CNC Plasma&Flame Cutting

Control System Manual

(Ver. 2.1)

(Model : 2100)

1
 Catalog

CHAPTER 1 SUMMARIZE .................................................................................................................................... 1

1.1 BRIEF INTRODUCTION ......................................................................................................................... 1

1.2 CHARACTERISTICS OF SYSTEM ....................................................................................................... 1
1.3 TECHNICAL STANDARD....................................................................................................................... 1
1.4 SYSTEM INTERFACE.............................................................................................................................. 2
1.5 HARDWARE CONFIGURATION .......................................................................................................... 3

CHAPTER 2 SYSTEM BOARD AND MAIN INTERFACE ..................................................................................... 4

2.1 INTRODUCTION OF OPERATING BOARD ....................................................................................... 4

2.2 POWER ON PROCESS AND MAIN INTERFACE .............................................................................. 4
2.3 F UNCTION INDEX OF MAIN INTERFACE ...................................................................................................... 7

CHAPTER 3 CUTTING FUNCTION ...................................................................................................................... 9

3.1 C UTTING O PERATION I NDEX ..................................................................................................................... 11

3.2 S PEED R EGULATION ................................................................................................................................... 12
3.3 F ORWARD .................................................................................................................................................... 12
3.4 B ACKWARD ................................................................................................................................................. 12
3.5 E DGE C UTTING / O FFSET C UTTING / R ETURN ......................................................................................... 13
3.6 B ACK TO R EFERENCE F UNCTION .............................................................................................................. 14
3.7 O XYGEN G AS P REHEAT T IME R EGULATION ........................................................................................... 15
3.8 P ERFORATION P OINT S ELECTION ............................................................................................................. 16
3.9 D YNAMIC A MPLIFICATION ........................................................................................................................ 17
3.10 C UTTING E XIT .......................................................................................................................................... 17

CHAPTER4 PART OPTIONS.................................................................................................................................. 19

4.1 XY MIRROR ................................................................................................................................................. 19

4.2 A NGLE ADJUSTMENT .................................................................................................................................. 20

4.3 A RRAY ......................................................................................................................................................... 21
4.4 Z OOM IN / OUT .............................................................................................................................................. 25

4.5 S ELECT ROW / NUMBER ................................................................................................................................ 26

4.5.1 Select row.................................................................................................................................. 27

4.5.2 select number ............................................................................................................................ 29
4.5.3 operation after select row/number .............................................................................................. 29
4.6 R ESTORE ..................................................................................................................................................... 30

CHAPTER 5 MANUAL FUNCTION..................................................................................................................... 31

5.1 F IXED M OVING F UNCTION ........................................................................................................................ 31

5.2 C ONTINUOUS M OVING F UNCTION ............................................................................................................ 32
5.3 FIXED -LENGTH MOVING ............................................................................................................................. 32
5.4 B REAKPOINT R ECOVERY ........................................................................................................................... 32

CHAPTER 6 FILE OPERATION ........................................................................................................................ 34

6.1 F ILES IN THE H ARD D ISK .......................................................................................................................... 34

2
 6.2 F ILES IN THE U D ISK ................................................................................................................................. 35
6.3 S EARCH F ILE .............................................................................................................................................. 37
6.4 E DIT C ODE .................................................................................................................................................. 37
6.5 N EW C ODE .................................................................................................................................................. 38
6.6 C OMPILE C ODE ........................................................................................................................................... 38

CHAPTER 7 PARAMETER SETTING................................................................................................................. 39

7.1 C OMMON PARAMETERS .............................................................................................................................. 39

7.2 F LAME P ARAMETERS ................................................................................................................................. 40

7.3 P LASMA P ARAMETERS ............................................................................................................................... 42
7.4 P OWDER P ARAMETERS .............................................................................................................................. 43
7.5 S YSTEM PARAMETERS ................................................................................................................................ 44

7.6 P ARAMETER IMPORT .................................................................................................................................. 46

7.7 P ARAMETER EXPORT .................................................................................................................................. 47

7.8 S AVE PARAMETERS .................................................................................................................................... 47

CHAPTER 8 DIAGNOSIS FUNCTION ................................................................................................................ 49

8.1 DIAGNOSIS INTERFACE INDEX ................................................................................................................... 50

8.2 I NPUT D IAGNOSIS ....................................................................................................................................... 50
8.3 OUTPUT D IAGNOSIS .................................................................................................................................... 50
8.4 K EY - PRESS D IAGNOSIS .............................................................................................................................. 51
8.5 S YSTEM SELF - CHECK ................................................................................................................................. 52

8.6 DATE AND TIME .......................................................................................................................................... 53

8.7 S YSTEM D EFINITION .................................................................................................................................. 54
8.7.1 Parameter backup and restore................................................................................................... 54
8.7.2 Input definition ........................................................................................................................... 55
8.7.3 Output definition ........................................................................................................................ 55
8.7.4 Coordinate definition .................................................................................................................. 56

CHAPTER 9 GRAPH......................................................................................................................................... 58

9.1 C HOOSE G RAPH .......................................................................................................................................... 58

9.2 F ILM /H OLE S IZE ......................................................................................................................................... 59

CHAPTER 10 PORT EXPLANATION ................................................................................................................. 61

10.1 I NPUT PORT ............................................................................................................................................... 61

10.1.1 Input Wiring Instructions.......................................................................................................... 63

10.1.2 Remote Input .......................................................................................................................... 64
10.1.3 Input Configuration.................................................................................................................. 65
10.2 O UTPUT P ORT ...........................................................................................................................................67
10.2.1 Output Wiring Instructions ....................................................................................................... 68
10.2.2 Output configuration ................................................................................................................ 72
10.3 M OTOR P ORT ............................................................................................................................................74
10.3.1 Typical wiring diagram of the electrical motor interfaces .......................................................... 75
10.3.2 Coordinate Mapping ................................................................................................................ 79

CHAPTER11 INSTALLATION AND DEBUGGING ............................................................................................. 80

3
 11.1 H ORIZONTAL / VERTICAL PULSES NUMBER SETTING ........................................................................... 80

CHAPTER12 THE USE OF BIOS ....................................................................................................................... 81

12.1 S YSTEM UPGRADE .................................................................................................................................... 82

12.2 W ELCOM INTERFACE UPGRADING .......................................................................................................... 82

12.3 M OVEMENT CONTROL UPGRADE ............................................................................................................ 82

12.4 M OVEMENT B ACKUP ............................................................................................................................... 82
12.5 S YSTEM R ESET ......................................................................................................................................... 82

APPENDIX 1 G, M CODE RAPID CONSULT ..................................................................................................... 83

CHAPTER 1 SUMMARIZE

1.1 BRIEF INTRODUCTION

The digital controller 2100 is a new production, which is integrated many merits of the same productions at
home and aboard. The controller can control the motion of two axis, which is apt to the application of flame or
plasma cutting. This controller is very light and handy and it is very easy to operate. The controller provides menu or
illustration for all the operations for the convenience of users. All key switches are human oriented designed, and
they are very convenient and comfortable.
The controller chooses high speed DSP and ARM as its core to assure the cutting process to be more stable.
The motion control algorithm is optimized so that the machine can move more stale and reliable, and it can save the
life of the motor and the mechanical parts.

00000000
00
|'JWE:| I I I ËNDj

0
Fig 1.2 2100

1.2 CHARACTERISTICS OF SYSTEM

1) 7 inches 800*680 dots color LCD.

Man-Machine-Dialog software and Professional Hot Key design for easy cutting operation,

4
 2100 CNC Controller

user-friendly as Hypertherm's EDGE controller.

2 ) Multi-language file system and menu, and the menu can be switched only by one key.
3 ) DSP core can control the machine move in high speed accurately, stably and in low noise. 4 )
Long-distance remote control can control the machine to move forward ,backward, left,
right and cutting start, stop and so on (optional configuration).
5 ) Support the EIA code (G code) and various FastCAML FreeNest> SmartNest> IBE softwares.
6) compact keyboard design and easy to input files.
7 ) Operations such as Proportion Zoom, Rotate, Mirror, Array display, Steel plate angle
adjust ........ all available and have professional solution in the CNC controller.
8) Coordinate system can be customized to support the two-dimensional coordinates of all eight kinds.
9) All input and output port type and the number can be customized (normally open or
normally closed)
10) System Self-diagnosis for easy trouble-shooting.
11) all functions and techniques can upgrade online 12 )
Import and export files by single or all files.
13) Support the Flame, Plasma, Dusting draw and Demonstration four kinds of mode.
14) Flame and Plasma are separated in the control IO ports.
15) Support THC, two level preheat, three level pierce in flame mode.
16) Plasma arc feedback, positioning feedback, automatically shut down the arc at the corner.
17) Support edge cutting. It can save the preheat time for the thick steel plate.
18 ) Movement speed can be real-time acceleration, deceleration.
19) According to plate thickness, the cutting speed is automatically restricted by a speed limit in the corner,
effectively preventing over burn.
20 ) Dynamic/static illustration o f the process, graphics zoom in / out, dynamically tracking
cut-off point under zooming state.
21 ) Automatically memorize the working situation and the last cutting point when power o f f .
22) "Cutting offset" function can avoid waste the steel plate when the nesting o f the plate is
calculated wrong.
2 3 ) set u p different administration authority and the corresponding password to safeguard the
interests o f managers.

5
 2100 CNC Controller

1.3 TECHNICAL STANDARD

1 ) Control Axis : 2
2) Control accuracy : +/-0.001mm
3) Coordinate range: +/- 99999.999mm
4) Max pulses : 200kHz Max speed: 15000 mm/m
5) Max lines o f code: 150000lines 6 )
Max size o f single code file : 4M 7 )
Time resolution : 10ms
8) Working Voltage : DC 24V in put
9) Working Temperature : -10 °C -60 °C. Relative Humidity, 0-95%.

1.4 SYSTEM INTERFACE

1 ) 15 pins interface o f 2 axis o f motor drive.

2 ) 25 pins interface o f 16 channels optical couple output ports, max back flow current 300mA.
3 ) 25 pins interface o f 16 channels optical couple input ports, max output current 300mA.
4 ) U S B interface on the front panel.
5 ) Extend I O input/output ports, PWM input ports, analog input ports.

1.5 HARDWARE CONFIGURATION

1 ) Monitor:15 inch, 1024*768, high definition 16 million colors and high brightness LCD or 10.4 inch 800*600,
26 million color LCD.
2 ) Memory: 64M SDRAM
3 ) Memory available for user: 256M or 1G electronic hard disk
4 ) System master frequency: 400MHz
5 ) U S B : U S B 1 . 1 front interface
6) Keyboard: electronic PCB foil keyboard( one machine) or standard industrial
keyboard(split type machine)
7) Chassis: full-steel structure completely shielded which defends electromagnetic radiation,
interference and static electricity.

CHAPTER 2 SYSTEM BOARD AND MAIN INTERFACE

2.1 INTRODUCTION OF OPERATING BOARD

-
6
 2100 CNC Controller

Enter

3iW o
H I [[Ici
non
Fig 2.1 board and keys [ F 1 ]

- [F8]: Function key in different interface

[ S t /PgUP]: page-up key o f code interface or Torch u p in other interface [S I /PgDn]:

page-down key o f code interface or Torch down in other interface [ F + / H O M E ] : Accelerate
or skip to the head o f code line [ F—/END ] : Decelerate or skip to the tail o f code line
[ 1 ]-[9]: during the cutting process, change the cutting speed to ratio o f the speed limit
you have set, for example press [ 1 ], change the cutting speed to 10% o f the speed limit
you have set, press [ 2 ] , change the cutting speed to 20% o f the speed limit you have set

2.2 POWER ON PROCESS AND MAIN INTERFACE

When power just on, the system will go for the process o f self scan:

7
 2100 CNC Controller

Fig 2.2 system self scan I n the starting process, there is 3 seconds to
countdown, before the countdown is over, i f pressing [ F 2 ] , it will enter the bios starting interface shown as Fig2.3
(please take the reference o f the appendix 2 to run bios). I f pressing any other key, it will jump over the countdown
and directly enter the welcome interface. I f pressing no key, it will countdown to 0 and then enter the welcome
interface shown as Fig2.4.

F1 - J^^Jrl^Syster ri software update)

F2 - ^M#M^^(Welcome picture update)
F3 - ìtijjféfW^Motion update)
F4 - J^^^ff^System backup)
F 5 - M^fcì&ìM (System recovery)
F6 - Jnsjj|lit(Start system)

Fig 2.3 bios interface

8
 2100 CNC Controller

Fig 2.4 welcome interface In the welcome interface, press any key to enter the main interface automatically shown
as Fig2.5:

FLSK F2500 Version Speed : File: Status: Current Line /Hole:

3.3.71.1 00000 SHAPE 43. TXT 00000/00000

• Ignition
• LowPreheat
• HighPreheat
• Pierce 1
• Pierce 2
• Pierce 3
• TorchUp
• TorchDn
• THC En
• Exhaust

CutSpeed [X] 1000.00 Kerf [Z] 1.20

ManualSpeed [Y] 3000.00 Angle 0.00
Manual [F] keepMov StepMov JConti StepDis
[G] 5.00 Flame Cu [G]

+X:500.00 -X:0.00 +Y:500.00 -Y:0.00

00001:(TEST PATTERN)
00002:G92

F3 F7
F1 ShapeLib F2 Files F5 F6 ZoomIn
PartOption ManualMov
Diagnose
e
F4 Setups
F8 Zero

Fig 2.5 the main interface

9
 2100 CNC Controller

In the main interface, press [ F 1 ] - [ F 8 ] for the following functions:

[ F 1 ]: ShapeLib: pressing F 1 to enter the Shape Library including 45 common shape, and most
o f them have plate size and hole size. [ F 2 ] : Files: You can load local files, U disk files or edit, import,
export and delete codes. [ F 3 ]: PartOption: make actions o f mirroring, rotation, plate adjusting, plate arraying,
selecting row and hole or code edition etc. [ F 4 ] : Setups: setting all parameters.
[ F 5 ] : Diagnose: including input ports diagnosis, output ports diagnosis, keyboard diagnosis, system self check,
date setting and system self defines. [ F 6 ] : ZoomIn: Zoom in the shape in full screen. [ F 7 ] : ManualMove:
Manually move the machine.
[F 8 ]: Zero: Clear the coordinate o f X and Y before starting cut or after cutting over.
[ X ] : CutSpeed: Setting the cutting speed.
[ Y ] : ManualSpeed: Setting the manual moving speed.
[ Z ] : Kerf: Setting the kerfs' compensate value.
[ F ] : Manual: Setting the mode o f manual movement including keepMov(keep movement), StepMov(step
movement), ContiMov(continue movement). The selected mode is black background.
[ G] StepDis: Setting the distance o f the fixed-length.
[ M ] Selecting the cutting mode including Flame Cu(flame cutting), Plasma C(plasma cutting), Demo run.

2.3 Function index of main interface

Main Interface

F1 F2 F3 F4 F5 F6 F7 F8

ShapeLib Files Part Setups Diagnose Zoom In Manual Move Zero

Cption
F1 F1
F1 F1
I—I Input keep
Disk File Mirror Diagno moving
F1 se
camon

--- F2 ---
F2 U
Cutput
Disk
Diagnose
F2 --- F2 ---
Angl continue
e moving
F2
Flam
e

Cpen Cutput step

F3 F3 F3
F3 movin
Search Arra Plasma
g
y -- F3 --

F4 F4 F4
Edit File Scale Speed-Down
F4
Powder
F4
Close
Cutpu
t
line and
pierce F5
F5
F5 Speed
Keyboar
Del File accelarat
d
F5 i on
Diagnos
F5 System
e
Select
Import I—I System
Parameters Self-chec
F6
k
Copy to U F6

F6

10
 2100 CNC Controller

F7
F7
Preview Export
Parameters
F7
F7
Revert
Date time
F7
Recovery

--- F8 ---
F F8
System
8 Sav
Definition
C e
K
F
8
C
K
F
8
C
K

F1 F2
F3 F4 F5 F6
F8 Update
Parameter Parameter Definitio Encryption Decryption Language
n
Recovery Backup
F1
Input

F2
Cutput

F3
Coordinate

F8
Sav
e

11
 2100 CNC Controller

CHAPTER 3 CUTTING FUNCTION

I n the main interface, press the [SPACE] to enter the cutting interface, shown as follows:

FLSK F2500 Version Speed rile: status : Current

3.3.71.1 : SHAPE 43. Line/Hole
00000 TXT 00000/000
00
T3
7
• Ignition
• LowPreheat
• HighPreheat
• Pierce 1
• Pierce 2
• Pierce 3
• TorchUp
• TorchDn
• THC En
• Exhaust

CutSpeed [X] 1000.00 Kerf [Z] 1.20

ManualSpeed [Y] 3000.00 Angle 0.00
Manual [F] keepMov StepMov |Conti StepDis
[G] 5.00 Flame Cu [G]

1
+X:500.00 -X:0.00 +Y:500.00 -Y:0.00
00001:(TEST PATTERN) 2 ]
00002:G92
'
F4 F6
F1 Back F2 Forward F3 GoBack
SpeedDown PreheatDow
n
F5 SpeedUp
F7
PreheatUp
F8
JumptoPier
ce

12
 2100 CNC Controller

Fig 3.1 cutting function interface Show the current

workpiece's cutting path, including the slotted value. Show the G-code being
processed, shows the current and next line.
Show the current cutting speed, during processing, you can press the keyboard's number keys [ 1 ] - [9]
to achieve quick speed regulation. For example, press the number [ 3 ] , the speed is automatically adjusted to 30%;
press the number [ 8 ] the speed is automatically adjusted to 80%.
X shows the absolute coordinate o f the torch in X direction. Y shows
the absolute coordinate o f the torch in Y direction. I n the cutting
interface:
• Press [ X ] : M o d i f y the current maximum cutting speed.
• Press [Y ] : M o d i f y the current maximum speed manual shift car.
• Press [ F ] : Change the current manual method.
• Press [ G ] : M o d i f y the current fixed-length fixed long-distance move.
• [ S T A R T ] ( [ F 9 ] ): Start cutting.
• [ S T O P ] ( [ F 1 0 ] ): Parking, the system can suspend all ongoing actions.
• [ F 1 ] :The torch move back along the cutting path(I / O port closed)

• [ F 2 ] : The torch forward along the path ( I / O port closed).

• [ F 3 ] : Return to the starting point o f cutting torch, i.e. the starting point o f the current work piece.
• [ F 4 ] : Decrease the cutting speed, each decrease o f 1% click rate.
• [ F 5 ] : Increase the cutting speed, each 1% increase in click rate.
• [ F 6 ] : Reduce the preheat time, skip the remaining preheat time, and the system automatically records
preheat time.
• [ F 7 ] : Increase the preheat time once 15 seconds.
• [ F 8 ] : When the system is suspended, for selecting perforation point; when the system begins to move, for
the dynamic amplification.
•four direction keys ( U p , down, left and right): When the gun through, manually move the torch.
3.1 Cutting Operation Index

Cutting
Interface

F1
Backward

F2 Forward

F3 Back to
reference

13
 2100 CNC Controller

F4 Speed
Down

F5 Speed
Up

1
F6 Preheat
Down

1
F7 Preheat
Up

F8 Jump to
pierce

Automatic operation index

3.2 Speed Regulation

3.2.1 Normal Speed Regulation

I n automatic operation, or when the system is suspended, in the cutting interface the system can regulate
speed.
The operation panel, press [ F 5 ] or [ P R E ] , increasing at a rate per click rate o f 1%.Hold the [ F 5 ] or
[ P R E ] , then the rate will continuously increase to 100%.Increased to 100%, the speed is "common parameters" in
the "cutting speed."
The operation panel, press [ F4 ] or [ N E X T ], each click rate o f speed reduced by 1%.Hold the [ F4 ] or
[ N E X T ], then the rate will be continuously reduced to1%. Reduced to a very slow speed when running in order to
ensure the accuracy requirements, the system may auto-adjust the speed based on the size o f "horizontal pulses" and
"vertical pulses", actual speed may not be the "cutting speed" o f 1% is greater than 1%.
3.2.2 Quick Speed Regulation
I n automatic operation, or when the system is suspended, in the cutting interface the system can carry out
quick speed regulation.
I n the cutting interface, on the operation panel, press the number keys [ 1 ] - [ 9 ], the speed will quickly adjust
to the corresponding percentage figures 10 times, for example press [ 3 ] , adjust to 30% o f the speed limit you
have set, press [ 8 ] , adjust to 80% o f the speed limit you have set.

14
 2100 CNC Controller

3.3 Forward

I n the automatic function interface, press key [ F 1 ] , the machine start to move without real cutting. The
process does not include any ignition, perforation and any other I / O working. The machine just moves the torch
according to the graphic figure.
The function can be used to check the trail and code before you start the real cutting process, or can also be used
when the process needs through the gun. Press the red "STOP" key to stop the null cutting process i f you want.

3.4 Backward

During the running process, i f you want to go backward according to the origin trail to (maybe the iron board
was not cut through), you can follow the following direction:
• First, press "STOP" key to set the machine at pause status.
• In the automatic function interface, press key [ F 3 ] (Back) to make the machine go backward along with the
original trail. When the torch reaches the position you need, press "STOP" key to stop it. You may press key [ F 2 ]
to go forward i f the machine just went back too much.
Notice: Go backward or forward function can be used repeatedly to make the machine reach an ideal position.
• When the torch reaches the position you need, press "START" key again, i f the current cutting code is G01,
G02 or G03, system will automatically perforate before performing these

15
 2100 CNC Controller

procedures, and then continue the current program, i f the current row is not G01, G02 or G03, the system will directly
continue the current line program.

3.5 Edge Cutting / Offset Cutting / Return

When the torch is not on the actual path o f the current work piece, it will prompt as follows:

FLSK F2500 Version Speed : File: Status Current Line/Hole:

3.3.71.1 00000 SHAPE_43. TXT : Pause 00000/00000

• Ignition
[G]Cutting return • Lowheat
• HighPreheat
[X]Offset cutting • Pierce 1
• Pierce 2
[Y]only return • Pierce 3 0.1

\ v\
• TorchUp
A/,/ •
•
TorchDn
THC En
• Exhaust

CutSpeed [X] 1000.00 Kerf [Z] 1.20

ManualSpeed[Y] 3000.00 Angle 0.00
Manual [F] keepMov StepMov | ContiMov
StepDis [G] 5.00 Flame Cu [M]

F4 F6
F1 Back F2 Forward
+X:500.00 -X:0.00F3 GoBack
+Y:500.00 -Y:0.00
SpeedDown PreheatDow
00001:(TEST PATTERN) n
00002:G92 F5 SpeedUp
F7
PreheatUp
F8
JumptoPier
ce

Fig. 3.2 edge perforation There are

two reasons led to this situation:
( 1 ) When the common parameter "edge perforation" selects "Yes" and the next processing line G-code is M07,
the system will be automatically suspended. At this time, the torch can be manually moved to any edge o f the plate,
press the "start" button, the system will prompt as above
( 2 ) When the processing is paused, due to mechanical failure or other reasons, it needs to move the torch out o f
the actual path o f the workpiece, the above prompt will appear.
• I f press [ G ] , the system cutting returns back to the paused point, continue to cut it. This feature is
particularly useful for thick steel plate, it can reduce the preheat time and increase cutting efficiency. This function is
the commonly-used edge perforation function.
• I f press[ X ] , the system considers current point is the paused point, it will continue cutting it. That is, the
system o f f s e t s the cutting point. When the cutting machine paused or a power outage, i f the cutting tip or steel plate
with the pan has been o f f s e t , or the user would like to think that is o f f s e t cutting, you can press this button.
• I f press[ Y ] , The system only return to the paused point quickly, and then break o f f . During the cutting
process, i f discovery cutting torch malfunction, or other issues, need to move the

16
 2100 CNC Controller

cutting tip out o f cutting region to overhaul. After the maintenance, this key can be pressed. Then return to the
paused point, press the "start" button, the system automatically continues to cutting.

3.6 Back to Reference Function

Pause in the processing, i f press the [ F 3 ] , then the system will prompt:

FLSK F2500 Version Speed : File: Status Current Line/Hole:

3.3.71.1 00000 SHAPE_43. TXT : Pause 00000/00000

[X] 1000.00 Kerf [Z] 1.20 [Y]

X7)
3000.00 Angle 0.00
•Ignition •
[F] keepMov StepMov | ContiMov
[G] • 5.00 Flame Cu [M]
Lowheat
HighPreheat • 0.1
Are you sure to return? ENTER : Pierce 1 •
Pierce 2 •
Pierce 3 •
Sure ESC: Cancel TorchUp •
TorchDn
A/,/ C
M
•THC En
M •Exhaust
S

F4 F6
F1 Back F2 Forward F5 SpeedUp
F3 GoBack PreheatDown
SpeedDown F7
PreheatUp
F8
JumptoPierc
+X:500.00 -X:0.00 +Y:500.00 -Y:0.00 e
00001:(TEST PATTERN)
00002:G92
Fig. 3.3 return reference prompt Press the Enter key, the system will automatically
return to the starting point o f the work piece, and then the system automatically switches to processing the main
interface, and waits for further user action.

17
 2100 CNC Controller

FLSK F2500 File: Status

Version 3.3.71.1 00000 SHAPE 43. TXT : Stop 00000/00000

•Ignition •
Lowheat •
HighPreheat •
Pierce 1 •Pierce
2 •Pierce 3 •TorchUp •
TorchDn 0.1
•THC En
•Exhaust

CutSpeed [X] 1000.00 Kerf [Z] 1.20

ManualSpeed [Y] 3000.00 Angle 0.00
Manual [F] keepMov StepMov JConti StepDis
[G] 5.00 Flame Cu [M]

F3 F7
F1 ShapeLib F2 Files F5 F6 ZoonIn
PartOption ManualMov
Diagnose
e
F4 Setups
F8 Zero

Fig. 3.4 main process interface During the return process, the user can press the
"Stop" button to stop the operation, and can continue to return operation after pressing o f [ F 3 ] . Number o f back to
+X:500.00 -X:0.00 +Y:500.00 -Y:0.00
reference and stop has no limit.
00001:(TEST PATTERN)
00002:G92

3.7 Oxygen Gas Preheat Time Regulation

• In the preheat process, press the START ( F 9 ) key to skip the process o f preheat and perforation delay, and
immediately open the perforation signal then begin to cut.
• In the preheat process, press the stop ( F 1 0 ) key to stop preheat, waiting for the F9 key is pressed again.
• In the preheat process, press the F6 key then the preheat time will be reduced to the current preheat time
spent, and skip the process o f preheat and perforation delay, and open the perforation signal then begin to cut..
For example: the original system sets the preheat time o f 60 seconds after null cutting, when preheat needed,
the interface will count down, under normal circumstances, till 0 , the system begins the next step o f cutting, but i f
the system has the remaining 10 seconds o f countdown time, press F 6 , then the system immediately stops preheat
to begin the next step o f cutting, and records the preheat time o f 50 seconds, the system automatically thinks that
users need preheat time o f 50 seconds, the next preheat after the null cutting when the preheat time becomes 50
seconds.
• I n the preheat process, each press the F7 key, preheat time increases by 15 seconds, and the preheat time
maintains the increased value.

18
 2100 CNC Controller

For example: The original system sets the preheat time o f 60 seconds after the null cutting, during the system
countdown, each press F7, on the interface the countdown increases by 15 seconds, and the next time you need to
preheat, the initial preheat time be 75 seconds.

3.8 Perforation Point Selection

Before you start cutting or cutting is paused, the function key prompt F 8 is "select new pierce", then press F 8 ,
the system will prompt:

FLSK F2500 Version int Line/Hole:

3.3.71.1 Pause 00000/00000

•Ignition •
Lowheat •
HighPreheat •
Pierce 1 •
Pierce 2 •
Pierce 3 • 0.1
TorchUp •
TorchDn
•THC En
•Exhaust

CutSpeed [X] 1000.00 Kerf [Z] 1.20

ManualSpeed[Y] 3000.00 Angle 0.00
Manual [F] keepMov StepMov |ContiMov
StepDis [G] 5.00 Flame Cu [M]

00006: G01 X0 Y500.00

00007:G01 X500.00 Y0

F4 F7 F8
F6
F1 Back F2 Forward F5 SpeedUp JumptoPierce
F3 GoBack PreheatDownl PreheatUp
SpeedDown

Fig. 3.5 select new pierce I f you press E S C , the system will then return the
cutting interface. I f you press ENTER, the system will again prompt:
 2100 CNC Controller

Status
: Pause 00000/00000

• Ignition
• Lowheat
• HighPreheat
• Pierce 1
• Pierce 2
• Pierce 3 0.
• TorchUp 1
• TorchDn
• THC En
• Exhaust

CutSpeed [X] 1000.00 Kerf [Z] 1.20

ManualSpeed [Y] 3000.00 Angle 0.00
Manual [F] keepMov StepMov |Conti
StepDis [G] 5.00 Flame Cu [M]

F6 EditFiH F7 Revert F8 OK

Fig. 3.6 pierce prompt

pierce point can be input manually at this time. You can also press E S C to exit without manual input
perforation point, and then press the left and right arrow keys to select the perforation point.

3.9 Dynamic Amplification

After the start o f cutting, the F 8 in the cutting interface will become "dynamic amplification", then press the
F 8 key, full-screen amplify the processing graphic , and dynamically tracking.

F4 Fjj
F2 Forward F5 SpeedUp PS ZOCTTTI
PrehnaiDown

• Press the F 8 key continuously, the system will progressively amplify graphic.
• Press E S C to exit the amplified display, back to the cutting interface.

3.10 Cutting Exit

When the cutting operation does not get finished, and the cutting machine also being in the pause condition, i f
press [ E s c ] , the system will query whether quit the cutting operation. I f pressing [ E n t e r ] , the system will exit,
and i f pressing [ E s c ] the system will not exit, get into the automatically interface and go on with the cutting
operation at the current place.
17

20
 2100 CNC Controller

Fig. 3.7 Quit o f cutting

CHAPTER4 PART OPTIONS

Before starting cutting, you can use "F3 PartOption" in the main interface. Press F3 to enter part options menu:

FLSK F2500 Speed : File: Status : Current Line/Hole:

Version 3.3.71.1 00000 SHAPE 43. TXT Pause 00000/00000

•Ignition s
•Lowheat s
•HighPreheat s
•Pierce 1 s
•Pierce 2 s
• Pierce 3 0.1 s
•TorchUp s
•TorchDn s
•THC En s
•Exhaust s
 2100 CNC Controller

CutSpeed [X]1000.00 Kerf[Z]1.20

ManualSpeed [Y] 3000.00 Angle 0.00 Manual
[F] keepMov StepMov ContiMov
StepDis[G] 5.00 Flame Cu [M]

+X:500.00 -X:0.00 +Y:500.00 -Y:0.00

Operate Mode:
PartCption
F1 Mirror F2 Angle F3 Array F4 Scale,-, F5 F6 EditFil ; F7 Revert F8 CK
Se
lLinePierce

Fig 4.1 Part options

4.1 XY mirror

Press F 1 , the system will prompt:

• Press F1 to mirror along the horizontal axis(X axis)

• Press F2 to mirror along the vertical axis(Y axis)

• Press ESC to exit mirror operation 4.2 Angle

adjustment

Press F2, the system will prompt:

F1- Steel plate adjust F2-

enter angle

• Press F1 to adjust steel plate

• Press F2 to enter angle directly
• Press ESC to exit angle adjusting

4.2.1 Steel plate adjustment

After entering steel plate adjustment menu, the system will prompt:

22
 2100 CNC Controller
X-start Y-OK ESC-exit
Adjust X:+00000.00 Adjust
Y:+00000.00 Angle :
+00000.00

Here, you can manually move the cutting tip to the edge o f one side or a corner o f the plate. When the cutting
tip moved to a good position, press [ X ] key to set the current point as the starting point o f correction.
And then manually move along the cutting tip, as long as moving to the edges o f the side. After ensuring the
two points far enough and two points at the same side o f the plate in the same line and press [ Y ] . The system will
automatically calculate the current o f f s e t angle o f plate, and then automatically rotate graphics.

Before adjusting After adjusting

After adjusting, the system will ask whether to return to the start point, i f press [ENTER],the system will back to the
start point o f the operation, i f press [ E S C ] , the system will do nothing but

23
 2100 CNC Controller

go back to the graphic interface.

FLSK F2500 Version Speed: File: Status: Current Line/Hole

3.3.71.1 00000 SHAPE 43. TXT Pause 00000/00000

• Ignition
ENTER: Return back ESC: • Lowheat
D o n ' t move back • HighPreheat
C •Pierce 1
M • Pierce 2
M •Pierce 3 0.1
S • TorchUp
• TorchDn
•THC En
•Exhaust

Manual [F] keepMov StepMov JConti

StepDis[G] 5.00 Flame Cu [M]

+X:500.00 -X:0.00 +Y:500.00 -Y:0.00

00006: G01 X0 Y500.00
00007:G01 X500.00 Y0

F5
F1 Mirror F2 Angle F3 Array F4 Scale F6 EditFiH F7 Revert F8 CK
SelLinePier

Fig 4.2 Return to the start point after adjusting

4.2.2 Enter angle
When the angle o f the current work piece is known, you can enter the angle:

Please enter angle

min:-360 max:360
Angle: 0.00

Enter angle
After manually enter the angle, press [ENTER] to make sure, the graphic will be rotate with the corresponding angle.
Positive angle means rotate in counterclockwise, while negative means clockwise. Press [ E S C ] to exit angle
adjusting.

4.3 Array

I n the part options menu, press [ F 3 ] , the system will prompt as Fig 4.3, there are three ways to arrange, arrange in
matrix, staggered arrange, arrange in stack.

24
 2100 CNC Controller

Fig 4.3 chooses arrange method Press [ F 1 ]

Fig 4.4 arrange in matrix

to carry on arranging in matrix:

25
 2100 CNC Controller

The result is shown in fig 4.5

Fig 4.5 result o f arranging in matrix Press

[ F 2 ] to enter staggered arrangement:

Fig 4.6 staggered arrange

26
 2100 CNC Controller

The result is shown in figure 4.7:

Fig 4.7 result o f staggered arrangement Press

[ F 3 ] to enter arrangement in stack:

Fig 4.8 arrange in Nest

The result is shown in figure 4.9:

27
 2100 CNC Controller

Fig 4.9 result o f arrangement in nest

4.4 Zoom in/out

I n the part options menu, press [ F 4 ] (zoom in/out),the system prompt as figure 4.10:

28
 2100 CNC Controller

Fig 4.10 set scale

After entering the scale, press [Enter], then the system will automatically zoom in or zoom out the
graphic when the parameter is checked to be correct.

4.5 Select row/number

I n part options menu, press [ F 5 ] t o enter selecting row/number, the system will prompt:

29
 2100 CNC Controller

Fig 4.11 select Line/Pierce

4.5.1 Select row

Press [ F 1 ] to select the number o f row to start cutting with, the system prompts:

30
 2100 CNC Controller

Fig 4.12 prompt to select row Here , you can directly enter the row number or press
ENTER to enter the interface and press —or—to select row.
After selecting row, press F 8 to confirm.

Fig 4.13 select row

31
 2100 CNC Controller

4.5.2 select number

The operation is similar to the choosing row operation.

4.5.3 operation after select row/number

After selecting row or number, press F 8 continuously to exit to the main interface. Press SPACE to
enter the cutting interface, there are two kind o f operation:
1 move from current position to the new position and then cutting
• Press F 1 in the cutting interface, the system will directly run to the position o f the selected row or number without

• Press START in the cutting interface, the system will prompt:

cutting, then pause and wait for the next operation.

Fig 4.14 operation after selecting row/number Press Y , the system will also directly move to
the selected row and number, then pause and wait for the next operation.
2 Cutting from the current position
After the prompt o f Fig 4.14, press X , then the system will start cutting from current position.

32
 2100 CNC Controller

4.6 Restore

I f you want to cancel all o f operations with graphics including mirror, rotation, adjust, scale and array, press [ F 7 ] in
the part options menu, the system automatically revert to original state o f the graphics.

CHAPTER 5 MANUAL FUNCTION

I n the automatic interface, press [ F 7 ] (Manual) to enter manual function interface, shown as Fig 5.1:

rFLSK F2500 Version Speed : File: Status Current Line/Hole:

3.3.71.1 00000 SHAPE 43. TXT : Stop 00000/00000

•Ignition •
Lowheat •
HighPreheat •
Pierce 1 •Pierce
2 •Pierce 3 •
TorchUp •
TorchDn
•THC En
•Exhaust

CutSpeed [X]1000.00 Kerf[Z]0.00

ManualSpeed[Y]3000.00 Angle 0.00
Manual [F] keepMov StepMov Conti
StepDis[G] 5.00 Flame Cu [M]

+X:500.00 -X:0.00 +Y:500.00 -Y:0.00

00006: G01 X0 Y500.00
00007:G01 X500.00 Y0

F2 F4 F7
F1 KeepMov
ContiMove SpeedDown Recover

F3 F5 SpeedUp
StepMove

Fig 5.1 manual function interface The speed in the manual status is controlled by the
manual moving parameters. During the process o f fixed moving function, you can adjust speed by acceleration or
deceleration key. I n the manual interface, press numeric key, the cutting speed changes to ratio which is 10 times o f
the corresponding figure o f the speed limit you have set, for example press [ 3 ] , change the cutting speed to 30% o f
the speed limit you have set, press [ 8 ] , change the cutting speed to 80% o f the speed limit you have set.

5.1 Fixed Moving Function

33
 2100 CNC Controller

When you enter into the manual interface, the default option is continuous moving function. Press key [ F 1 ] to
go for the fixed moving function. At this moment, the system will move toward the specified direction i f any directory
key is pressed, and when the directory key is released, the system will stop.

34
 2100 CNC Controller

5.2 Continuous Moving Function

When in the manual interface, press F 2 to enter the continuous-moving function interface. At this moment, the
system will move toward the specified direction i f any directory key i s pressed and then released, and when the
directory key or stop key i s pressed the system will stop.

5.3 Fixed-length moving

I n the manual interface, press F 3 to enter the interface o f fixed-length moving,. The system prompts to input
the fixed length:

SLaLus
:
Stop 00000/00000

• Ignition
• Lowheat
• HighPreheat
• Pierce 1
• Pierce 2
• Pierce 3
• TorchUp
• TorchDn
• THC En
• Exhaust

CutSpeed [X] 1000.00 Kerf [Z] 0.00

ManualSpeed [Y] 3000.00 Angle 0.00
Manual [F] keepMov StepMov StepDis
ContiMov
[G] 5.00 Flame Cu ' [M]

F7
Recover

Fig 5.2 Input the fixed length After inputting the fixed length, press ENTER. Press
any direction key and then release, the system will move the fixed length toward the direction, in the process o f
moving, when any direction key or stop key i s pressed, the system will stop moving.

5.4 Breakpoint Recovery

To guarantee that the breakpoint could work correctly, you need to satisfy the following conditions:
1. When the system i s paused, the system will automatically regard the paused point as the current breakpoint and
remember it.

35
 2100 CNC Controller

2. When the system is in the process o f incising, the breakpoint signal is connected with the urgent alarm input,
when power is o f f , the system will regard the power-off point as the breakpoint and remember it.
When you need to process after the breakpoint, after the system powers on, don't move the torch, press F7 in
the main interface to enter the manual function interface, then press F7 to recover the breakpoint. After recovering it,
i f the torch hadn't been moved and is on the position when the power is o f f , press START keyboard, the system
will process directly.
After the breakpoint is recovered, i f the position is o f f from the original one, you could move the torch to the
original point manually, or realizing it through choosing rows or numbers. (Please refer to chapter 4.5 Row and
number Selection). The method i s : choose stopping incising, move the torch to the original point manually, choose
the nearest row through choosing the row selection(or number selection), press "START", then the system will show
in Fig 5.3:

FLSK F2500 Version Status Current Line/Hole:

3.3.71.1 00000 SHAPE 43. TXT : Pause 00000/00000

•Ignition •
[G]Cutting return Lowheat •
HighPreheat •
I [X]Offset cutting Pierce 1 •Pierce
2 •Pierce 3 •TorchUp •
[Y]only return TorchDn 0.1

\ \A
•THC En
•Exhaust

CutSpeed [X] 1000.00 Kerf [Z] 1.20

ManualSpeed [Y] 3000.00 Angle 0.00
Manual [F] keepMov StepMov ContiMov
StepDis [G] 5.00 Flame Cu [M]

F4 F6
F1 Back F2 Forward F3 GoBack
SpeedDown PreheatDow
+X:500.00 -X:0.00 +Y:500.00F5-Y:0.00 n
SpeedUp
F7
00001:(TEST PATTERN)
00002:G92 PreheatUp
F8
JumptoPier
ce

Fig 5.3 restore breakpoint

• Press G, the system will start incising from point which i s after moving, and after returning to the position
before the torch moves, it will process according to the normal curve.
• Press X , regarding the position after moving as the position before moving, and then process.
• Press Y, move from the position after moving to the position before moving, then wait for the next
operation.

Chapter 6 File Operation

36
 2100 CNC Controller

The system supports cutting code which has txt and CNC postfix. And the maximum capacity is 1 M , the largest
number o f rows i s 10000 lines. You can edit, compile, delete, export internal document, also you can import the file in
the U disk into system.
I n the main interface, press key [ F 2 ] (code) to enter local machine code interface, shown as follows:

1: SHAPELIB/SHAPE18.TXT
2: SHAPELIB/SHAPE00.TXT
3: SHAPELIB/SHAPE01.TXT
4: SHAPELIB/SHAPE43.TXT
5: SHAPELIB/SHAPE.TXT
6: SHAPELIB/UsedPart.abs
7: SHAPELIB/UsedNoKf.abs

F4 F7
F1 DiskFile F2 UDisk F3 Search F6 CopyToU
EditFile Preview
F5 F8 OK
DelFile

Fig 6.1 code interface

6.1 Files in the Hard Disk

I n the file manage interface, press F 1 to enter the hardware file list, as shown in Fig 6.1 the system only lists the
folder, T X T file and CNC file.
• Press F 4 , i f the current position o f the cursor is txt file or cnc file, you could edit them. Please refer to
chapter 6.5 on how to edit files.
• Press F 5 , i f the current position o f the cursor i s txt file or cnc file, you could delete them.
• Press F 6 , i f the current position o f the cursor is txt file or cnc file, you could copy the current file to the
flash disk when it is connected to the U S B interface.
• Press F7, i f the current position o f the cursor is txt file or cnc file, you could preview the
current graphic.

37
 2100 CNC Controller

1: SHAPELIB/SHAPE_18.TXT 2:
SHAPELIB/SHAPE00.TXT 3:
SHAPELIB/SHAPE01.TXT

F4 F7
F1 DiskFile F2 UDisk F3 Search
EditFile Preview
F5
DelFile

F6 CopyToU

F8 OK

Fig 6.2 Graphic preview • Press F 8 , i f the current position o f the cursor is
txt file or cnc file, you could import the current file to the system, after importing, the system will return to the
main interface.

6.2 Files in the U Disk

38
 2100 CNC Controller

I n the code interface, press key [ F 2 ] to go for U Disk interface.

I n the U Disk interface, choose the corresponding cutting code, press [ F 6 ] , the system will save this code into
the internal documents.
Notices: When you open a file on U disk , you must save it as the local machine code before you start cutting.
When saved the U disk documents, file name automatically memory, shown as
Fig 6.3:

39
 2100 CNC Controller

1: SHAPELIB/SHAPE_18.TXT
2: SHAPELIB/SHAPE_00.TXT
3: SHAPELIB/SHAPE_01.TXT
4: SHJPE'IBfSHIPE 13 TXT
5: SH
6: SH
7: SH

File name:

\SHAPE_43. TXT

Fig 6.3 save U disk files When input file name, i f you do not want to
change the file name, you can be directly press [Enter] to preserved; or m o d i f y the file name and then press
[Enter] to save. I f the same named file has already exited, the system prompts:

1: 2: 3:
4: 5: SH
6: SH 7:
F4 F6 F7
SH
F1 DiskFile F8 OK
F2 UDiskH F3 Search F5 DelFile
EditFile CopyToDisk Preview

SHAPELIB/SHAPE_18.TXT
SHAPELIB/SHAPE_00.TXT
SHAPELIB/SHAPE_01.TXT
SHA PEL IB/SHAPE 13 TXT

File exist, confirm to cover? ENTER:

confirm / ESC: cancel

Fig 6.4 Replacement documents I f you want to replace the internal documents,
press [Enter] key, i f you want to change the file name, press [ E s c ] , change the file name and then save.
6.3 Search File

I n the file manage interface, press key[ F3 ]to search a file. You can input all or part o f the file name, then
press [Enter] , and the system will list all the files that include the input word or file name.

F4 F6 F7
F1 DiskFile F8 OK
F2 UDiskH F3 Search F5 DelFile
EditFile CopyToDisk Preview

1 : SHAPELIB/SHAPE_18.TXT
2 : SHAPELIB/SHAPE_00.TXT
3: SHAPELIB/SHAPE_01.TXT
4 : SHAPELIB/SHAPE_43.TXT
5 : SHAPET IB/SHAPE TXT
6 : SHAPELIB/I
7 : SHAPELIB/I

Input searched string

Fig 6.5 search file

6.4 Edit Code

40
F2 UDisk F4 F6 F7
F1 DiskFile F3 Search EditFile F5 DelFile CopyToDisk Preview F8 OK
 2100 CNC Controller

I n the local machine code interface, move the cursor to the file that you want to edit, then press [ F 4 ] to
enter the edit interface.
When enter the characters, some keys are reuse keys. Press these keys directly, enter the characters under the
button. I f first press [ S h i f t ] key, release the [ S h i f t ] key and then press Shift Multiplexing button, then
enter characters on the button. Or press both [ Shift] and reuse keys, then enter characters on the button.
When editing the code, press [ F2 ] can insert a new line after the current line, and press [ F3 ] to delete the
current line. Press [ F + Home] key, the cursor automatically moved to the first character o f the current editing line,
press the [ F - E n d ] , the cursor automatically moved to last character o f the current line.
Each edit line supports 128 characters maximum.
When you open a file on U disk or new a code file, you must save it as the local machine code before you start
cutting. Otherwise, you cannot make use o f the breakpoint recovery function or power o f f protection function.
After edit the code , press [ F 8 ] to save the code.
6.5 New Code

I n the editing code interface (reference 6.4 edit code ), you can press key [ F 4 ] to create an new file to input
your own code, shown as Fig 6.5.

1: G21
2: G91
3:

F1 compile F2 AddRow F3 Del Rowl F8 save

Fig 6.6 new code

6.6 Compile Code

After create a new code or edit the code, i f you want to know the code i s valid or not , in the edit interface,
press [ F1 ] ,you can compile code to check whether the code i s correct.

Chapter 7 Parameter Setting

41
 2100 CNC Controller

I n the main interface, you can get the parameter interface by pressing key [ F3 ] (Para). The parameter
function interface is showed in Fig 7 . 1

Cutting speed Manual 500.000

move speed G00 move 3000. 000
speed Demo/back speed 1000. 000
Dust speed Kerf value 2000. 000
Corner speed(1-100) 1000.000
Cutting type Demo Run 0.000
Speed 100.00
Flame
500.00
mmpm mmpm
mmpm mmpm
mmpm mm
% mmpm
<->
mmpm

F1 Common F2 Flame F3 Plasma F4 Powder F5 System F6 Import F7 Export F8 Save

Fig7.1 Parameter Interface You

can set five kinds o f parameter in the parameter interface:
1) Common parameters: cutting speed, manual move speed, G00 move speed, the size o f kerf g a p , corner speed,
cutting type, edge cut enable, hold preheat.
2) Flame parameters: all the parameters used in oxygen gas cutting
3) Plasma parameters: all the parameters used in plasma cutting
4) Maring parameters: ignition, perforation cycle parameters, dry dusting o f f s e t
5) System parameters: you can set system pulses, maximum speed limit, motor parameters and soft limit
parameters.

7.1 Common parameters

It is the favorite's parameters in Fig7.1.

• Cutting Speed: the maximum cutting speed, unit is mm/m.
• Manual Move Speed: the moving speed o f cutting torch in manual, unit is mm/m.

42
 2100 CNC Controller

• G00 Move Speed: the cutting torch speed when G00 is executed or the cutting torch go back to the reference or
some other occasion, unit is mm/m.
• Kerf: According to the cutting gap width, users set Kerf Gap compensation(the value should be half o f the
cutting gap ) to ensure the dimensional precision, the system will generate a new path automatically to make
compensation to work piece. Before cutting a work piece, you can modify kerf gap value, once begin to cut,
you are not permitted to modify the value.
• Corner speed: Plate thickness a f f e c t the cutting tip's ac/dc rate when it moving. The angle between the end
o f a cut-point line's tangential direction and the direction o f the tangent line o f the beginning o f next cutting
point, and the thickness o f plate determines cutting tip speed at the transition.
I f the normal cutting speed is V , angle is a, plate thickness is h, then cutting tip speed in at the time o f
intersection i s V x

50n
Notice: The unit is mm. The max thickness o f plate is 100 mm, i f more than 100mm also are considered to be
100mm
• Cutting Type: There are two cutting types : Oxygen fuel gas and Plasma parameters. You can press [ —] or
[ —] to switch with them.

7.2 Flame Parameters

The oxygen fuel parameters, in Fig 7.2, control time delay in I O operation, and whether use high adjustment.
Ignition time 0.00 s
Low preheat time 0.00 s
High preheat time 0.00 s
Pierce 1 time 0.00 s
Pierce 2 time 0.00 s
Pierce 3 time 0.10 s
Exhaust time 0.00 s
Torch up time 0.00 s
Torch down time 0.00 s
Pierce up time 0.00 s
Pierce down time 0.00 s
THC enable No <->
Hold preheat Yes <->
Edge cutting enable No <->
Fl Common F2 Flame F3 Plasma F4 Powder F5 System F6 Import F7 Export F8 Save

• •

43
 2100 CNC Controller

rs Ignition Time: theF time delay o f opening ignition I / O .

i Low Preheat Time: The preheating time before perforating the steel plate. Enter any
g positive number ,unit i s s . During the low pressure preheating process, you can prolong
7 the preheating time by pressing "stop" key, then the preheating time will delay until you
. press the "start" key to start to high pressure preheat delay.
2 High Preheat Time: Like Low Preheat Time except open different I O .
Pierce 1 time: Perforation time with low pressure fuel gas. Enter any positive
F number ,unit is s .
l Pierce 2 time: Perforation time with middle pressure fuel gas. Enter any positive number ,unit is s .
a Pierce 3 time: Perforation time with high pressure fuel gas. Enter any positive number ,unit is s .
m Exhaust Time: The delay o f turned o f f oxygen gas to open the exhaust. Enter any positive number
e ,unit is s .
Torch Up Time: When oxygen gas i s turned o f f , the time for the torch to l i f t u p . Enter any positive
P number ,unit is s .
a Torch Down Time: When oxygen gas i s turned o f f , the time for the torch to put down. Enter any
r positive number ,unit is s .
a Pierce Up Time: Time for the torch to l i f t u p during perforating. The difference between Torch Up
m Time and Pierce Up Time i s that: Torch Up Time means the time that the torch needs to l i f t u p
e when it needs to move to another place after the current
t
e

cutting i s over; while the Pierce Up Time means the time that the torch needs to l i f t u p after preheating in
the fixed cycle o f perforation.
• Pierce Down Time: Time for the torch to put down in the perforation. The difference between Torch Down
Time and Pierce Down Time is that: Torch Down Time means the time that the torch needs to put down
before preheating; while the Pierce Down Time means the time that the torch needs to put down after finishing
Torch Up Time and opening cutting oxygen in the fixed cycle o f perforation.
• THC Adjustment: According to the user device configuration, choose whether or not to use high adjustment
box.

7.3 Plasma Parameters

As shown in the fig 7.3, these are Plasma Parameters, which are related with the precision o f transmission
shaft o f the machine.

Arc time Pierce time Distance 0.00 0.00

Torch up time Arcing to close 0.00 0.00
check time Position Arc Lose 0.00
check time Position up arc delay 0.00 0.00
time Close arc Watch arc 0.00 0.00
enable

44
 2100 CNC Controller

No s s s s s s s
mmpm% mm <->

Fl Common F2 Flame F3 Plasma F4 Powder F5 System F6 Import F7 Export F8 Save

Fig 7.3 plasma parameters Arc time: Before the arc starting, the system
• time to wait. At this point, all output I /O are turned o f f . Enter any positive number ,unit is s . Pierce
time: Perforation time. Enter any positive number ,unit i s s . Torch Up Time: When arc press i s
• turned o f f , the time for the torch to l i f t u p . Enter any positive number, unit i s s .

• Arcing Check Time: Enter any positive number, unit is s . I f not detected any feedback signal o f
success arc starting within the detection time, the system prompts an error

message and terminates the current work o f cutting, according memory breakpoints to withdraw from
the program.
• Position check Time: Enter any positive number, unit is s . Delay time o f the success o f position
check.
• Position up Time: Enter any positive number, unit is s . Before positioning check, the time for the torch
to l i f t u p .
• Close arc: I n setting the rate o f X % , open the output port, close the arc press signal, to prevent the
steel melting under low-speed cutting tip due to temperature is too high.
• Distance to close arc: in the minimum distance o f the cutting line o f the initial segment or end
segment, close the arc voltage increases.
• Lose arc delay: detect the delay time o f the feedback o f the broken arc, i f there's still no arc voltage
input, the situation i s considered to be broken arc. This parameter can effectively avoid the arc broken
alert because o f the sensitivity o f the broken arc detection in the cutting methods with lead, this
guarantees the continuousness o f the cutting and avoid the interrupt o f frequent alert .
• Watch arc enable: Real-time detection o f arc voltage signal in cutting process.

I f setting "yes", in the cutting process, the system detects he real-time arc voltage feedback signal. I f do
not detect the signal, the system terminates the current work o f cutting, according memory breakpoints to
withdraw from the program. I f installing a "No", then in the cutting process does not detect arc voltage
feedback signal.

7.4 Powder Parameters

As shown in the Fig 7.4, these are Powder Parameters, which are related with the precision o f transmission
shaft o f the machine.

45
 2100 CNC Controller

Dust Ignition time Dust 0.00 ssssss

preheat time Raise Dust 0.00 mm
Open time Raise Dust Close 0.00 mm
time Dust Up time Dust 0.00
Down time Dust Horizontal 0.00
Offset Dust Vertical 0.00
Offset 0.00
0.00

Fl Common F2 Flame F3 Plasma F4 Powder F5 System F6 Import F7 Export F8 Save

Fig 7.4 powder parameters Dust

Ignition Time: Enter any positive number, unit is s . Dust Preheat
Time: Enter any positive number, unit i s s .
Raise Dust Open/ Close Time: The time of raise dusting port relatively to the powder port. Enter any
positive number, unit is s . Dust Up Time: The time for the torch to l i f t u p . Dust Down Time: The
time for the torch to put down.
Dust Horizontal Offset: The horizontal displacement o f powder gun relative to the cutting tip.
Dust Vertical Offset: The Vertical displacement o f powder gun relative to the cutting tip.

7.5 System parameters

The system parameters, as showed in Fig 7.5, are related with the precision o f transmission shaft o f the
machine.
Horizontal Axis Pulse 125.000 n/mm
Vertical Axis Pulse 125.000 n/mm
Max cutting speed 2000. 000 mmpm
Max G00 speed 6000. 000 mmpm
Max Manual speed 3000. 000 mmpm
Small arc limit 500.000 mmpm
Flame adjust time 0.40 s
Plasma adjust time 0.30 s
Emergency stop time 0.08 s
Start speed 250.000 mm
Max +X 100000.000 mm
Max +Y 100000.000 mm

46
 2100 CNC Controller

Min -X -100000.000 mm
Min -Y -100000.000 mm
Fl Common F2 Flame F3 Plasma F4 Powder F5 System F6 Import F7 Export F8 Save

Fig 7.5 System Parameters

• Horizontal Axis Pulse: The number o f pulse that system needs to generate when the machine
move1mm towards X axis, maintaining 3 digits at most after decimal point.
• Vertical Axis Pulse: The number o f pulse that system needs to generate when the machine move 1mm
towards Y axis , maintaining 3 digits at most after decimal point.
• Max Cutting Speed: the maximum cutting speed, unit is mm./m.
• Max G00 speed: the allowable maximum speed when cutting tips idling.
• Small Arc Limit: Maximum speed at cutting a small arc. Small arc
definition:
small arc=5mm small
0 mmpm< cutting speed <2000mmpm
arc =10mm small arc
2000 mmpm< cutting speed <4000mmpm
=15mm small arc
4000 mmpm< cutting speed <6000mmpm
=20mm small arc
6000 mmpm< cutting speed <8000mmpm
=25mm

small arc =30mm small

arc =35mm
Flame adjust time: the whole time for the system accelerates from its start speed to the expected cutting
speed.
Plasma adjust time: when plasma cutting , from the time the motor starts to the time

8000 mmpm< cutting speed <10000mmpm

10000mmpm< cutting speed <12000mmpm

•
12000mmpm< cutting speed <15000mmpm

•
when the motor is u p to the cutting speed.
• Emergency STOP Time: When encounter Emergency Stop input, the time for dropped from the
current speed to zero.
• Start Speed: the system's speed when it began to start. Generally do not have to start from 0 ,
motor will allow a start speed.
• Max Coordinate: The maximum positive coordinate which the machine can reach horizontally.
I t s unit i s mm(millimeter). I f current coordinate exceeds the value, the system will stop
running.
• Min Coordinate: The minimum negative coordinate which the machine can reach horizontally. Its
unit is mm(millimeter). I f current coordinate is less than the value, the system will stop running

47
 2100 CNC Controller

7.6 Parameter import

I n the parameter configuration interface, press F 6 to import the parameters. The parameters
should satisfy two conditions:
1 . The parameters exported from the incising machine control system( refer to 7.7 Parameter Export)
should satisfy the specified format. The file format is F2500.DAT
2. The file should be stored under the root folder o f flash disk which is connected to the U S B interface.
When the above condition is satisfied, in the Fig 7.6, press Enter to confirm, and then you could import
the backup parameters to the system.

Fig 7.6 Parameter import

48
 2100 CNC Controller

7.7 Parameter export

After the parameter configuration is over, press F7 in the parameter configuration interface to export the
parameters, you should connect the flash disk to the U S B interface before exporting.
I n the interface shown in Fig 7.7, after pressing Enter, the parameters will automatically be saved in the
root folder o f flash disk, the file name i s F2500.DAT

Fig 7.7 Parameter export

7.8 Save parameters

After parameter modification, press [ F 8 ] to save, shown in Figure 7.8

49
 2100 CNC Controller

Fig 7.8 System Parameters

Note: when any parameter has been modified, you must take preservation operation to keep modification valid, or
the system will take the original parameters.

50
 2100 CNC Controller

Chapter 8 Diagnosis Function

input

Forward limit Up move input Down move

Back limit Right input Left move input
limit Left limit Right move input
Emergency stop Acceleration input
Arcing feedback Deacceleration input
Position detect Torch up input Torch
Plasma crash down input

F7 F8
F1 Input F2 Output F5 KeyBrd '6 SelfChecl DataTime SystemDef

Fig8.1 Diagnostic interface You can

be diagnosing the I / O and keyboard in the interface.

51
 2100 CNC Controller

8.1 Diagnosis interface index

F5
System Diagnosis

F1
Input Diagnosis

F2 Output
Diagnosi
s

F5
Keyboard
Diagnosi

F6
System Self-test

F3
Definition

F4 F5 F6
Encryption Decrption Language

8.2 Input Diagnosis

52
 2100 CNC Controller

The system will read current I O information when press [ F 1 ] (Refresh) to refresh the interface, and display
all IO's status. "On" means the input is effective, and " O f f " means the input is ineffective.

8.3 output Diagnosis

I n diagnosis interface ,press [ F 2 ] to enter output diagnosis interface, shown as Fig8.2

Output

Ignition Low exhaust THC

preheat High enable Position
preheat Low detect Arc
Oxygen Medium starting
Oxygen High HoldTorch Dust
Oxygen Torch up spray Raise dust
Torch down Dust preheat

F5 KeyBrd F6 SelfChecU F7
F1 Input F2 Output F3 OpenOutF4 CloseOut
DataTime
F8
SystemDef

Fig 8.2 Output diagnosis

Press 11],[<—], [—►], you can move the cursor to the corresponding output port, press [ F 3 ] to open the
corresponding output port, press [ F4 ] to close the corresponding output. • represents the valid output, o represents
the invalid output.

8.4 Key-press Diagnosis

I n the diagnostic interface, a key value will be displayed behind "KEY:", whenever the key is pressed.

53
 2100 CNC Controller

Fig 8.3 Keyboard Diagnosis

8.5 System self-check

I n the system diagnosis interface, press F 6 to enter the system self-check interface.

54
 2100 CNC Controller

1. backup parameter first all

2. lose breakpoint
3. restart after selfcheck

Are you sure?

F6
F1 Input F2 Output F5 KeyBrd
SelfCheck
F7
DataTime
F8
SystemDef

Fig 8.4 System self-check I f the

self-check is O K , the system will show:

Fig 8.5 Self-check pass I f the

self-test i s down, there will be the following alarm type:
• D S P Dual ram is error
• ARM Dual RAM is error
When coming across these situations, please power o f f , reboot after about half minutes. I f the situation
happened on the machine which has been working for long time, please open the chassis and clean u p the dust.

8.6 date and time

Press F7 in the system diagnosis interface to set the date and time

55
 2100 CNC Controller

2010-08-21 15:51:37 Sun Up or

down to modify

Fig 8.6 System time

Move the cursor to the corresponding date, time or week, press [f]i|Sc[J]to adjust the
time

8.7 System Definition

I n the system diagnosis interface, press F 8 to enter the system custom definition interface, in the interface, you
could set the input I O , output I O or system coordinate, also reset or backup the parameters and one key switch between
r
F1 Input F2 Output F5 KeyBrd 6 SelfChec I F7 F8
DataTime

English or Chinese.

8.7.1 Parameter backup and restore

Parameter Backup: The process o f parameter backup i s , in the main interface press F5(System Diagnosis), F 8 (
System Definition), F2(Parameter Backup). The system will need code, after inputting the code "1396", press Enter, the
system will import the default parameters. I n the following process, i f the parameters is modified or some o f them is
broken, reset the parameters.
Warning: after adjusting the equipment, please backup the parameters.
Parameter Reset: The process o f reset the parameters i s , press F5(System Diagnosis) in the main interface,
F8(System Definition), F1(Parameter Reset).
Warning: After resetting successfully, please restart the system.

56
 2100 CNC Controller

8.7.2 Input definition

The controller could change the I O definition, including changing the order o f I O number, the type o f IO(
normally open or closed) according to the user's need. I n the system custom definition interface, press F 3 to enter
the definition interface, press F 1 to enter the input definition interface. As shown in fig 8.7.
F1 Input F2 Output F3 Axes F4 Motor F8 Save

• •
Definition of input

• •
Port Type Port Type

• •
Forward limit 02 Up move input 09
Back limit 15 Down move input 10
Left limit 14 Left move input 07

• •
Right limit 01 Right move input 08

• •
Sharpstop 03 Acceleration input 16
ArcFeedback 04 Deacceleration input 17
PosFeedback 05 Torch up input 18
PlasmaCrash 06 Torch down input 19

Port- Press PgUp/PDn Type-Press Enter

Fig 8.7 input definition

I n the interface press [ t ] > [""L [^"] , move the cursor to the position that
needs changing, press [PageUp] Jl£ [PageDown] to change the number o f the Input, press [ E n t e r ] to change
the t y p e o f the input.
I f the external t y p e o f input is normally closed, please set the I O t y p e to i f the type is normally open,
please set the I O t y p e to • .

8.7.3 Output definition

The controller could change the I O definition, including changing the order o f I O number, the type o f IO(
normally open or closed) according to the user's need. I n the system custom definition interface, press F 3 to enter the
definition interface, press F 1 to enter the input definition interface. As shown in fig 8.8.

57
 2100 CNC Controller

Ignition
Port
03 •
Definition of output

•
Type
Exhaust
Port
06 •
•
Type

• •
LowPreheat 01 THC 08
HighPreheat 17 PosDetect 19

• •
LowOxygen 04 ArcStart 16
MidOxygen 05 LowSpdInCorner 18
HighOxygen 14 Dust spray 07
TorchUp 02 Raise dust 20
TorchDown 15 Dust preheat 21 #

Port- Press PgUp/PDn Type-Press Enter

F1 Input F2 Output F3 Axes F4 Motor F8 Save

Fig 8.8 output definition

I n the interface press [ t ] > [^"] , move the cursor to the position that
needs changing, press [PageUp]Jl£ [PageDown] to change the number o f the Output, press [ E n t e r ] to
change the t y p e o f the Output.
The output type is open drain transistor output type.
t y p e • means that i f the output signal is effective, the transistor i s on. type# means that i s the output
signal is effective, the transistor is o f f .

8.7.4 Coordinate definition

The system could provide I O definition for the user. As shown in Fig 8.9
Press Enter to change coordinate

+Y
t
-X — — +X

-Y

58
 2100 CNC Controller

F1 output F2 output F3 Axes F4 Motor F8 save

Fig 8.9 Coordinate Definition I n the interface, press Enter repeatedly to

change among 8 type o f coordinates. Press F 8 to
save.

59
 2100 CNC Controller

Chapter 9 Graph

I n the main interface, press [ F l ] (ShapeLib) to enter graph interface, shown as follows:

□• il
Rectangle Circle Triangle L-Bracket Trapezoid Slant Rec GambrelRec RoofedRec Oval CircleFla

CirSector ConcaveT Octagon CornerR. ConcaveR. FLange Elbow Convex

RecinRec CircleinRec

ConvexR. ConcaveR. ConcaveT ConcaveP. BevelRec Cross L Corner U Shape Groovel Groove2

Horizont Vertical HoleCir. RecWin. Hole-in-Rec. HolesCir. HolesFla. 4HoleRec. 4HolesRec.

5HolesRec.
5HolesRec. CurvedTr. CurveP. Testing GridShape

F8 OK

Fig 9.1 first page o f graph

You can press [ j l- [—[—l to choose different graph.

9.1 Choose Graph

I n home interface o f graph, move the cursor to the required graph, press [ F 8 ] to confirm, shown as Fig 9.2:

60
 2100 CNC Controller

Fig 9.2 Chip size interface You can press [ |L [|L [<—]-. [—to modify sizes,
after modification , press [ F 8 ] to confirmed.
Press any key to return to graphics processing interface as shown in Fig3.3.

9.2 Film/Hole Size

I n Fig 9.2 interface, you can press [ F 2 ] to choose hole size, shown as Fig 9.3:

F2
Outside

61
 2100 CNC Controller

Fig 9.3 hole size

M o d i f y sizes like modify chip sizes.
After modification , press [ F 8 ] to confirmed.
Press any key to return to graphics processing interface as shown in Fig3.3. Note:
The following graphics don't have hole sizes:
Straight line groove, Bevel groove, Straight line k e r f , Vertical k e r f , Hole-in- Rotundity, Rectangle
window, Hole-in-Rectangle, Four-holes in Rotundity, Holes in flange, Four-holes in rec, Four-holes in Filleted
corner rec, Five-holes in rec, "Five-holes in Filleted corner rec, Curved trapezoid, Curved polygon, Testing Shape,
Grid Shape.

Chapter 10 Port Explanation

10.1 Input port

62
 2100 CNC Controller

^External
input
signal

Fig10.1 input port circuit

• Input signal i s a mechanical contact switch, normally open type, it is effective when it is

connected to 24VG, and it is ineffective when it is float or connected to 24V

• 16 input ports totally

• Input signal definition

Pin number Signal name remark
1 X+ limit X + stop input, float it i f not use, this is horizontal
14 X - limit X - stop input, float it i f not use, this is horizontal
2 Y+ limit Y+ stop input, float it i f not use, this is vertical
15 Y- limit Y- stop input, float it i f not use, this is vertical
3 Emergency stop Emergency stop input, float i f not use
4
Arcing

successfully
5
Positioning

successfully
6 Plasma collision
7 Move left/C Remote control input
8 Move right/D Remote control input

63
 2100 CNC Controller

10.1.1 Input Wiring Instructions

q Right limit input

Right limit Left

limit Front limit

© Left limit input

Back limit

Emergency Stop]

ignition
Arcing
0- ©
successfully
Cutting oxygen|
O
Positioning
successfully

Torch up
©- ©
Plasma collision

Torch down 6 Plasma collision feedback

Move left NC

Move right

NC
0 © ________ c ___________________________________
1 .For Plasma cutting
Move ahead 8 2.Accessed when CNC positioning is
needed. And positioning successfully
NC input should be configured as
normally open type. Or it can be not
Move backward
0 accessed when using height adjusting
device to positioning.
NC NC 3 .When plasma collision detection is

+24V

+24V
© needed, accessed to plasma collision
feedback.
Caution: All inputs can be normally
closed or normally open, and all
24VG inputs are normally open in defualt.

24VG

©
com
(connecting to 24VG of the system or
connecting to the 24VG of the external
24V switching power supply. )

©
©

64
 2100 CNC Controller

Fig 10.2 External input terminal

10.1.2 Remote Input

The system supports two external remote control input, one for line input type, the other for 8421 encoded input
type.

> Line Input T y p e

The pin 7 , 8,9,10 o f input port represents l e f t , right, forward, backward, when inputting valid signal , the
machine can move toward the corresponding direction, when the input signal is invalid, the machine stop moving.
When the input signal o f pin 16 is valid, the system will ignite the torch , the ignition time is the setting value
in system parameters, please take the reference o f part o f "ignition time " in "7.2 oxygen gas parameters " .
When the input signal o f pin 17 i s valid, the system will turn on or o f f the cutting oxygen. When the cutting
oxygen is on, the system cut o f f the oxygen, when the cutting oxygen i s o f f , open the cutting oxygen system.
When the input signal o f pin 1 8 is valid, the system will raise the cutting torch, when the signal invalid, the
torch stops.
When the input signal o f pin 19 i s valid, the torch goes down, when the signal invalid, the cutting torch stops.
The external switches o f line input are designed by the user..

> 8421 code input

Input pin 9 , 10, 7 , 8 is the A, B, C, D bits o f the 8421 code. Functions are shown in Table

Table 10.2 function of 8421 code input

Decimal 8421 code(DCBA) Function

0 0000 No Input
1 0001 Turn on or off the cutting oxygen
2 0010 Go back according to the original track
3 0011 Move forward according to the original track
4 0100 Left lateral movement
5 0101 Ignite Input
6 0110 Start

10.2
7 0111 Slow down
8 1000 Accelerate
9 1001 Move for the negative direction vertically
10 1010 Move forward vertically
11 1011 Pause

65
 2100 CNC Controller

12 1100 cutting torch

13 1101 raise the cutting torch
14 1110 Move toward right horizontally
15 1111 Start

8421-type remote control input i s designed by the user, the user can also use the company's wireless remote
control module.

10.1.3 Input Configuration

The number and type of input port can be reconfigured. For example, the right input port can be Pin 1 , also
can be configured to Pin 7 , input t y p e can be normally open t y p e , can also be normally close type.
Configuration methods are shown in Fig 10.3.
Press F 5 (Diagnosis), F 8 ( S y s t e m D e f ) , F3 (Define), enter the password"1396"and press ENTER. in turn on
the main Interface

66
 2100 CNC Controller

Port
••
Definition of input
Type Port
•
•
Type

•• •
Forward limit 02 Up move input 09
Back limit 15 Down move input 10

•
Left limit 14 Left move input 07
Right limit 01 Right move input 08

•
Sharpstop 03 Acceleration input 16
ArcFeedback 04 Deacceleration input 17
PosFeedback 05 Torch up input 18
PlasmaCrash 06 Torch down input 19

Port- Press PgUp/PDn Type-Press Enter

F1 Input F2 Output F3 Axes F4 Motor F8 Save

Fig10.3 Input Port Configuration I n the input configuration interface, move the

cursor to numbers o f the serial number, Press

the PgUp or PgDn to change the input port number, which also change the pin number o f

25-pin input terminal. Move the cursor to • place, you can press ENTER to change

the input type. is for the normally open t y p e o f the input , when invalid , it is for the signal

o f turning o f f , when effective, it i s for the signal o f closure. " O " is the normally closed t y p e

o f input , when invalid ,it is the signal o f closure, when effective ,it is the signal o f turning o f f .

67
 2100 CNC Controller

10.2 Output Port

External
Relay

Fig10.4 output port circuit

• Output voltage is 24VDC low level is effective;

• Maximum output currentImax = 300mA ;

• 16 output ports totallu

• Output signal definition

Signal Remark
25Chip interface Pin No.(Main connector)
3 Ignite
1 Low pressure preheat
17 High pressure preheat
4
Low pressure cutting oxygen
5
Medium pressure cutting oxygen
14
High pressure cutting oxygen
2 Torch up
15 Torch down
6 Exhaust
8
Enable high adjusting box
19 Plasma locating
16 Plasma arc starting
18
Corner low-speed output Or

68
 2100 CNC Controller

automatic / manual
07 Spray dust
20 Raise dust
21 Dusting Preheat
9, 10, 22, 23 Not used
11,12,24 +24V +24V/3Aoutput
13,25 24VG +24Vground

10.2.1 Output Wiring Instructions 10.2.1.1

oxygen gas typical connection

69
 2100 CNC Controller

+94V I'mmmnn't
Control o f perheat
oxygen and fuel gas r ^_ Control
Low pressure (low active) of
.ZT
preheat High ^ _ gas and
pressure cutting Control o f cutting preheat oxygen
oxygen oxygen(low active) Torch u p control(low active)
Torch u p
0 VcdvfJ
Torch down
Ignite
Plasma arc 0
© Torch down control(low active)

Ignition enable(low active)

starting Low
pressure cutting
oxygen High
0
©
pressure preheat
Mid-pressure
preheat ©
Low rate at
corner
©
exhaust 0
Plasma
positioning 00 Exhaust control(low active)

Spray powder ©
Raise powder
Enable height
0
adjusting Powder
Capacitor height adjusting
preheating
0© enable(low active)
unused

unused

unused
©
unused

+24V
0
Caution: All outputs can be high active
+24V

+24V
© or low active, system default i s low
active

24VG 0
24VG COM
(connecting to system supply 24VG.
0 Or connecting to the +24V side of
external 24V switching power supply.
)

©
©

©
70
 2100 CNC Controller

Fig10.5 oxygen gas typical connection

71
 2100 CNC Controller

10.2.1.2 Three level perforation circuit

+24V(common)

J:
Control o f perheat
oxygen and fuel __ Control o f
Low pressure gas(low active) ^ __ gas and
preheat High
zr Level three preheat oxygen
pressure cutting perforation(low active) Torch up control(low
oxygen active) valve
Torch u p

Torch down
©- © Torch down control(low active)
Ignition control(low active)
Ignite
Plasma arc ©- 20
starting Low
pressure cutting Level one perforation(low active)
oxygen High
pressure preheat
Mid-pressure
CD © High pressure preheat(low active)

Level two perforation(low active)

preheat
Low rate at
corner
-C 22

exhaust Exhaust control(low active)

Plasma
positioning
Spray powder
D- ©
Raise powder
Enable height
©■ Capacitor height adjusting
adjusting Powder enable(low active)
preheating
0 ©
unused

unused

unused
CD
unused

+24V
© Caution: All outputs can be high active or
low active, system default i s low active.
+24V

+24V
©
COM

©
(connecting to system supply 24VG.
24VG Or connecting to the +24V side of
external 24V switching power
24VG
supply.)

©-

©-
©

18

72
 2100 CNC Controller

Fig 10.6 three level perforation circuit

10.2.1.3 Typical circuit of using powder

+24V
Low pressure
preheat High
pressure cutting
oxygen
©
Torch u p

Torch down

&
Ignite Ignition control(effective low)
Plasma arc
starting Low
pressure cutting
©
oxygen High
pressure perheat
0
18
Mid-pressure
preheat
Low rate at
corner
exhaust
©
Plasma
positioning
©0 20
Spray powder

Raise powder

Enable height
© Spray powder control(low active)

Raise or stir powder control(low active)

adjusting Powder
preheating © 22 Powder preheat (low active)
unused
©
unused

unused ©
unused ©
Caution: All outputs can be effective
+24V
high or effective low, system default i s
+24V © effective low .
©
©
+24V

24VG COM
(connecting to system supply 24VG,
24VG Or connecting to the +24V side of
external 24V switching power
supply.)

©
Fig 10.7 powder typical circuit

73
 2100 CNC Controller

10.2. 1.4 typical circuit of using plasma cutting

+24V (common)

Low pressure
preheat H i g h pressure
cutting o x y g e n Torch
u p Torch down
© Torch u p control(Low
, ---------- a c t i v e ) ---
Ignite Torch down control(Low
Plasma Low ©- © ---------- a c t i v e ) ----
pressure cutting Connect to high adjusting device' s
oxygen High arc starting input or arc starting delay ( Low
pressure
preheat
© active )

Medium Connect to high

pressure cutting
o x y g e n Corner
© adjusting device' s
corner low speed or
low speeed -------------- :—--------- , ( L o w active)
Exhaust automatic / manual
Plasma locating ©© Connect to the locating input
o f lifting device when C N C
Spray dust Low active

Raise dust
Enable high
©© locating i s needed

adjusting box
Dusting preheal 0©
Not used

Not used 0©
Not used
Note:All outputs
Not used ©© are low active or
+24V +24V high active, the

+24V

24VG
© © system takes low
active as default ________
COM
(Connecting to the system' s +24V supply, also
24VG © external 24VSwitch supply +24V port allowed)

©- ©
©
Fig 10.8 Typical wiring diagram o f the plasma
Instruction:
> THC wiring with corner low-speed( Corner signal/Torch height control signal)
When the T H C takes corner low-speed input control signal, the HYD-2100 "corner low speed" output signal is
used to control the T H C ' s corner low-speed input(Auto mode enable/disable signal). The CNC signal is an
open-colletor transistor output, with the default low-level effective. When the T H C is not matched t y p e , it needs
to be converted by the relay. THC wiring with automatic / manual
When T H C is automatic / manual control function instead o f corner low-speed input, the system needs to use
the "corner low-speed" output to control the T H C ' s automatic / manual signal. When the T H C is not matched

74
 2100 CNC Controller

type, it needs to be converted by the Relay. Meanwhile, it needs to change the type o f corner low speed from
normally-open to normally-closed in the output configuration interface (Section 10.2.2), i.e from red "•" to green
"O". > Using THC for initial sense( IHS)
When using the locating function o f the T H C , the locating o f CNC should be closed. The approach is to
change the input type o f successful locating from normally-open to normally-closed in the input configuration
interface(Section 10.1.3), i.e from "•" to "O". There are two types o f locating:
The first: locating controlled by the plasma arc starting. CNC output the plasma arc starting, the T H C
starts arc after I H S , and sends ARC O K signal back to CNC after pierce. Such T H C is available on the market
like H Y D ' s X P T H C series. Such devices can connect the "plasma arc starting" output o f CNC system to the "
arc on with I H S " input o f the T H C , and at the same time in the plasma parameters (refer to section 7.4 o f plasma
parameters) set the arc detecting time to the value that allows for completing the testing and starting arc.
Using CNC system locating When using the Initial Sense function o f CNC system, first entering the
input configuration interface, set the input type o f successful location from normally closed to normally open type,
ie, from "O" to At the same time, return the signal o f successful location to the input o f the successful
location o f the C N C .

10.2.2 Output configuration

The number and type o f the output could be configured, for example, the igniting output number could be
3,also it could be configured to 07, the output type could be normally open or normally closed. The detailed methods
are shown in figure 10.9.
Press F5(Diagnosis) in the main interface, F 8 ( S y s t e m d e f ) , F3 (Define), enter the password "1396" and
press ENTER, F2(output).

75
 2100 CNC Controller

Ignition
Port
03 •
Definition of output

•
Type
Exhaust
Port
06 •
•
Type

• •
LowPreheat 01 THC 08
HighPreheat 17 PosDetect 19

• •
LowOxygen 04 ArcStart 16
MidOxygen 05 LowSpdInCorner 18
HighOxygen 14 Dust spray 07
TorchUp 02 Raise dust 20
TorchDown 15 Dust preheat 21 #

Port- Press PgUp/PDn Type-Press Enter

F1 Input F2 Output F3 Axes F4 Motor F8 Save

Fig 10.9 Output Configuration I n the output configuration interface, move the
cursor to numbers o f the serial number, Press the PgUp or PgDn to change the input port number, that also changes
the pin number o f 25-pin input terminal. Move the cursor to • place, you can press ENTER to change the input
type. " • " is for the normally open t y p e o f the input , when invalid , it is for the signal o f turning o f f , when
effective, it is for the signal o f closure. "O" is the normally closed t y p e o f input , when invalid ,it is the signal
of closure, when effective ,it is the signal o f turning o f f .

10.3 Motor Port

76
 2100 CNC Controller

XCP+
XCP-
XDIR/XPWM-X _n_ X
YDIR+
YDIR-
PWM+ Signal
Y+
Shaping YCP+
YDIR/YPWM-Y Photoele
-- \A Photoele ------- V YCP-
-ctric Different
PWM+ -ial
isolation
output
XDIR+
XDIR-

F i g l O . 1 0 motor port schematic diagram

• Signal definition table
signal Remarks
Number of the 15 pin

interface
1 XDIR+ Positive at the horizontal axis
9 XDIR- Negative at the horizontal axis
2 XCP+ Positive pulse at the horizontal axis
10 XCP- Negative pulse at the horizontal axis
3 YDIR+ Positive at the vertical axis
11 YDIR- Negative at the vertical axis
4 YCP+ Positive pulse at the vertical axis
12 YCP- Negative pulse at the vertical axis
5 ZCP + Positive pulse at the perpendicular axis
13 ZCP- Negative pulse at the perpendicular axis
6 ZDIR+ Positive at the perpendicular axis
14 ZDIR- Negative at the perpendicular axis
7 +5V +5V/500mA Power output
15,8 5VG 5V Power Ground

System
10.3.1 Typical wiring diagram of the electrical motor interfaces

10.3.1.1 connection methods for differential stepper driver

77
 2100 CNC Controller

Power input
XDIR+
XDIR-

XCP+

XCP-

YDIR+

YDIR-

YCP+

YCP-

+5V

5VG

5VG

Fig 10.11 connection methods for differential stepper driver

78
 2100 CNC Controller

10.3.1.2 Com -anode connection methods for stepper driver

DIR
XDIR+
+V
XDIR-

XCP+ ©
XCP- ©- PUL Free

YDIR+

YDIR- 0-
YCP+

YCP- ©- Stepper
drives

0© Power

+5V 5VG
© Power
input

5VG

© Offline
switch

©
© input
Stepper drives

© n
[=1

Figure 10.12 com-anode connection methods for stepper driver 10.3.1.3

Connection methods o f Servo driver o f Panasonic Company

XCP+
XDIR+
XCP-
XDIR-

79
 2100 CNC Controller

YDIR+ ©
YDIR-YC 0 5 SING1
6 SIGN2
P+ YCP-
- 3 PULS1

4 PULS2

©
■
+5V 5VG
Panasonic
5VG
©- A5/A4

0-
5 SING1
0 6 SIGN2

3 PULS1
© 4PULS2
Power input

0
u
[=]
Power input
0
0
0

80
 2100 CNC Controller

Panasonic
A5/A4

Figure 10.13 Connection methods o f Servo driver o f Panasonic Company

10.3.2 Coordinate Mapping

I n order to change the map coordinates o f the system, you need to go to the define interface. The process is to
Press F5(Diagnosis) in the main interface, F 8 ( S y s t e m d e f ) , F 3 (Define), enter the password "1396" and press
ENTER, then press F 3 (Axes). As shown in Figure 10.14.

Fig 10.14 Coordinate Mapping Continuously press [ E n t e r ] key, the direction o f the
arrow outside coordinates definition will change , the maximum coordinate mapping i s eight. After adjusting the
direction o f the coordinates mapping, press F 8 to Save.

Chapter11 Installation and Debugging

11.1 Horizontal / vertical pulses number setting

• Horizontal / vertical pulses number setting

It's easy to set the horizontal(vertical) pulses number. Before drawing a line , assume one value o f horizontal
pulses X P l s and one value o f vertical pulses Y P l s , set these two parameters and then save the settings. Enter the

81
 2100 CNC Controller

manual interface, choose fixed moving function. Assume the fixed distance is Amm. Move A mm horizontally, and
the actual length o f the line is B mm (which is generally not equal to A), then we can calculate the horizontal pulses
number. The equation is

XPls • —
B
. After calculating , replace the outcome with the assumptive Xpls(take three decimal places at most).

Similarly, move C mm vertically, the actual length is D mm, then the vertical

YPls • —
D
pulses number i s .

• requirement o f pulses number:

The maximum frequency o f output pulses from the system i s 200 K H z . I t is not possible to work properly
according to the order i f the pulse frequency is higher than 200KHz. Assume the pulse number i s x, the highest
speed is M v (mm/min), then ( M v * x / 6 0 ) should be less than 200000.
For example, the pulse number is x=2000, the highest speed is Mv=12000(mm/min).Because o f
Mv*x/60=12000*2000/60=400000>200000, the speed o f 12000(mm/min) is not reachable. I f we set x to be 1000,
then Mv*x/60 = 12000*1000/60 = 200000, this time it can just to reach the operating speed o f 12,000. While in
principle the number o f pulses can be set to a large value, in fact it should follow these two settings. Because the
frequency is too high, some drives can't work very well, the motor will be out o f synchronism. On the other hand,

Chapter12 The use of BIOS

When the system powers on, it will display as shown in Fig 12.1. the
performance
of
anti-jammin
g is of
foreign
interference
is poor, and
the external
interference
is strong.
Fig 12.1
power on
When press
DEL before
the system
counts down
to 0 , the system will enter the B I O S . I f other keys are pressed, the system will enter in before counting down to
0.

82
 2100 CNC Controller

F1 - pp^JrlKSystem software update)

F2 - $CiQl#ffi5Tl$(Welcome picture update)
F3 - ìtijjféfTOll(Motion update)
F4 - Pp|lt^fzr(System backup)
F5 - Pp|ltJ3SJjÌ (System recovery)
F6 - /äsjJppi^Start system)

Fig 12.2 B I O S interface

12.1 System upgrade

After entering B I O S , press F 1 to upgrade the system, it should s a t i s f y the following conditions:
Flash Disk i s connected to the system.
There should be the UserApp.exe upgrade file in the root folder o f the flash disk.
Pressed F 1 to upgrade when the conditions are satisfied, when completing the upgrading, press F 6
to reboot.

12.2 Welcom interface upgrading

After entering B I O S , press F2 to upgrade the welcome interface completely, it should s a t i s f y the
following conditions:
• Flash Disk is connected to the system.
• There should be the STARTBMP.BIN upgrade file in the root folder o f the flash disk. Pressed F6 to
upgrade when the conditions are satisfied, when completing the upgrading, press F 6 to reboot.

12.3 Movement control upgrade

After entering B I O S , press F2 to upgrade the welcome interface completely, it should s a t i s f y the following
conditions:
• Flash Disk is connected to the system.
• There should be the M O T I O N . D S P upgrade file in the root folder o f the flash disk. Pressed F 3 to
upgrade when the conditions are satisfied, when completing the upgrading, press F 6 to reboot.

12.4 Movement Backup

83
 2100 CNC Controller

after entering B I O S , press F 4 to backup.

12.5 System Reset

After entering B I O S , press F 5 to return to the original system that has been backup.

Appendix 1 G> M code rapid consult

Serial number order function

1 G99 rotation > proportion > mirror image
2 G92 reference coordinate
3 G91 Relative coordinate system
4 G90 Absolute coordinate system
5 G20 English unit
6 G21 Metric unit
7 G41 Left kerf gap compensation
8 G42 Right kerf gap compensation
9 G40 Cancel kerf gap compensation
10 G00 Quickly move
11 G01 Liner cutting
12 G02 Clockwise arc cutting
13 G03 Anticlockwise arc cutting
14 G04 Program delay
15 M07 Start cutting cycle
16 M08 Stop cutting cycle
17 M02 Program end
14 G04 Program delay
15 M07 Start cutting cycle
16 M08 Stop cutting cycle
17 M02 Program end

84