avoid prolonged contact with this dust Wear protective clothing and wash exposed areas with soap and water Allowing dust to get into your mouth eyes or lay on...

Page 13: ...an create fire hazards or overheat lifting chains or cables until they fail 4 7 Hydrogen gas may be formed and trapped under aluminum work pieces when they are cut underwater or while using a water table DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated Trapped hydrogen gas that is ignited will cause an explosion 4 8 Read and follow N...

Page 14: ... FIELDS may be dangerous 8 1 Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Cutting or gouging current creates EMF fields around torch cables and cutting machines 8 2 EMF fields may interfere with some pacemakers so operators having a pacemaker should consult their physician before cutting or gouging 8 3 Exposure to EMF fields during cutting or gou...

Page 15: ... information on how to test for noise refer to the publications section of this manual 11 HEAVY PARTS 11 1 Parts of CNC machines are heavy Also material you are cutting may be heavy Use caution when lifting or moving them To avoid injury get someone to help you or use a mechanical lifter When using a mechanical lifter follow all the manufacturer s safety guidelines 11 2 Review the Occupational Saf...

Page 16: ...ecently cut material Also consider other devices for safe hot material handling 15 3 It is safest to let material cool completely before handling 16 MECHANICAL DRIVES 16 1 High speed mechanical drives made of gears belts and or drive screws are used by CNC machines Keep clear of them during operation 16 2 Do not attempt to service adjust or otherwise touch these components while the machine is on ...

Page 17: ...btainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 51B CU...

Page 18: ... a question or concern arises or a part seems to be missing please contact Torchmate technical support Technical support will also help you with operating the CNC system and troubleshooting problems Technical support is available every day from 6 30 AM to 4 00 PM Pacific Time Zone Call fax or email Technical Support Call us for Consumables or visit our web store www TorchmateStore com ...

Page 19: ...11 Installation and Operations Guide Hardware Installation ...

Page 20: ...section 2 1 to 5 61 Rail assembly May be pre installed TMS 140 0001 06 1 per base machine 1 per add on 3 6 to 30 5 16 18 X socket head cap screw May be pre installed TMS 410 0016 12 6 per rail assembly 3 0 to 8 20 X hex head cap screw May be partly or fully pre installed TMS 410 0014 12 2 per add on 3 0 to 8 SAE washer May be partly or fully pre installed TMS 413 0001 14 2 per add on 3 2 to 6 Cabl...

Page 21: ...May be partly or fully pre installed TMS 140 0002 78 9 4 1 4 20 X 3 4 Hex head cap screw May be partly or fully pre installed TMS 410 0014 12 9 4 1 4 Washer May be partly or fully pre installed TMS 413 0001 14 9 1 Height control torch mount assembly May be partly or fully pre installed TMS 140 0001 14 Optional 10 1 Oxy fuel torch mount assembly May be partly or fully pre installed TMS 140 0001 16 ...

Page 22: ...ly dry and filtered 17 1 Pro Series CNC controller rear view 4 axis drive box 18 1 CNC interface cable Supplied with your plasma cutter 19 20 1 AVHC controller 03 0001 001A 25 or 03 0001 003A 50 or 03 0001 005A 75 optional purchase 20 1 Signal cable package Supplied with optional AVHC 20 1 Desktop or laptop computer separate purchase 21 1 USB A B cable USB Cable 21 1 USB flash drive Driver softwar...

Page 23: ...15 Installation and Operations Guide Qty Part Description Part Number Step 1 Chuck key included with base machine 26 1 Plasma cutter with cut charts seperate purchase Kaliburn Dagger 100 shown here 27 ...

Page 24: ... controller provides motor drive electronics with power and accuracy This reliable unit has been used in thousands of CNC systems The Torchmate Driver software runs on your standard PC and communicates with the CNC controller using a standard USB printer cable Torchmate Driver works with G code such as that produced by the optional WinMPM software Designing your own cutting files cannot be any eas...

Page 25: ...iction roller balls supported by interior ball bearings make turning various sized pipe in the roller transfer cradles smooth and easy Position the cradles away from the cutting action by just sliding them down the tubular support rails The standard torch mount is fully adjustable and even allows the adjustment of pipe centered bevel angles Particularly on straight cuts this bevel can produce cuts...

Page 26: ...ed with add on sections up to 25 feet Consider placing the initial equipment in an area that can accommodate any expansion as needed The following components of the system must be supplied with power CNC Control box Plasma power supply separate purchase Computer separate purchase Air compressor separate purchase AVHC Control box optional Oxyfuel plate marker relay box optional Consult with your el...

Page 27: ...oving empty and replacement cylinders and for safe placement of pressurized and flamamble gases well away from the operation of the cutting torch Recognize that smoke and dust are created by the cutting processes Plan to remove it and to provide a supply of clean air The Lincoln Electric Modular Extraction Hood can remove dust and smoke from cutting The Lincoln Electric Mobile Welding Fume Extract...

Page 28: ...rial flow Review the necessity of safely locating the base machine away from where people frequently travel and away from flammable material storage Ensure that power has been properly provided to the location and that two clean dry compressed air lines are available at 90 psi minimum 120 psi maximum Provide for ventilation of the smoke and gas produced by cutting and a good supply of fresh air Pr...

Page 29: ... it to the base machine or the last add on section attached with 3 8 hardware Roughly adjust the leveling feet These will be accurately set in a later step Illustration Qty Part Description Part 1 MPMP Base Machine From Step 1 0 to 4 Optional add on section TMS 050 0005 02 0 to 24 3 8 16 X 5 8 Socket head cap screw TMS 410 0018 10 6 per optional add on section 0 to 24 3 8 Washer TMS 413 0001 18 6 ...

Page 30: ...re installed TMS 140 0001 06 1 per base machine 1 per add on 6 to 30 5 16 18 X socket head cap screw May be pre installed TMS 410 0016 12 6 per rail assembly 0 to 8 20 X hex head cap screw May be partly or fully pre installed TMS 410 0014 12 2 per add on 0 to 8 SAE washer May be partly or fully pre installed TMS 413 0001 14 2 per add on Lay the rail mount plates on the rail and pipe supports and a...

Page 31: ...ns From Step 3 2 to 6 Cable Carrier Hanger may be pre installed TMS 140 0002 12 2 per base machine 1 per add on section 4 to 12 5 16 18 X 3 4 Socket head cap screw may be pre installed TMS 410 0014 12 4 per base machine 2 per add on section 4 to 12 5 16 Washer may be pre installed TMS 413 0001 14 4 per base machine 2 per add on section 1 to 5 Cable carrier support tray TMS 140 0002 13 1 per base m...

Page 32: ...eling instrument From your toolbox Required parts components Instructions Use a spirit level laid across the 11 2 diameter tubes at various places to check the side to side level of the module s Use the spirit level laid along the rail mount plate to check the end to end level of the module s Adjust the height of the leveling feet to compensate for any variations in the level of the floor and to b...

Page 33: ...en the bolts holding the modules together rechecking alignment Include the bolts on the rail connector plates installed in Step 2 Illustration Qty Part Description Part 1 Leveled modules base and any attached add on sections From Step 3 1 Divider calipers or similar instrument from your toolbox 2 C clamps or similar clamps from your toolbox Use the divider calipers to scribe ref erence marks an eq...

Page 34: ...eveled MPMP base ma chine plus aligned add on sections From Step 6 1 Small section of gear rack used as an alignment tool 08 0013 0015 Required parts components Instructions Use the small piece of gear rack included to align the gear rack of one module with the gear rack of the next module With the gear rack mounting bolts slightly loosened position the gear rack over the end of both gear racks Ad...

Page 35: ...mount Qty Part Description Part 1 Leveled MPMP and any add on sections with aligned gear racks From Step 7 1 Torch mount carrier as sembly may be pre installed TMS 140 0001 05 Required parts components Instructions Remove the motor covers loosen the motor mount screws to adjust the motor position then if not already installed slide the V rollers over the V rails Re engage and adjust the motor gear...

Page 36: ...Illustration Qty Part Description Part 1 MPMP base machine and any attached add on sections From Step 8 2 Y axis hard stop may be partially or fully pre installed TMS 140 0002 78 4 1 4 20 X 3 4 Hex head cap screw may be partially or fully pre installed TMS 410 0014 12 4 1 4 Washer may be partially or fully pre installed TMS 413 0001 14 Use the 1 4 hardware to attach the Y axis hard stops to each e...

Page 37: ... 1 Torch mount for AVHC torch arc voltage hieght control TMS 140 0001 14 Required parts components Instructions Instead of the manual height control torch mount install the AVHC torch mount instead The same basic mounting and motion control hardware is used by by both mounts differing only in the ability to support the heavier AVHC unit If it is not already attached attach the lifter station to th...

Page 38: ... 1 MPMP with torch mount carrier and motor installed From Step 9 1 Oxy fuel torch mount TMS 140 0001 16 Required parts components Instructions Instead of the manual height control plasma torch mount install the oxy fuel torch mount The same basic mounting and motion control hardware is used by both mounts differing only in the connections to be made to the torch and the actual torch clamp If it is...

Page 39: ...ct the 115VAC extension power cable from the oxy fuel torch solenoid to one of the outlets typically Output A on the back of the relay Connect the interface cable from the Control Signal port of the relay to the output port on the CNC controller Refer to the Output Line testing section of the Driver chapter of this manual for identifying the relay to the software Illustration The Relay Interface C...

Page 40: ... 8 or Step 9 0 to 4 Ball transfer cradle TMS 050 0001 01 2 per module recommended 2 Long catch tray TMS 140 0002 14 2 per module 2 Short catch tray TMS 140 0002 15 2 per module Required parts components Instructions Position a short catch tray at each end of each module Fill in the center with two long catch trays The trays rest on the module s rectangular tubing Set the ball transfer cradles on t...

Page 41: ...aighter resulting in more accurate cutting Qty Part Description Part 1 MPMP with torch mount From Step 8 or Step 9 2 Clamping cradle TMS 050 0001 02 optional 2 per module Required parts components Instructions Remove or re position any ball transfer cradles away from the cutting area Set the clamping cradles on the tubular rails positioning them as needed Additional clamping cradles may be purchas...

Page 42: ...quired parts components Instructions Begin by feeding the torch up through the square tube on the torch mount and securing it in the mounting clamps Leave a generous loop in the lead for strain relief Attach the motor cable Y cable to the motor and replace the cover Route the cable through the revealed slot Attach the cable carrier links together and to their link ends to form the cable carrier Op...

Page 43: ...ot that the air line and ground lead will run through Avoid crossing the ground lead Thread the cable through the rubber grommet leading into the chuck box and secure it to to the strain relief with cable ties Connect the cable securely to the motor pigtail connector inside the chuck box Ensure that the cable runs safely and tangle free to the CNC controller location Place the CNC controller well ...

Page 44: ... gases This would included specifications for flow volume pressure and quality Ensure that you have the appropriate regulators and filters for the air or other gas lines Connect one air hose to your plasma cutter and the other to the compressed air connection near the chuck mount Route the compressed gas lines so that they will not be damaged when handling material before during or after cutting S...

Page 45: ...s The Pro Series CNC Controller has motor cable connections on the rear panel The XLR type connectors click into place to provide a secure connection Connect the chuck motor cable X cable to the AXIS 1 connector Connect the torch carrier motor cable Y cable to the AXIS 2 connector Place the CNC controller well away from the plasma power source to avoid electromagnetic interference EMI Note The Pro...

Page 46: ...and black that should be connected to the relay terminals on the CNC Controller You may have to cut off existing lug connectors and strip the insulation from the wires to insert them into the terminal connectors on the CNC Controller this is the normal procedure Tighten the screw to provide electrical and mechanical contact The terminals shoud grip the wire and not the insulation and the insulatio...

Page 47: ...r Qty Part Description Part 1 MPMP with cables routed to CNC Con troller From Step 13 1 AVHC controller 03 0001 001A 25 or 03 0001 003A 50 or 03 0001 005A 75 optional purchase 1 CNC interface cable Supplied with plasma cutter 1 Signal cable package Supplied with AVHC Required parts components Instructions Connect plasma cutter wires to the AVHC Controller and also from the AVHC Controller to the C...

Page 48: ...rd USB printer A B cable to connect the computer laptop or desktop to the CNC controller Consider locating the computer and the CNC Controller as far from the plasma cutter as possible This helps reduce electromagnetic interference EMI EMI can reduce cut quality Illustrations Closeup of the USB port on the CNC Controller This photo shows two USB ports stacked vertically There may be a different nu...

Page 49: ...ts components Instructions The Torchmate Driver software to be installed is on the USB Flash Drive in a folder called Driver Software Double click on Torchmate4LiveSetup The installer wizard will start and ask to continue installation Approve and click Next Under Customer Information enter a User Name and a Company Name then click Next For the Destination Location accept the default folder and cli...

Page 50: ...ly click on the icon for the Torchmate4 Driver software It has a black background Note the Torchmate CAD software if you have that installed has a white background The Torchmate Driver software loads new setup files for different configurations from a special original folder then prompts you to save the selected file using the same name by default in the working folder This allows custom configura...

Page 51: ...Jog control panel with the control panel selection buttons Leave the drop down selections at Continuous and Medium Click on the yellow jog arrows to jog the torch and the chuck Click and hold the jog arrow buttons to get continuous motion Make sure the torch and chuck move in both forward and reverse directions If the motion is not satisfactory or troubled check the connection status the configura...

Page 52: ...ty Part Description Part 1 MPMP with CNC Controller From Step 24 1 Laptop or PC with Torch mate Driver software From Step 24 Required parts components Instructions Make sure the correct configuration file is loaded for the pipe diamenter See Step 20 Select Configuration Machine Drive Parameters Click the X button Select Edit Drive Mechanism Enter the pipe O D into the field for Lead Screw Thread P...

Page 53: ...er length of 6 I D Sch 40 pipe from your stock or scrap Required parts components Instructions Obtain a 4 or longer length of Sch 40 pipe with an I D of 6 and load it onto the ball transfer cradles Loosen the height adjustment levers and set the chuck height and jaw opening to hold the pipe Lightly tighten the jaws with the chuck key Jog the chuck X axis in either direction Refer to Step 24 Tighte...

Page 54: ...ut chart Use the menu item File Open G code select the appropriate speed test file and click the Open button Again select a file with the cut chart s speed nearest the center of the speed ranges 220 to 150 180 to 110 140 to 70 or 100 to 30 Illustration Select the chart for the material type amperage and thickness near the center of the chart if possible Then find the recommended speed values Here ...

Page 55: ...e torch position so that the distance from the torch tip to the pipe being cut corresponds to the cut chart for the material thickness for the amperage being used for the particular plasma cutter See Step 27 For instance For the Kaliburn Dagger 100 as shown in the cut chart example cutting 6 I D sch 40 pipe at 60 amps set the height to 0 13 inches For the Hypertherm PowerMax 65 cutting 6 I D sch 4...

Page 56: ...with that material near the center line Verify amperage and install the consumable set for that amperage 60 amps for the demo cut pipe in illustrated cut chart Use the menu item File Open G code select the appropriate speed test file and click the Open button Again select a file with the cut chart s speed nearest the center of the speed ranges 220 to 150 180 to 110 140 to 70 or 100 to 30 Illustrat...

Page 57: ...pre cut conditions Cut file is loaded and TM4 shows Connected status Air gas supply is connected and in the correct pressure range Air is being directed through the chuck Correct amperage range has been selected for the installed consumables The torch height is correctly set Click on the Start button to begin cutting Illustration Click the Start button WARNING Cut parts retain heat for many minute...

Page 58: ...es have short lives and initiation of cutting is difficult When heights are too small the bevel is wide at the bottom the arc may be unstable and hard to start or pierce and the arc tends to extinguish if the material is touched A correct height will have an appropriate bevel and a stable arc With a higher amperage higher speeds are possible within the reasonable capacity of the plasma cutter Too ...

Page 59: ...nts Qty Part Description Part 1 MPMP system From Step 31 Required parts components Instructions Start the Torchmate Driver software on the computer and connect to the CNC controller Load the G code file Select File Open G code Navigate to C WinMPM FGC select demo fgc and click Open Illustration The file demo fgc was created with the WinMPM design program which we highly recommend for use with the ...

Page 60: ...uctions The G code that controls the cutting speed feed rate begins with the letter F and it is followed by the speed value in inches per minute If using the example above the best line in the line speed test was the 90 ipm line then F90 would set that feedrate in the G code Double click on the G code window to open the G code editor and change the second line to F90 Click Close and when asked Sav...

Page 61: ...t file is loaded and TM4 shows Connected status Air gas supply is connected and in the correct pressure range Air is being directed through the chuck Correct amperage range has been selected for the installed consumables The torch height is correctly set Click on the Start button to begin cutting Click the Start button WARNING Cut parts retain heat for many minutes Handle only with approved tools ...

Page 62: ...54 MASTERPIPE Mini Profiler ...

Page 63: ...55 Driver Software Driver Introduction ...

Page 64: ...oth a User Name and a Company Name Click Next to continue For the Destination Location we recommend using the default install location unless you have a specific reason to install at another location Click Next to continue Review the installation setup information Use Back to correct any errors Click Next to begin the installation The software installs all the necessary components including any ne...

Page 65: ...57 Driver Software Illustrations screen shots of the TM4 installation pro cess ...

Page 66: ...nstall them manually Go to the Start menu and right click on Computer or My Computer Then select Manage Select the Device Manager from the left menu in the Computer Management screen Look under either Universal Serial Bus Controllers or Other Devices Click the to expand the listings of devices Select the USB Signal Generator 501A Right click on this and select Update driver This will begin the dri...

Page 67: ...59 Driver Software Illustrations screen shots of the device driver installa tion process ...

Page 68: ...lan Settings window From the dropdown list for Turn off the display select Never From the dropdown list for Put the computer to sleep select Never Computers and particularly battery powered laptop computers frequently come pre con figured to save energy by turning off the screen and putting the computer into a sleep mode if no keyboard or mouse activity is detected for a certain period Since you d...

Page 69: ...61 Driver Software Set both to Never Select Change when the computer sleeps Power options Control Panel Edit power plan settings ...

Page 70: ...file go to File X New Setup An information box appears reminding you that you are about to load a pre configured setup file Use this reminder to remember that if you want to save your current configuration before loading a new one you should use the menu selection File X Save Setup You ll have a chance to cancel Click OK to continue A selection box appears Make the appropriate selection refer to t...

Page 71: ...These setup files contains presets for pierce delays and for importing files with two dimensions of movement Select the file that corresponds to your Growth Series size Torchmate2x2Router stp Torchmate2x4Router stp and Torchmate4x4Router stp are for router configurations on a Torchmate Growth Series table They contain settings to enable z axis for routing and for importing files with three dimensi...

Page 72: ...al representation of what is being cut Can be configured to display different views for routing applications G code Displays the machine code for the file loaded Control Panel Selection Allows different control panels to be selected Current Control Panel Displays the selected control screen Output Box A user defined screen that shows different parameters for tools delays and outputs Coordinates or...

Page 73: ...65 Driver Software VIEWPORT OUTPUT BOX CONNECTION STATUS G code COORDINATES CURRENT CONTROL PANEL CONTROL PANEL SELECTION Illustration screen shot of the TM4 screen showing the location of the panels ...

Page 74: ...t pull down is how fast the machine will move Point Similar to the jog panel the point panel moves the machine for positioning Type a coordinate and pressing move to have the machine travel that distance A list of reference points allows quick movement The feed rate for the motion can also be set Home The home panel is used only if optional limit switches are installed on the machine Limit switche...

Page 75: ...will start the code entered here reset will jump back to the beginning and hold will pause the code Cycles The cycles panel creates G code files without the use of a CAD software The cycles represent simple programs for routing and drilling Each cycle will open a configuration screen with options to write the program Illustrations screen shots of the different control panels G code Jog Point Home ...

Page 76: ...so be zeroed individually by selecting either Zero X or Zero Y Any non zero coordinates can be set for the current position using the Set XEnter function For equipment that has limit switches installed you ll want to define the coordinates for a machine envelope which is the area in which the tool must remain and cannot be exceeded by jogging or under program control The Machine coordinates displa...

Page 77: ...To set the program zero point jog the machine to the de sired zero point and click Set Illustrations screen shots of the Coordinates panel ONLY on machines with limit switches will you normally want to display the Machine coordinates or change their zero point ...

Page 78: ...rom the driver software will be executed on the machine Note For safety reasons before the connection is made the operator should have a basic understanding of TM4 operation If a connection to the electronics unit fails check the power connection and the USB connection Refer to the Troubleshooting section for more steps regarding problems with connecting 1 Never let the machine tool run unattended...

Page 79: ...ots of the connection status panel showing Not Connected and Connected states Illustration screen shot of the Safety First warning and agreement Illustration screen shot of the error window indicating a problem connecting to the CNC Controller ...

Page 80: ...ls on G code programming are available on the Internet These can be helpful for you when using TM4 software If you create and export a DXF file from a drawing program and particularly from Torchmate CAD CAM and then import it into TM4 TM4 will convert it into G code prompt you to save the G code with a file extension of FGC and display the G code lines in the G code display panel In the future you...

Page 81: ...holes X and Y codes Identify absolute or incremental destination positions on the respective X and Y axes F codes Specify the feed rate typically in IPM or inches per minute I and J codes Specify the respective arc center coordinates on the X and Y axes There are many other G codes that may be used but these account for many of the operations you would perform with your CNC plasma cutting system F...

Page 82: ...ears as a dotted line Completed movement and jogged movement appears in blue yet to be completed movement appears in red A viewport can be Zoomed in and out using a mouse with a scroll wheel Panned by holding down a right mouse click while moving the mouse Rotated in 3D X Y Z views by holding down both the right mouse button and the Ctrl key while moving the mouse Additional zoom options are avail...

Page 83: ...is screen capture the router is completing the first of four passes The bit height is shown on the z axis on the left the top right shows the x and y axes and the bottom left shows a three axis view The coordinates panel also shows the z axis Halfway finished cutting at line 36 with moves turning blue when complete Cut completed at line 74 with coordinates at zero again with all moves showing blue...

Page 84: ...iety of functions from counting pierces to setting preheat delays To edit any of the values in the set of user defined variables select Edit Once a change has been made select Accept to keep the changes or Cancel to undo the changes and revert to the previous settings When editing the user defined variables all other functions of the software are locked out until either Accept or Cancel is selecte...

Page 85: ...n Configure status buttons for the output lines to control them from the Output panel or the Aux panel On the output panel the yellow status button for Marker shows it is On while the gray status button for Plasma shows it is Off Click a button to toggle its state You can have the same buttons appear on the Aux panel ...

Page 86: ...must read and agree to the safety rules for CNC machine operation before the connection between your CNC Controller and your compter will be completed Please remember Safety First Before running a program jog the machine to verify that it moves correctly Use the jog buttons to move the machine to its zero location and use the Program Set X Zero All to set the new zero When TM4 loads it uses its st...

Page 87: ...79 Driver Software Set the zero position First use the jog buttons to move to the zero position Next select Zero All after clicking this Set button ...

Page 88: ...h motor is plugged into a corresponding numbered port on the back of the electronics unit Set the axis and direction For X Y CNC tables it may be most helpful to set the axes and directions so that from the operator s viewpoint the machine moves the same as it does on the screen For example from your perspective if you see the machine move left or right instead of closer or away from you when you ...

Page 89: ...1 Driver Software Use the jog buttons to test the orienta tion and direction of the motor signals Change the orientation by reversing the axis labels Change the direction by reversing the motor polarity ...

Page 90: ... connected to the CNC Controller it will turn on activate and the button turns yellow Turn the tool off by clicking the status button again The button becomes gray again If additional tools are set up the activation and operation of these tools will also need to be setup and tested To perform the tests first identify the output lines that control the different tool Go to Configuration X I O X Outp...

Page 91: ...on the Output panel When the output lines have been identified re label them in the Output Lines configuration pane Label each output line with its corresponding number to easily identify the controlled tool Display the status buttons in the Output panel by setting these value to Yes Test each line in the Aux panel or the Output panel by toggling its status ...

Page 92: ... direction Set the amperage on the plasma cutter appropriately for the material being cut Consult the cut charts in the plasma cutter manual Select Start from the G code panel The machine cuts multiple parallel lines and then cuts around all of the lines The first line is cut at a high speed and each subsequent line is cut slower Right after the cut the part will be very hot Carefully handle it wi...

Page 93: ... min 50 in min 40 in min 30 in min 20 in min 10 in min Thick Excessive Slag Not Cut Through Cleanest Cut Typical underside of typical cut Load the line speed test file Analyze the line speed test cuts Use the Set button to set the zero point The G code shows the feedrate of the line being cut If the machine must be stopped while in motion at any time press any key on the keyboard to pause the prog...

Page 94: ...rface of the material Select Set X Zero All in the Program panel This sets the X Y and Z zero points of the program to the current router bit location The test cut is about 2 X 2 It can vary based on the bit type Select Start from the G code panel to begin routing the test part After the test is complete examine the piece for quality of cut When testing begin slower than expected and increase the ...

Page 95: ...mber Final Tool Down Mill ing Total removed in all passes Positive Number XY Feedrate Feedrate after reaching cutting depth Plunge Feedrate Z axis feedrate to reach cutting depth Set the test parameters Run the test file and evaluate the results If the machine must be stopped while in motion at any time press any key on the keyboard to pause the program ...

Page 96: ...88 MASTERPIPE Mini Profiler ...

Page 97: ...89 Installation and Operations Guide Parts ...

Page 98: ... carrier links support tray and hanger TMS 050 0005 02 to max of 4 add on sections When ordering parts for the MASTERPIPE Mini Profiler please contact the Vernon Tool Parts Desk Technical Support will also help you with parts in addition to helping you with operating the CNC system and troubleshooting problems The Parts Desk is available Monday through Friday from 7 30 AM to 4 00 PM Pacific Time H...

Page 99: ...Guide Toll Free 1 866 571 1066 x5 3 International 775 673 2200 x5 3 Fax 775 673 2206 Email service vernontool com Call Vernon Tool for Consumables or visit our web store at TorchmateStore com www TorchmateStore com Call Fax or Email ...

Page 100: ...92 MASTERPIPE Mini Profiler ...

Page 101: ...93 Installation and Operations Guide Troubleshooting ...

Page 102: ...d Watch for unusual wear or build up of spatter When replacing consumables always use the parts that go with the consumable set for the amperage you are using For instance if you are cutting at 60 amps repacement parts should come from the 60 amp set For trouble free cutting the torch must be the correct distance above the workpiece This results in the best arc shape which reduces bevel and the co...

Page 103: ...nsumable sets available The cut chart will suggest a feedrate for the type of material thickness and amperage being used Use of the speed tests files helps you build your own cut chart for the materials you typically use for cutting See Step 30 Cut the speed test The pierce delay allows the pierce to complete before moving the torch into its cutting motion Set the Pierce Delay value with AVHC fals...

Page 104: ...he level of the floor and to bring the sections to level Find the original scribe marks or scribe new reference marks on the rail support plates an equal distance from the rail edge at the ends and at each module joint Pull a string taut across the marks Gently move the modules to align them as illustrated You may need to loosen the bolts on the rail connector plates underneath the rail assembly j...

Page 105: ...adjustable leveling feet to level the base machine and any add on sections Use the divider calipers to scribe ref erence marks an equal distance from the side of the rail Mark each module where they join and at the ends Check each reference mark along the string and adjust the position of the module so that all reference marks are aligned Pull a string taut along the rail and clamp it next to the ...

Page 106: ...on or concern arises or if a part is missing please contact Torchmate Technical Support Technical Support will also help you with operating the CNC system and troubleshooting problems Technical Support is available Monday through Friday from 6 30 AM to 4 00 PM Pacific Standard Time Call Fax or Email Technical Support Call us for Consumables or visit our web store www TorchmateStore com ...

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