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Hypertherm Powermax65 Manual
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Hypertherm Powermax65 Manual

Serial communication protocol
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Powermax65/85
Serial Communication Protocol
807220 – Revision 1 – January, 2011

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Summary of Contents for Hypertherm Powermax65

  • Page 1 Powermax65/85 Serial Communication Protocol 807220 – Revision 1 – January, 2011...

  • Page 3: Communication Ports

    Both the Powermax65 and Powermax85 can support serial communications with a CNC. A five-pin serial port sends and receives the signals over an RS-485 connection using the ModBus ASCII serial protocol. The power supplies require both the serial port and the machine interface port (CPC connector) to be installed to provide full communications capability. Both ports are located on the rear panel of the Powermax65 and Powermax85: Machine interface port Serial port (also called a CPC connector) power supply Hardware requirements machine torch Using the Powermax65 and Powermax85 in a mechanized application requires a machine torch. Either the M65/M85 or M65m/M85m can be mounted to an X-Y table or other platform. See the Powermax65/Powermax85 Operator Manual (806650) for more information on mounting a machine torch. communication ports The Powermax65 and Powermax85 may not have either the serial port or machine interface port installed at the factory. serial port To upgrade a power supply for serial communication, order the following upgrade kit and cables: • 228539 – Includes serial interface port, internal cables, and RS-485 board. • Serial cables: 223236 – RS-485 cable, unterminated, 25 ft / 7.6 m 223237 – RS-485 cable, unterminated, 50 ft / 15 m 223239 – RS-485 cable, 9-pin D-sub connector for Hypertherm controls, 25 ft / 7.6 m 223240 – RS-485 cable, 9-pin D-sub connector for Hypertherm controls, 50 ft / 15 m...

  • Page 4: Serial Port Pin Assignments

    The serial port on the Powermax65 and Powermax85 is a 5-pin male connector (also called a Phoenix connector). The wiring diagram below shows the signals and show they would connect to a 9-pin connector on the CNC. The 9-pin connector shown below is the one used on the Hypertherm EDGE Pro control. Be sure to check the serial port on your CNC for the correct pin assignments. If you will be using one of the unterminated serial cables (223236 or 223237) the diagram below shows the wire colors and the signals carried on each of the wires. CNC 9-pin serial port or unterminated Not connected Powermax65/85 RS-485 5-pin TxD- Black serial port Black RxD- Black White TxD+ White Green Black Not connected Green RxD+ Not connected Not connected machine interface port The machine interface port (also called a CPC connector) gives the CNC access to arc start and transfer, and to the voltage divider. To add the machine interface port to the Powermax65 or Powermax85, order the following upgrade kit: •...
  • Page 5 To use signals for arc transfer and plasma start only: 023206 – terminated with spade (fork) connectors, 25 ft / 7.6 m 023279 – terminated with spade (fork) connectors. 50 ft / 15 m Spade connector Refer to the following diagram and table when connecting the Powermax65 or Powermax85 to a CNC with a machine interface cable. signal type notes connector cable wires sockets Start (start Input Normally open. 3, 4 Green, black plasma) 18 VDC open circuit voltage at START terminals. Requires dry contact closure to activate. Transfer Output Normally open. Dry contact closure 12, 14 Red, black (start when the arc transfers. machine 120 VAC/1 A maximum at the motion) machine interface relay or switching device (supplied by the customer). Ground Ground...
  • Page 6 For information on the ModBus ASCII serial protocol, please see the following documents: • http://www.modbus.org/docs/Modbus_Application_Protocol_V1_1b.pdf • http://www.modbus.org/docs/Modbus_over_serial_line_V1_02.pdf The ModBus ASCII standard defines the serial frame as: • 19200 baud • 1start bit • 8 data bits • 1 stop bit • even parity The most significant bit is the first bit and the least significant bit is the last bit. The ModBus data envelope is: start address Function Data 1 character 2 characters 2 characters 0 up to 2x252 characters 2 characters 2 characters Colon : CR/LF: 0D0A address The power supply address is set by the first valid ModBus message it receives from the CNC. The power supply uses this address until it is powered down. When it is powered up again, the power supply will not have retained...
  • Page 7 After the CNC takes control of the power supply, the switches and adjustment knob on the front panel are disabled, and the LCD displays the remote control icon: The power supply responds to commands with either the ModBus function code and data, or with a ModBus exception function code followed by an error code. For a list of the Modbus function and exception codes, see http://www.modbus.org/docs/Modbus_Application_Protocol_V1_1b.pdf. calculating the checksum (lrc) ModBus ASCII requires a longitudinal redundancy check (LRC, also called a checksum) on each message. NOTE: In the example below, and throughout this document, when you see 0x, the characters following the 0x are hexadecimal (hex) numbers. To calculate the LRC: Example: :010108080001ED0D0A – the LRC is 0xED Add the hex values of the message but exclude the start (:) and end characters (0D0A) and the LRC itself: 0x01 + 0x01 + 0x08 + 0x08 + 0x00 + 0x01 = 0x13 Subtract from 0xFF: 0xFF - 0x13 = 0xEC Add 1: 0xEC + 0x01 = 0xED Variable scaling In addition, Hypertherm uses variable scaling on some of the values as defined below: First bit – Most Last bit – Least 16 15 14 13 12 11 10...
  • Page 8 The following tables show sample command strings that could be sent from the CNC and the responses from the power supply. The sample command strings show a single register write function. While the ModBus protocol allows you to write to and read multiple registers, these functions are not shown in the samples. command name register Description (Hex) cut_mode_force 0x2093 Sets the cut mode to one of these values: Scaling is 16-bit, fixed- Normal = 1 point binary with 1-bit sign CPA = 2 at MSB and 0-bit decimal at LSB. Gouge = 3 cut_mode_force value :01062093xxxxcc where xxxx equals the cut mode value cc equals LRC (checksum) Samples: normal :010620930001450D0A Response: :01062093000145 cpa :010620930002440D0A Response: :01062093000244 Gouge :010620930003430D0A Response: :01062093000343...
  • Page 9 Description (Hex) current_set_force 0x2094 Changes the amperage setting. Scaling is 16-bit, fixed-point current_set_force value :01062094xxxxcc binary with 1-bit sign at where xxxx equals the hex value of the amperage MSB and 6 bit decimal at decimal multiplied by 64. LSB. cc equals LRC (checksum) Samples: 40 a :010620940A003B0D0A 40 A × 64 = 2560 = 0xA00 Response: :010620940A003B 45 a :0106209400B40FA0D0A 45 A × 64 = 2880 = 0x0B40 Response: :0106209400B40FA 65 a :010620941040F50D0A 65 A × 64 = 4160 = 0x1040 Response: :010620941040F5 85 a :010620941540F00D0A 85 A ×64 = 5440 = 0x1540 Response: :010620941540F0 Note: Assigning a value to current such as 55.5...
  • Page 10 Description (hex) pressure_set_force 0x2096 When pressure_set_force = 0, the gas mode is set to Automatic mode at the power supply. Scaling is 16-bit, fixed- point binary with 1-bit sign When pressure_set_force > 0, the CNC controls the gas pressure and the at MSB and 7-bit decimal pressure controls on the power supply are disabled. at LSB. pressure_set_force value :01062096xxxxcc Where xxxx equals the hex value of the PSI decimal value multiplied by 128 cc equals LRC (checksum) Samples: 45 psi :010620961680AD0D0A 45 PSI × 128 = 5760 = 0x1680 Response: :010620961680AD 70 psi :010620962300200D0A 70 PSI × 128 = 8960 = 0x2300 Response: :01062096230020 fault_code 0x2098 Reads the fault condition. Sample: :010420980001420D0A Response: :010402006F8A fault_code value :010402xxxxcc...
  • Page 11 Description (hex) current_set min 0x2099 Reads the minimum current setting limit for the power supply. Scaling is 16-bit, fixed- Sample: :010420990001410D0A point binary with 1-bit sign Response: :0104020500F4 at MSB and 6 bit decimal at LSB. current_set_min value :010402xxxxcc Where xxxx equals the hex value of a decimal value. Divide by 64 to get the amperage. cc equals LRC (checksum) 0x0500 = 1280 ÷ 64 = 20 The minimum current setting limit in this example = 20Amp current_set_max 0x209A Reads the maximum current setting limit for the power supply. Scaling is 16-bit, fixed- Sample: :0104209A0001400D0A point binary with 1-bit sign Response: :0104021040A9 at MSB and 6 bit decimal at LSB. :010402xxxxcc Where xxxx equals the hex value of a decimal value. Divide by 64 to get the amperage. cc equals LRC (checksum) 0x1040 = 4160 decimal÷ 64 = 65 The maximum current setting limit in this example = 65 Amp...
  • Page 12 Description (hex) pressure_set_max 0x209D Reads the maximum pressure setting limit for the power supply. Scaling is 16-bit, fixed- point binary with 1-bit sign Sample: :0104209D00013D0D0A at MSB and 7-bit decimal Response: :0104022700D2 at LSB. pressure_set_max value :010402xxxxcc Where xxxx equals the hex value of a decimal value. Divde by 128 to get the PSI. cc equals LRC (checksum) 0x2700 = 9984 decimal ÷ 128 = 78 In this example, the maximum pressure setting limit for the power supply is 78 PSI. arc_time_low 0x209E Reads the amount of time the arc has been on in seconds. The commands work together to read the upper and lower 16 bits arc_time_high 0x209F of the 32-bit unsigned integer. Sample: :0104209E00023B0D0A Response: 010404lllhhhcc llll = ARC time lower 16 bits hhhh – ARC time higher 16 bits cc equals LRC (checksum) Sample responses: 1 second – :01040400010000F6...
  • Page 13 Description (Hex) torch_index 0x0808 Reads the torch lead length. Hypertherm controls use this 0x0809 command to set gas pressure and load the correct cut charts. (Coils) The sample below reads the two coils. Sample: :010108080002EC0D0A Response: :010101xxcc Where xx equals torch length cc equals LRC (checksum) Torch lead length is contained in the last 2 bits of the 8-bit response value. Bit 1 Bit 0 Length 15 - 25 ft (≤7.6 m) 35 - 50 ft (≤15 m) 75 ft (≤23 m) Responses: :01010100FD 15 – 25 ft (≤7.6 m) :01010101FC 35 – 50 ft (≤15 m) :01010102FB 75 ft (≤23 m)

  • Page 14: Fault Codes

    Fault codes The chart below summarizes some fault codes that could be returned by the power supply. For a complete list of fault codes, see the Powermax65 and Powermax85 Service Manual (80xxxx) All values are decimal without the symbol “-”. Fault code Description 0-11-0 Invalid cut mode setting 0-11-1 Current setting value is out of range 0-11-2 Gas pressure setting value is out of range 0-12-0 Low input gas pressure 0-13-0 AC input unstable warning 0-19-0 Power board hardware protection 0-20-0 Low gas pressure 0-21-0 Gas flow lost while cutting 0-22-0 No gas input 0-30-0 Torch consumables stuck 0-40-0 Over temperature 0-50-0 Retaining cap off 0-51-0 Start/trigger signal on at power-up 0-52-0 No torch connected to the power supply. 0-60-0...
  • Page 16 Hypertherm (india) thermal Hanover, NH 03755 USA cutting pvt. ltd. 603-643-3441 Tel Chennai, Tamil Nadu 91 0 44 2834 5361 Tel Hypertherm europe B.V. 4704 SE Roosendaal, Nederland Hypertherm Brasil ltda. 31 165 596907 Tel Guarulhos, SP - Brasil 55 11 2409 2636 Tel Hypertherm (shanghai) trading co., ltd. Hypertherm méxico, s.a. de c.V. PR China 200052 México, D.F. 86-21 5258 3330 /1 Tel 52 55 5681 8109 Tel Hypertherm (s) pte ltd. www.hypertherm.com Singapore 349567 65 6 841 2489 Tel...

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