powermax65/85 serial communication protocol powermax65/85 serial communication protocol overview...

Powermax65/85 Serial Communication Protocol

807220 – Revision 1 – January, 2011

1

powermax65/85 serial communication protocol

overview

BoththePowermax65andPowermax85cansupportserialcommunicationswithaCNC.Afive-pinserialportsendsandreceivesthesignalsoveranRS-485connectionusingtheModBusASCIIserialprotocol.Thepowersuppliesrequireboththeserialportandthemachineinterfaceport(CPCconnector)tobeinstalledtoprovidefullcommunicationscapability.BothportsarelocatedontherearpanelofthePowermax65andPowermax85:

power supply Hardware requirements

machine torch

UsingthePowermax65andPowermax85inamechanizedapplicationrequiresamachinetorch.EithertheM65/M85orM65m/M85mcanbemountedtoanX-Ytableorotherplatform.SeethePowermax65/Powermax85 Operator Manual (806650)formoreinformationonmountingamachinetorch.

communication ports

ThePowermax65andPowermax85maynothaveeithertheserialportormachineinterfaceportinstalledatthefactory.

serial port

Toupgradeapowersupplyforserialcommunication,orderthefollowingupgradekitandcables:

• 228539–Includesserialinterfaceport,internalcables,andRS-485board.

• Serialcables:

- 223236–RS-485cable,unterminated,25ft/7.6m

- 223237–RS-485cable,unterminated,50ft/15m

- 223239–RS-485cable,9-pinD-subconnectorforHyperthermcontrols,25ft/7.6m

- 223240–RS-485cable,9-pinD-subconnectorforHyperthermcontrols,50ft/15m

Serialport Machineinterfaceport(alsocalledaCPC

connector)

2


Tx+

Tx-

Rx+

Rx-

GND

1

2

3

4

5

serial port pin assignments

TheserialportonthePowermax65andPowermax85isa5-pinmaleconnector(alsocalledaPhoenixconnector).Thewiringdiagrambelowshowsthesignalsandshowtheywouldconnecttoa9-pinconnectorontheCNC.The9-pinconnectorshownbelowistheoneusedontheHyperthermEDGEProcontrol.BesuretochecktheserialportonyourCNCforthecorrectpinassignments.

Ifyouwillbeusingoneoftheunterminatedserialcables(223236or223237)thediagrambelowshowsthewirecolorsandthesignalscarriedoneachofthewires.

1

2

3

4

6

7

8

9

5

TxD+

TxD-

RxD-

RxD+

GND

NotconnectedPowermax65/85RS-4855-pin

serialport

CNC9-pinserialportorunterminated

machine interface port

Themachineinterfaceport(alsocalledaCPCconnector)givestheCNCaccesstoarcstartandtransfer,andtothevoltagedivider.ToaddthemachineinterfaceporttothePowermax65orPowermax85,orderthefollowingupgradekit:

• 228697–Includesmachineinterfaceport,internalcables,andvoltagedividerboard.

• Cables:

- Tousethebuilt-involtagedividerthatprovidesascaleddownarcvoltage,inadditiontosignalsforarctransferandplasmastart:

- 228350–terminatedwithspade(fork)connectors,25ft/7.6m

- 228351–terminatedwithspade(fork)connectors,50ft/15m

- 123896–terminatedwithD-subconnector(compatiblewithHypertherm’scontrols),50ft/15m

Notconnected

Notconnected

Notconnected

Red

Black

Green Red

Black

White

Black

GreenWhite

Black

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RefertothefollowingdiagramandtablewhenconnectingthePowermax65orPowermax85toaCNCwithamachineinterfacecable.

34

12

13

14

56

signal type notes connector sockets

cable wires

Start(startplasma)

Input Normallyopen.18VDCopencircuitvoltageatSTARTterminals.Requiresdrycontactclosuretoactivate.

3,4 Green,black

Transfer(startmachinemotion)

Output Normallyopen.Drycontactclosurewhenthearctransfers.120VAC/1Amaximumatthemachineinterfacerelayorswitchingdevice(suppliedbythecustomer).

12,14 Red,black

Ground Ground 13

Voltagedivider

Output Dividedarcsignalof20:1,21.1:1,30:1,40:1,50:1(providesamaximumof18V).

5(-),6(+) Black(-),white(+)

Spadeconnector

- Tousesignalsforarctransferandplasmastartonly:

- 023206–terminatedwithspade(fork)connectors,25ft/7.6m

- 023279–terminatedwithspade(fork)connectors.50ft/15m

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TheModBusdataenvelopeis:

start address Function Data lrc end

1character 2characters 2characters 0upto2x252characters 2characters 2charactersColon: CR/LF:0D0A

addressThepowersupplyaddressissetbythefirstvalidModBusmessageitreceivesfromtheCNC.Thepowersupplyusesthisaddressuntilitispowereddown.Whenitispoweredupagain,thepowersupplywillnothaveretainedtheaddress,andwillagaintakeitsaddressfromthefirstvalidModBusmessageitreceives.

Function FunctionsaredefinedintheModBusASCIIdocumentsreferencedearlier.Examplesinclude04forregisterreadand06forasingleregisterwrite.

Data Includestheregisterlocation,andthedatabeingrequestedfromthePoiwermaxorsenttotheCNC.

lrcLongitudinalRedundancyCheck,amethodforperformingachecksumonthemessage.

cr/lFCarriagereturn,linefeedinhexadecimal:0D0A.TheendcharactersaretypciallyremovedonincomingmessagesbytheCNC.

TheCNCcancontrolthefollowingPowermaxoperationsbywritingtospecificinputregisters,alsocalledforceregisters.

• Cutmode(normal,continuouspilotarc(CPA),gouge)

• Amperage

• Gaspressureandcontrolmode

Toputthepowersupplyintoremotecontrolmode,theCNCneedstowritetoallthreeforceregisterstogether,once,withcorrectnon-zerovalues(seethesamplecommandstringtableslaterinthisdocument).Afterward,theCNCcanwritetotheforceregistersoneatatimeasneeded.Toreturnthepowersupplytomanualcontrol,allforceregistersmustbesettozero.

serial communications with modBus ascii

ForinformationontheModBusASCIIserialprotocol,pleaseseethefollowingdocuments:

• http://www.modbus.org/docs/Modbus_Application_Protocol_V1_1b.pdf

• http://www.modbus.org/docs/Modbus_over_serial_line_V1_02.pdf

TheModBusASCIIstandarddefinestheserialframeas:

• 19200baud • 1startbit• 8databits • 1stopbit• evenparity

Themostsignificantbitisthefirstbitandtheleastsignificantbitisthelastbit.

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Lastbit–Leastsignificantbit

(LSB)

1bitsign+/-atMSB

Decimalpointatspecifiedbitfrom

LSB,forexample,6bitsdecimal.

8 7 6 5 4 3 2 1Firstbit–Mostsignificantbit

(MSB)

Variable scaling

Inaddition,Hyperthermusesvariablescalingonsomeofthevaluesasdefinedbelow:

calculating the checksum (lrc)

ModBusASCIIrequiresalongitudinal redundancy check(LRC,alsocalledachecksum)oneachmessage.

NOTE:Intheexamplebelow,andthroughoutthisdocument,whenyousee0x,thecharactersfollowingthe0xarehexadecimal (hex) numbers.

TocalculatetheLRC:

Example::010108080001ED0D0A–theLRCis0xED

Addthehexvaluesofthemessagebutexcludethestart(:)andendcharacters(0D0A)andtheLRCitself:

0x01+0x01+0x08+0x08+0x00+0x01=0x13

Subtractfrom0xFF:0xFF-0x13=0xEC

Add1:0xEC+0x01=0xED

ThepowersupplyrespondstocommandswitheithertheModBusfunctioncodeanddata,orwithaModBusexceptionfunctioncodefollowedbyanerrorcode.ForalistoftheModbusfunctionandexceptioncodes,seehttp://www.modbus.org/docs/Modbus_Application_Protocol_V1_1b.pdf.

16 15 14 13 12 11 10 9

AftertheCNCtakescontrolofthepowersupply,theswitchesandadjustmentknobonthefrontpanelaredisabled,andtheLCDdisplaystheremotecontrolicon:

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command name register (Hex)

Description

cut_mode_force

Scalingis16-bit,fixed-pointbinarywith1-bitsignatMSBand0-bitdecimalatLSB.

0x2093 Setsthecutmodetooneofthesevalues:

Normal=1

CPA=2

Gouge=3

cut_mode_forcevalue:01062093xxxxcc

wherexxxxequalsthecutmodevalue

ccequalsLRC(checksum)

Samples:

normal:010620930001450D0A

Response::01062093000145

cpa :010620930002440D0A

Response::01062093000244

Gouge:010620930003430D0A

Response::01062093000343

sample modBus command string tables

ThefollowingtablesshowsamplecommandstringsthatcouldbesentfromtheCNCandtheresponsesfromthepowersupply.Thesamplecommandstringsshowasingleregisterwritefunction.WhiletheModBusprotocolallowsyoutowritetoandreadmultipleregisters,thesefunctionsarenotshowninthesamples.

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Description

current_set_force

Scalingis16-bit,fixed-pointbinarywith1-bitsignatMSBand6bitdecimalatLSB.

0x2094 Changestheamperagesetting.

current_set_forcevalue:01062094xxxxcc

wherexxxxequalsthehexvalueoftheamperagedecimalmultipliedby64.


Samples:

40 a

:010620940A003B0D0A

40A×64=2560=0xA00

Response::010620940A003B

45 a

:0106209400B40FA0D0A

45A×64=2880=0x0B40

Response::0106209400B40FA

65 a :010620941040F50D0A

65A×64=4160=0x1040

Response::010620941040F5

85 a :010620941540F00D0A

85A×64=5440=0x1540

Response::010620941540F0

Note:Assigningavaluetocurrentsuchas55.5followsthesameequation:

55.5 a:010620940DE0580D0A

55.5Ax64=3552=0x0DE0

Response::010620940DE058

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command name register (hex)

Description

pressure_set_force


0x2096 Whenpressure_set_force=0,thegasmodeissettoAutomaticmodeatthepowersupply.

Whenpressure_set_force>0,theCNCcontrolsthegaspressureandthepressurecontrolsonthepowersupplyaredisabled.

pressure_set_forcevalue:01062096xxxxcc

WherexxxxequalsthehexvalueofthePSIdecimalvaluemultipliedby128


Samples:

45 psi :010620961680AD0D0A

45PSI×128=5760=0x1680

Response::010620961680AD

70 psi :010620962300200D0A

70PSI×128=8960=0x2300

Response::01062096230020

fault_code 0x2098 Readsthefaultcondition.

Sample::010420980001420D0A

Response::010402006F8A

fault_codevalue :010402xxxxcc

wherexxxxequalsthehexvalueofthedecimalfaultcode


0x006F=111

Faultcode0-11-1Currentsettingvalueisoutofrange

Thefullsetoffaultcodesisshownonpage11.

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Description

current_set min


0x2099 Readstheminimumcurrentsettinglimitforthepowersupply.

Sample::010420990001410D0A

Response::0104020500F4

current_set_minvalue:010402xxxxcc

Wherexxxxequalsthehexvalueofadecimalvalue.Divideby64togettheamperage.


0x0500=1280÷64=20

Theminimumcurrentsettinglimitinthisexample=20Amp

current_set_max


0x209A Readsthemaximumcurrentsettinglimitforthepowersupply.

Sample::0104209A0001400D0A

Response::0104021040A9

:010402xxxxcc

Wherexxxxequalsthehexvalueofadecimalvalue.Divideby64togettheamperage.


0x1040=4160decimal÷64=65

Themaximumcurrentsettinglimitinthisexample=65Amp

pressure_set_min


0x209C Readstheminimumpressuresettinglimitforthepowersupply.

Sample::0104209C00013E0D0A

Response::0104021F805A

:010402xxxxcc

Wherexxxxequalsthehexvalueofthedecimalvalue.Divideby128togetthePSI.


0x1F80=8064decimal÷128=63

Theminimumpressuresettinginthisexample=63PSI

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Description

pressure_set_max


0x209D Readsthemaximumpressuresettinglimitforthepowersupply.

Sample::0104209D00013D0D0A

Response::0104022700D2

pressure_set_maxvalue:010402xxxxcc

Wherexxxxequalsthehexvalueofadecimalvalue.Divdeby128togetthePSI.


0x2700=9984decimal÷128=78

Inthisexample,themaximumpressuresettinglimitforthepowersupplyis78PSI.

arc_time_low

arc_time_high

0x209E

0x209F

Readstheamountoftimethearchasbeenoninseconds.Thecommandsworktogethertoreadtheupperandlower16bitsofthe32-bitunsignedinteger.

Sample::0104209E00023B0D0A

Response:010404lllhhhcc

llll=ARCtimelower16bits

hhhh–ARCtimehigher16bits


Sampleresponses:

1second–:01040400010000F6

60seconds(1minute)-:010404003C0000BB

3600seconds(1hour)-:0104040E100000D9

360000seconds(100hour)-:0104047E40000534

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Description

torch_index 0x08080x0809

(Coils)

Readsthetorchleadlength.Hyperthermcontrolsusethiscommandtosetgaspressureandloadthecorrectcutcharts.

Thesamplebelowreadsthetwocoils.

Sample::010108080002EC0D0A

Response::010101xxcc

Wherexxequalstorchlength


Torchleadlengthiscontainedinthelast2bitsofthe8-bitresponsevalue.

Bit1 Bit0 Length0 0 15-25ft(≤7.6m)0 1 35-50ft(≤15m)1 0 75ft(≤23m)

Responses:

:01010100FD15–25ft(≤7.6m)

:01010101FC35–50ft(≤15m)

:01010102FB75ft(≤23m)

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Fault code Description0-11-0 Invalidcutmodesetting0-11-1 Currentsettingvalueisoutofrange0-11-2 Gaspressuresettingvalueisoutofrange0-12-0 Lowinputgaspressure0-13-0 ACinputunstablewarning0-19-0 Powerboardhardwareprotection0-20-0 Lowgaspressure0-21-0 Gasflowlostwhilecutting0-22-0 Nogasinput0-30-0 Torchconsumablesstuck0-40-0 Overtemperature0-50-0 Retainingcapoff0-51-0 Start/triggersignalonatpower-up0-52-0 Notorchconnectedtothepowersupply.

0-60-0 ACinputvoltageerror0-61-0 Arcinputunstable,shutdown0-98-0 Internalcommunicationerror0-99-0 Systemhardwarefault–servicerequired

Fault codes

Thechartbelowsummarizessomefaultcodesthatcouldbereturnedbythepowersupply.Foracompletelistoffaultcodes,seethePowermax65andPowermax85ServiceManual(80xxxx)Allvaluesaredecimalwithoutthesymbol“-”.

©2010Hypertherm,Inc.AllRightsReserved

Hypertherm,Powermax,andEdgeProaretrademarksofHypertherm,Inc.andmayberegisteredintheUnitedStatesand/orothercountries.

Hypertherm, inc. Hanover,NH03755USA603-643-3441Tel

Hypertherm europe B.V.4704SERoosendaal,Nederland31165596907Tel

Hypertherm (shanghai) trading co., ltd. PRChina20005286-2152583330/1Tel

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www.hypertherm.com

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