Kar CNC

Operation Manual
Manufactured by ProMotion Controls

Document v1.01
Koike KAR CNC
Table of Contents
Part I Warranty 1
1 Warnings
................................................................................ 1
2 Contact ................................................................................
Info 2
Part II Overview 3
1 Main Screen
................................................................................ 4
Info (System Status) ............................................................................ 4
ProMotion Cut - Next............................................................................
Job 5
Current Job ............................................................................ 7
2 KAR CNC
................................................................................
Operating Control Panel 10
Emergency Stop - Off
............................................................................
Button 11
Input Power Switch............................................................................ 11
Drive Enable Switch............................................................................ 12
IHS Switch ............................................................................ 13
Floating Head Switch
............................................................................ 13
Plasma Switch ............................................................................ 14
Torch Raise / Lower............................................................................
Switch 15
Speed Potentiometer
............................................................................ 15
Eight Direction Jog ............................................................................
Keys 16
Manual Mode Button
............................................................................ 16
Zero Button ............................................................................ 17
Start Button ............................................................................ 18
Torch On/Off Button............................................................................ 19
Speed Up & Speed Down
............................................................................
Buttons 20
Move Ahead Button............................................................................ 20
Stop / Backup Button
............................................................................ 21
Part III Setup of KAR CNC 22

1 Starting
................................................................................
and Turning off the Controller 22
Starting Procedure ............................................................................ 22
Shutting Off / Removing
............................................................................
Power 22
2 Homing
................................................................................
Procedure 22
1997 - 2005 Robotronic Oy

I
Koike KAR CNC
3 Jog ................................................................................ 23
4 Parameter
................................................................................
Quick View 24
Advanced Setup ............................................................................ 26
Plate Alignment ............................................................................ 29
Part IV ProMotion Nest 30

1 File Menu
................................................................................ 32
New Plate ............................................................................ 32
Open ............................................................................ 32
Trash ............................................................................ 34
Save As ............................................................................ 34
Macro ............................................................................ 34
Print ............................................................................ 38
DNC ............................................................................ 38
Import ............................................................................ 39
Export ............................................................................ 39
Exit ............................................................................ 39
2 View Menu
................................................................................ 39
3 Tools Menu
................................................................................
/ Toolbox 40
Move Shape ............................................................................ 40
Rotate Shape ............................................................................ 40
Mirror ............................................................................ 41
Remove ............................................................................ 41
Change Piercing Point
............................................................................ 41
Change Compensation
............................................................................
Side 41
Change Cutting Direction
............................................................................ 42
Change Cutting Order
............................................................................ 42
Split Element ............................................................................ 44
Join Profiles ............................................................................ 44
Leadins ............................................................................ 44
Zoom In / Out ............................................................................ 45
Reset View ............................................................................ 45
Pan View ............................................................................ 45
Ruler ............................................................................ 46

II
Koike KAR CNC
Copy ............................................................................ 46
Cut ............................................................................ 46
Paste ............................................................................ 47
Undo ............................................................................ 47
4 Options
................................................................................
Menu 47
Handling Options ............................................................................ 48
EIA Options ............................................................................ 51
Language Options ............................................................................ 53
5 Help Menu
................................................................................ 54
6 Toolbar................................................................................ 54
MicroCAD ............................................................................ 55
NestInfo ............................................................................ 57
7 List Windows
................................................................................ 58
Plate List ............................................................................ 58
Part List ............................................................................ 59
8 Miscellaneous
................................................................................ 60
Terminology ............................................................................ 60
DXF ............................................................................ 60
Improving DXF Loading
............................................................................
Times 61
CNC-2 ............................................................................ 65
Line and point marking
............................................................................ 65
Part V Monograph Training Guide 66

1 Introduction
................................................................................ 66
2 Independent
................................................................................
Systems 66
ATC - Arc Voltage Controller
............................................................................ 66
Trouble Shooting AVC
............................................................................. 69
Other Issues Which Influence
Proper Arc Voltage.............................................................................
Control 71
Torch Lifter/ Linear ............................................................................
Slide 72
Lifter Check Out / Setup
Procedure ............................................................................. 73
Koike HS-5 Lifter Technical
Information ............................................................................. 75

III
Koike KAR CNC
Lifter Sequencing Conditions

............................................................................. 77
Sequence of Operation
Manual mode ............................................................................. 78
Sequence of Operation Auto
mode ............................................................................. 79
State of Lifter Motion
Trajectory ............................................................................. 80
3 IHS (Initial
................................................................................
Height Sensing) 81
IHS Checkout Procedure
............................................................................ 82
Initial Height Sensing
............................................................................
Troubleshooting Guide 83
4 Process
................................................................................
Controller 85
Plasma Cutting (Tab............................................................................
0) 86
Plasma Cutting (Tab............................................................................
1) 87
MNM Model Plasma............................................................................
Cutting Sequence of Operation 87
BASIC SETUPS ............................................................................ 89
ADVANCED SETUPS
............................................................................ 90
Show Delay Names ............................................................................
In Readjust Field 93
Aux Parameters ............................................................................ 95
Floating Head Setup............................................................................
Tables 97
5 Plasma................................................................................
Power Supply 99
General Information............................................................................ 99
Part VI Connector Review 101

Index 108

IV
Warranty Koike KAR CNC
1 Warranty
ProMotion Controls Inc. warrants to the purchaser that products

shall be free from defects in materials and workmanship, under
normal and proper use, for a period of one (1) year from shipment
date from seller's factory. Labor expenses are covered for a period
of 90 days on equipment installed by ProMotion Controls, from date
of installation. The warranty shall not extend beyond this time for any
reason.
Improper use, modification, mishandling, or incorrect installation by

others will exclude ProMotion Controls from warranting this product.
ProMotion Controls, at its option, shall repair or replace free of

charge any product covered by this warranty, which has been
returned with prior authorization. The product must be properly
packaged and returned with all costs, freight and insurance prepaid
and is subject to inspection of proper use as noted above.
Replacement or repaired parts will be sent standard ground delivery

and insured, at no charge, to the end user. The warranty on
replacement or repairs shall expire on the same date as the
warranty on the originally purchased product. Shipment costs and
insurance when expedited services are required will not be covered.
Under no event will this warranty obligate ProMotion Controls for any
amount exceeding the price of the goods upon which liability is
based.
The applicable warranty expressed in this section constitutes the

only warranty of Promotion Controls, Inc. and no other warranty or
condition statutory or otherwise shall be implied.
1.1 Warnings
DO NOT CONNECT the controller directly to a computer through the

RJ45 or RS232 port! Connections must be made with fiber optic
devices, wireless LAN, short haul modems or other approved
devices which provide galvanic isolation, due to ground loops,
electrical noise, or high frequency which can destroy electrical
components in the controller or host computer. Failure to follow
these rules will VOID THE WARRANTY!

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Koike KAR CNC Warranty
1.2 Contact Info
Koike Aronson, Inc.
Eastern Region
Divisional Headquarters, Arcade NY
1 585-492-2400
Southern Region
Houston, TX 77055
1 713-682-9645
www.koike.com
ProMotion Controls
780 W. Smith Rd. Unit F

Medina, Ohio 44256
Tel: +1 330 721 1464

Fax: +1 330 721 1463
E-mail: [email protected]
www.promotioncontrols.com
International Office
Robotronic Oy
Sammonkatu 66 B
FIN-33540 Tampere
Finland
Tel: +358 3 276 0500

Fax: +358 3 222 5967
E-mail: [email protected]
www.robotronic.fi

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Overview Koike KAR CNC
2 Overview
Introduction
The KAR CNC controller is a two axis servo controller specifically
designed for the Monograph Millennium plasma cutting machine by
Koike Aronson, Inc.
The system includes two microprocessors to offer TRUE-
MULTITASKING functions, download or prepare your next job while
the machine is cutting.
With a 12.1 inch TFT color screen you can graphically see your
current job being cut and look at your next job simultaneously.
The KAR CNC controller is designed to be user friendly and simple

to use. Please review the functionality of the screens and the
operational of the front panel keys to take full advantage of the KAR
CNC controller.

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Koike KAR CNC Overview
2.1 Main Screen
The main screen is divided in three parts.

Info (Systems Status)
Promotion Cut Next Job
Current Job
2.1.1 Info (System Status)

This is located on top of the screen. The info screen shows
information to the operator and used for diagnostics and
troubleshooting.
Speed IPM (or metric) indicates machine speed.

X & Y readouts indicates position of cutting torch.
Speed Bar in %. This is interfaced directly with the Speed

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Potentiometer. If the speed pot is turned completely 100% CW the

Speed Bar will show 100%.
Jogging direction indicator. Monitors and shows which direction
jogging key is pressed.
Operational Panel Interfaced with the 8 push buttons. Monitors
which button is pressed or activated.
System Running Indicates that the second CPU is activated and
functionally properly.
2.1.2 ProMotion Cut - Next Job

Located on the left hand side of the screen, the Promotion Cut
Screen is the starting point to navigate through out the different
screens.

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Selecting the Shapes button will automatically open the Macro

Shape Library in ProMotion Nest.

-6-
The Download button opens the Windows Open File to select a

stored program from the internal drive system or external device.
'The Setup button opens the Parameter Quick View Screen to allow
you to change values for Kerf, Speed etc.
Selecting rows & columns button will ask you how many rows and
columns of the shape currently shown.
Opens to the jog screen dialog box. Functions like Drive machine
to and Rip cut are located under this jog dialog box.
Selecting on the Act button will allow you to do a trial run of the
program, select on board manual, and the options to open the menu
bar on Promotion Cut - Next Job Screen.
HINT: To perform a trial run properly the manual mode button must
not be activated.
2.1.3 Current Job

The current job screen located on the right hand side of the screen.
This screen displays the current job being cut with real time tracking.

-7-
Normally this button is grayed out. Activated when a cutting program

is stopped by pressing the torch on/off and or the StopBackup
buttons located on the front panel of the controller. Selecting the
cancel program will suspend the current job program.

-8-
Normally this button is grayed out. Activated when a current program

is stopped and the manual mode button is activated. When
confirming if a program fits on a plate i.e. in trial mode it will
reposition the program the same distance as the torch movement.
Normally this button is grayed out. Activated when a current program

is stopped and the manual mode button is activated. Selecting Cut
Path Recovery will re-start the pierce cycle at the point the torch is
located and will find the program path at the point the torch existed
in manual mode.
Selecting the readjust cut parameters button will allow the operator
to change certain parameters i.e. cutting speeds, creep speed,
creep time and pre-stop distance to the cutting program on the fly.
This will eliminate the need to stop the machine to make these
changes.
Refresh the current job screen.
Selecting the next job preview allows the transfer of next program
from the next job preview screen with out activating the cutting
sequence. This is grayed out during cutting.

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Selecting the view track during cutting will zoom in on the cutting
path.
The Cut again box allows the opportunity to suspend and save a job
and restart a saved job.
Show new start point Selecting this function allows the mouse
pointer to automatically change to a cross hair when a pierce point
is identified on a part.
Restart- After locating a new pierce point , select restart to start
cutting cycle.
Zoom Expands on the save job screen
Save job Will store existing suspended program in temporary
file
Reload saved job Brings back the suspended saved program
from the temporary file.
Cancel Cancel any selected functions under the cutting again
box.
2.2 KAR CNC Operating Control Panel
The KAR CNC operating controls functions are locate below the
LCD graphic screens. Most of all the machines motion and cutting
are initiated using the operating control panel.

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2.2.1 Emergency Stop - Off Button
The emergency stop off button is used to remove power from the
entire system in case of an emergency. It supplies power to the
servos, and cutting controls. The power to the CNC is not removed.
Motion and cutting will stop immediately when the Emergency stop is
pushed in.
Turn the E-stop button clockwise and release to apply power to the
servos and cutting controls.
2.2.2 Input Power Switch

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The power switch is a momentary switch. Toggle the switch up and

hold two seconds will turn on power to the CNC and the system.
The proper way to switch power off is using Windows

shutdown. This will switch off all power in the controller.
In case Windows shutdown is not available, it is possible to force

power off by pressing down this switch for 20 seconds. This method
is not recommended, unless there is no other way to shutdown the
system.
Note: After switching off the controller it is advisible to wait at least

25 seconds to allow the capacitors to discharge before switching on
again.
2.2.3 Drive Enable Switch
This is a two position switch on or off. In the off position it disables

the servo drives. When the drive switch is in the on position it
enables the servo drives allowing the machine to move when
commanded to do so.

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2.2.4 IHS Switch
This is a two positions switch In the Auto mode the inital height
sense will automatically be turned on by the controller to locate the
initial height before cutting. In the manual mode the initial height can
be turned on manually and controlled by the UP/DOWN switch or by
the ARC voltage control height system.
2.2.5 Floating Head Switch
This is a three position switch ON/OFF/AUTO. In the On position the

floating head will lower on the surface of the material. In Auto mode

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the floating head will lower automatically commanded by the

controller. In the OFF position the floating head will be disabled and
stays in the up position.
2.2.6 Plasma Switch
This is a three position switch ON/OFF/AUTO. In the On position the

plasma can be turned on manualy using the torch on/off button. In
Auto mode the plasma will be turned on automatically commanded
by the controller. In the OFF position the plasma is disabled and
cannot be operated.

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2.2.7 Torch Raise / Lower Switch
This is a momentary two position switch to raise or lower the torch.
2.2.8 Speed Potentiometer
Turning the potentiometer counter clockwise decreases the actual

speed in comparison with the programmed speed. This
potentiometer is only for special cases, it used to temporarily slow
down the cutting speed. Turning down the speed below 100 % the
Torch Hold / Corner signal will be activated on, which freezes the
automatic torch height control at that height. In most case the speed

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potentiometer is set at 100% clockwise.
2.2.9 Eight Direction Jog Keys
The manual mode must be activated before using the jog function.
Press and hold a directional button and the machine will move in
that direction, releasing the button will cause the machine to stop.
Pressing and holding two adjoining directional buttons will move both
axes in a 45 degree direction.
2.2.10 Manual Mode Button

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Pressing the MANUAL MODE button activates the capability to jog

and reposition the machine. Pressing it again will turn off the manual
mode and will return the machine to the last know parked position.
HINT: When locating a new starting point on the table (using the jog
function keys) press the Zero button to reset X & Y counters to zero,
this will automatically turn off the manual mode and the machine will
stay at this new zero, zero point location.
2.2.11 Zero Button
Resets the X & Y counters to zero after locating a new starting point
on the table using the jog function keys.
HINT: Pressing the zero button will automatically will turn off the
manual mode button if it was activated on.

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2.2.12 Start Button
Sends the cutting program from the next job preview screen to the
current job screen to be executed and starts the cutting cycle
sequence. The light of the START-button is on during the entire
execution of the program. No programs can be transferred to current
job screen if the START button is on.
HINT: If this button is pressed during a programmed delay the delay

is terminated at once without memorising the interrupted time of the
delay in cutting parameters.

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2.2.13 Torch On/Off Button
Pressing the torch on /off button when the manual mode is activated
will start or turns off the plasma arc manually When the start button
is activated the cutting sequence is initiated the TORCH ON/OFF
button will go on automatically indicating the torch is on and has
started to cut. At the end of the program the light on the TORCH
ON/OFF will go out automatically indicating end of cut. Press and
release the TORCH ON/OFF button during the cutting, the machine
motion and cutting stops . Pressing this button again starts the
machine motion and the cutting sequence with the programmed
delays.

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2.2.14 Speed Up & Speed Down Buttons
Short pushes increase or decrease the actual and set speed in small
steps. Long lasting push changes the speeds at a faster rate The
lights will come on the buttons on during the automatic corner
deceleration and acceleration respectively.
2.2.15 Move Ahead Button
The MOVE AHEAD button is illuminated when a program is cutting.

Pressing the Torch on/off button will stop the machine and cutting
and the Move Ahead button will turn off. At this stage pressing the

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MOVE AHEAD button the program will move forward on

programmed path with out cutting, pressing the MOVE AHEAD
button again will stop machine motion.
HINT: Turn speed potentiometer counter clockwise when using the

Move Ahead feature for more precise control.
2.2.16 Stop / Backup Button
Press and release the STOP BACKUP button once durring the
cutting process stops cutting sequence and machine motion. Press
and release the STOP BACKUP button again will move the machine
in reverse on path. Pressing STOP BACKUP button again will stop
motion.
HINT: Both the Stop-Backup and Torch on/off buttons work identical
the same when a cutting program is on and you would like to stop
cutting.

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Koike KAR CNC Setup of KAR CNC
3 Setup of KAR CNC
3.1 Starting and Turning off the Controller
3.1.1 Starting Procedure

Make sure that the red Emergency Stop button is pressed in and the
drive enable switch is in the off position.
Switch on the system by toggling up the power switch located on the
far right hand side. When power is applied, the KAR CNC controller
will take approximately 2-3 minutes to go through the internal
diagnostics and boot up procedure to the Promotion Work Screen
displaying Promotion Cut next job preview and current job screen
along with Info (System Status). In addition, you will see the yellow
Zero button start flashing, this will stop automatically.
HINT: The flashing Zero button indicates that the second CPU used
for motion has booted up correctly.
Release the red E-Stop button by turning it clockwise and external

stop limit dialog warning box will disappear on the screen. Switch the
drive enable switch to the on position to enable the drives. A dialog
box will appear START HOMING PROCEDURE,
see section 2.2 for detail information.
3.1.2 Shutting Off / Removing Power

After locating a safe parked position, disable the drives by switching
the drive enable switch to off. Turn off computer by clicking on Start
(bottom left hand corner) on window's task bar and click on Turn off
computer and Turn off.
After the controller goes through a proper cycle down procedure the
controller will turn off. Press in the Emergency stop button.
3.2 Homing Procedure
During initial power up the KAR CNC controller displays a Start

Homing procedure dialog box. If you select Yes, the machine will
automatically locate the (factory set) absolute zero home location.
Normally this is at the bottom left corner of the cutting table - the

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Setup of KAR CNC Koike KAR CNC
same corner where the KAR CNC controller is. If you select No, the
dialog box disappears and no movement is executed.
3.3 Jog
When selecting the Jog Button, the Jog dialog box will appear.
You can use Jog tool only when a cutting program is not running
and the controller is not in the manual drive mode. Use this tool to
drive the machine to the position (X,Y) or to drive a distance (X,Y)
from the current position. Driving is usually done in rapid speed. It's
also possible to cut with this tool, if you have checked the Rip Cut
box.
If Use program rotation is checked, the coordinates where you

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drive, are corrected according to the program rotation. The program

rotation is set in the parameter quick view screen.
It is possible to define several different home positions. These can

be used to define the home positions of different plates, which are
on the cutting table. Select the number of the table from the list and
click the Drive to button. The machine drives to the defined home
position of the selected table.
If there is a need to drive the same distance often (for example

plasma torch to the same position where gas torch was), it's useful
to save these kind of distances as default offsets (offset 1 and 2).
This way you can drive the default offset just by clicking a button
once.
Set absolute zero (home) position by clicking the Set absolute 0,0
here button. This tool is needed, if the programmed working area
limits are in use. Those limits force the machine to stop before it hits
the electrical limit switches. Setting absolute zero position can also
be automatic, when the machine is driven to the predefined zero
position every time the controller is turned on. Absolute zero position
is also needed, if there is a need to set several home positions.
3.4 Parameter Quick View
The parameter quick view screen opens automatically when a

program is sent to cutting from Promotion Nest or when the Setup
button is clicked. The quick view screen allows the operator to
change the most comely used and variable parameters quickly. It
also provides options for plate alignment and advance set up.

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Kerf
Specifies the amount of kerf (compensation) that will be applied to
the cutting program. Caution should be taken when selecting the
amount of kerf, to high of a value can cause the program to be
altered especially when a radius of an arc is smaller than the kerf
value.
Cutting Speed
This is the speed of the cutting process.
Program Rotation
Any value (degree) will rotate the cutting program. When a plate
alignment is performed the rotation of the skewed plate is
automatically enter here. Also, by clicking on the +/- 90 the part
program will rotate at 90 degrees intermittent. Clicking on the zero
box will clear any value of rotation to zero degree.
Pierce Height
It is the distance from the plasma tip to the work piece at initial
pierce. Note this is a time based value (in seconds) from the point
the plasma tip contacts the work piece and retracts to the initial

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pierce height.
Pierce Time
This is a move delay after the pierce has started.
Parameter Set (Plasma)

If selected in the advanced set up screen the material, thickness and
tool used will appear here to guide the operator on the current
parameter selection.
3.4.1 Advanced Setup

The advanced set up screen allows the operator the flexibility to
change more parameters if needed. On the 1 Parameters tab the
parameter quick view settings are shown again, along with creep
speed, mirror and tool location. In addition a cutting process
database can be set up by selecting material, thickness and tool.
Kerf, Cutting Speed, Pierce Height, Pierce Time, Program

Rotation

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These settings are identical as described in the parameter quick

view screen. Changing the setting here will also change in the
parameter quick view screen automatically.
Creep Speed
This is the process cutting speed at beginning of the cutting
program. The duration of this speed is determined by the setting of
the creep time in Tab 6 Cutting parameter. After the creep time is
completed, the controller accelerates up to the set cutting speed.
Tool Location
If a laser pointer is installed to the machine, it is best to define tool
locations relative to the laser pointer. This way you can position and
set the zero point using the laser pointer and the system knows the
location of all the tools and can automatically handle them while
cutting a program. Adding tool offset in your cutting program is not
required.
Mirror
Checking the mirror box will mirror your program in the X axis.
Gas and Plasma 2 Tabs

Not used.
General
If this button is clicked on a dialog box will appear regarding kerf
compensation loops. In most case the box is checked. On small
occasions the kerf compensation calculation adds an extra loop
which it may be undesirable on certain parts with very small radius.
Un-checking this box will remove the loops created.
OK
Clicking on the OK button is a temporary change only to the cutting
program in Promotion Cut Next Job screen.
SAVE
Clicking on the Save button after a change has been made a
password box will automatically appear. After the password the
changes will become permanently per that settings.
Close
Clicking on this button will close this screen.

- 27 -
Process Data Base

The KAR CNC has a unique feature that allows building a data base
for specific cutting parameters based on material, thickness and
tool.
Based on material, thickness and tool selected the cutting

parameters will change automatically, for example kerf and cutting
speeds. Once a data base is built up with all the correct information,
the guessing work where to set the cutting parameters will be
minimized. This would be helpful when a new operator is trained to
operate a cutting machine and maintain consistent cut quality.
Note: It is not necessary to use all three fields to set the data base
e.g. use material and thickness only and leave tool at Default.
Set up Data Base

A) Click inside Add/Remove box to activate the new box. Click new
for material and a new material dialog box opens up. Click on other
than ok. Type in your description for material. Repeat steps for
thickness and tool.
B) Select the wanted material, thickness and tool and enter all
correct corresponding values for cutting speed, kerf, pierce height
and pierce time. Review the entire screen that every field is correct,
click on the save button and enter password to lock it in.
C) Repeat steps A &B to re-enter new parameter settings for new

material, thickness and too.

- 28 -
3.4.2 Plate Alignment

When plate alignment is activated it allows a quick way to pick two
points on the edge of a skewed plate. Performing this exercise will
automatically rotate a part or nest program the same amount so that
it will fit precisely onto the plate without running of material at the
edge of the plate.
To use the plate alignment find the first corner and click on Set point
1 here. Select which direction the next point is relative to the first
location, travel to the second point and click on confirm point here.

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Koike KAR CNC ProMotion Nest
4 ProMotion Nest
What is it?
ProMotion Nest is a software, which converts CAD pictures (DXF
format) to cutting programs. It is also possible to modify existing
cutting programs (EIA, ESSI or CNC-2 format) by ProMotion Nest.
Basics
When ProMotion Nest loads a CAD picture, it adds cutting
technology (kerf side, piercing points, cutting order, etc.) to shapes
automatically. If you want, you can easily change any of those
settings. Copy shapes to a plate, nest, set cutting order, etc. When
ready, send your cutting program to ProMotion Cut or save it for
later use.
ProMotion Nest user interface

ProMotion Nest's user interface is a collection of several small
windows, buttons and bars. Below is a brief description of all of
them.

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ProMotion Nest Koike KAR CNC
1. Title bar
Title bar is at the top of the ProMotion Nest window. It contains the
version number, the name of the registered user and the name of
the active job.
2. Menu bar
Menu bar lies just below the title bar. Menu bar has following menus:
File Menu
View Menu
Tools Menu
Options Menu
Help Menu
3. Toolbar
Toolbar lies just below the menu bar. Toolbar contains buttons for
quick access to most important tools of ProMotion Nest (like load,
save, macros). See more from chapter Toolbar.
4. Work window
Work window is the large white area in the middle of the screen.
Active job is displayed here and editing is also done here.
5. Coordinates
Y-coordinates are displayed on the left side of the work window and
X-coordinates just below of the work window.
6. Status bar
Status bar lies at bottom of the ProMotion Nest window. Status bar
displays messages and hints from ProMotion Nest. It also displays
the current coordinates of the mouse cursor, when it is on the work
window.
7. Toolbox
Toolbox is located at the top right corner of the ProMotion Nest
window. It contains buttons for most editing tools.
8. Plate list
Plate list is located just below of the toolbox. Plate list contains a list
of all plates loaded to ProMotion Nest. See Plate list for more
information.
9. Part list

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Part list is located at the bottom right corner of the ProMotion Nest
window. Part list contains a list of all shapes loaded to ProMotion
Nest. See Part list for more information.
4.1 File Menu
The File menu provides tools for opening existing files, saving files
and exiting the application. ProMotion Nest can read files which
are in DXF-, EIA- or ESSI-format.
4.1.1 New Plate
When you activate this tool, a window appears asking the length and
width of the new plate.
Insert the values and click the "Ok"-button and a new empty plate
appears. The name of the plate appears in the Plate List.
You can also create round plates, if you check the round plate
option. Then you only need to enter the diameter of the circle. This is
handy option, if you are nesting on a circular remnant plate.
4.1.2 Open
Loads an existing file and reconstructs it for further use. If the file
contains lots of elements, reconstruction may take a while.

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DXF-files:
If you load a file, that is in DXF-format and that file includes more
than one layer, then ProMotion Nest asks you to select which
layers are loaded to the nesting.
If there are line and/or point markings in the DXF-file, they must be
in their own separate layers. Line and point marking layers are
chosen in the same dialog as the profile layers. In the example
above the layer "PROFILES" is selected for containing the profiles.
The layer "POWDER" is selected as line marking layer and there is
no selected point marking layer.
Select all button loads all layers to the nesting.
Normally ProMotion Nest starts to load elements from DXF file,

after it has found a certain keyword from the file. This is for speeding
up the loading process and to cut off all auxiliary elements (like
measure lines). Sometimes however, there is a need to load
elements before that keyword. Raw Load is made for cases like this.
It loads every possible element from the DXF file to your nesting.

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Other files:
ESSI and EIA files don't have any layers to choose. Just make sure
that your options are set correctly.
See also Line and point marking.
4.1.3 Trash
Closes the current nesting, which is seen at the work window. If

there are more than one nesting open, then next one will be
displayed at the work window.
4.1.4 Save As
Saves the current nesting (the one in the work window).
4.1.5 Macro
When you select this tool, the macro list window (picture 1) opens.
This window displays small images of the available macros. There
are only 20 macros displayed in any time, but you can see more
macros, if you click the "Next" and "Previous" buttons.

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Picture 1.
Creating a new shape with macros
Select the macro you want by double-clicking it. The window below
(picture 2) opens. Enter all the measures to the measure list. In the
picture on the left side of the window you can see the shape and red
lines. Those red lines are measure lines and they show you, what is
the actual measure you are entering to the measure list. When you
have entered all the measures, you can preview the shape by
clicking the "Preview"-button. If you want to change some of the
measures after preview, click the "Back"-button and change the
measures. When you are satisfied, click "Ok"-button and the shape
appears in the ProMotion Nest's work window.
Note: You can use the number pad of this window or the wheel of
your mouse to input numbers.

- 35 -
Picture 2.
Editing the macrolist
Click the button "Edit macrolist" in the first window (picture 1) to

open the macrolist edit window (see below). The list "Current
macros" shows the macros currently in the list. The list "Available
macros" shows all the macros, which you can add to the macrolist.
The dashed line in the "Current macro" list shows, where is the page
break. There can be only 20 macros visible in any time in the macro
list (see picture 1).

- 36 -
Picture 3.
How to change the order of macros in the macro list:

Select one of the macros in the list "Current macros". The macro
you selected is displayd in the little picture box just below the list.
Click the button "Up" to move the selected macro one step
towards the beginning of the list.
Click the button "Down" to move the selected macro one step
towards the end of the list.
How to remove a macro from the macro list:

Select one of the macros in the list "Current macros". The macro
Click the button "Remove" and the macro you selected is removed
from the list.
How to add a macro to the macro list:

Select one of the macros in the list "Available macros". The macro
Click the button "Add" and the macro you selected is added to the
end of the list.

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4.1.6 Print
This tool prints the current nesting to the default printer.
4.1.7 DNC
Use this tool to load files from DNC connection. There must be
ProMotion iLink running on the PC from where you download files.
Next Use this button to browse the files available in ProMotion

iLink working directory (folder). Available filenames are displayed in
the text field just below this button.
Load Click this button, when you want to start DNC download. The
file currently displayed in the tect field starts loading. If you know the
file you want to download, you can just type it's name to the text field
and click Load button.
Abort Click this button to abort DNC download
Load Previous If you have previously downloaded a file and you

want to use that same file again, you don't need to download it
again. Just click "Load Previous" button and the last file, you have
downloaded will be loaded.
File Open Click here to change to normal File Open dialog. Use this
if the file you want to use locates in the KAR CNC's hard drive or
some where in the network, where you have access.

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ProMotion iLink LT
There is a free copy of ProMotion iLink LT in your KAR CNC's hard
drive at "C:\Program Files\ProMotion Nest\iLink\iLinkLT.exe". There
are also instructions how to use ProMotion iLink LT.
4.1.8 Import
This tool imports a nesting created by ProMotion Cut.
4.1.9 Export
This tool exports the current nesting to ProMotion Cut. Please
note, that the exported nesting won't open automatically in
ProMotion Cut. To open it, you must use the import tool of
ProMotion Cut.
4.1.10 Exit
Exits the ProMotion Nest application.
Important! All nestings will be closed and all data they contain will be
lost. If you want to save one or more of those nestings, you should
save them before exiting.
4.2 View Menu
Black and White view

This turns drawing color to black.
Outbits
If this option is checked, then ProMotion Nest displays special
outbits, if there are any in a nesting. See more info from ProMotion
Cut manual.
Transferlines
Hide All Transferlines can be toggled on or off by selecting this
option.
Show Cut When this is selected, you can see transferlines
between cutting profiles. This is the default setting.
Show Powder When this is selected, you can see transferlines
between powder marking profiles.

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Show Drill When this is selected, you can see transferlines

between drill marking points.
4.3 Tools Menu / Toolbox
The Tools menu / Toolbox provides tools to edit a nesting.
4.3.1 Move Shape
By using this tool you can manually change the position of a shape.
Move cursor over a shape and press the left mouse button down.
Now the shape will follow the movement of the mouse as long as
you press the button.
4.3.2 Rotate Shape
Rotates a shape counter clockwise, if the left mouse button is

pressed and clockwise if right mouse button is pressed. Rotation
angle can be changed in options menu.

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4.3.3 Mirror
This tool let's you mirror shapes in X or Y axis. If you move the
mouse cursor over a shape and click the left mouse button, the
shape will be mirrored in Y axis. If you click the right mouse button,
the shape will be mirrored in X axis.
4.3.4 Remove
The left mouse button activates area deletion. Keep the left mouse
button pressed down and move the mouse. A rectangle will follow
the movement of the mouse. When you release the left mouse
button, all the profiles that are completely inside the rectangle will be
deleted. If you click the right mouse button, then a single element
will be deleted.
4.3.5 Change Piercing Point
To change the piercing point move the mouse cursor over that
element where you want to place the piercing point. If you click the
left button, the piercing point will be the first point of the element. If
you click the right button, the piercing point will be that point, where
your mouse cursor is. This action can only be done on complete
profiles.
4.3.6 Change Compensation Side
The compensation side can be changed by pointing a profile with the

mouse cursor and clicking the left button.

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4.3.7 Change Cutting Direction
The cutting direction can be changed by pointing a profile with the

mouse cursor and clicking the left button.
4.3.8 Change Cutting Order
When this tool is activated, the following dialog will appear.
By using this dialog you can choose the type of objects, whose
cutting order will be changed, and the method of changing the

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cutting order.
The cutting order can be changed between parts (shapes), holes,

line marking profiles and point marking points.
There are five methods which can be used to change the cutting
order: show order, swap, move one step, line and free select.
In the Show order method you just click the objects in that order
they are about to be cut or marked. When you click an object, it will
change its color to indicate that it is selected. If the color of the
object will not change, then you cannot change its order (it's
probably of wrong type). Selections can be removed by clicking the
unselect button in the "Change cutting direction" dialog. The option
Lock first object can be used with this method. If "Lock first object"
is selected, then you cannot change the cutting order of the objects,
which are before the first selected object in the cutting order. When
you are ready, click the Apply button to create the new cutting order.
This is the only method, that you can use on powder and drill
markings.
In the Swap method you click two objects and their positions in the
cutting order will be changed between them. When you click the first
object, it will change it's color to indicate selection. When you click
the second object, the first object will become unselected and the
cutting order will change.
In the Move one step method you just choose the object, which
cutting order you want to change, and then use the Step arrows to
change the cutting order. If you click the left "Step" arrow, the
selected object will be cut earlier and if you click the right arrow, it
will be cut later.
In the Line method you draw a line over the parts or holes, which
cutting order you want to change. The cutting order of the first
part/hole, that the line overlaps, won't change. The rest of the
overlapped parts/holes will come immediately after the first one.
In the Free select method you just click the profiles in that order you
want to cut them and then click the apply button. This method is
named free select, because you can select any cutting order
between parts and holes (e.g. you can first cut all the holes in your

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nesting and then all the parts). This method may disarrange the
internal data structures of ProMotion Nest, which may cause
automatic nesting and some other tools to fail. For this reason, it's
recommended, that you use this method only, if you can't set the
cutting order with the other methods. If you decide to use this
method, use this when you have done everything else for your
nesting. So this is the final thing to do for a nesting.
Close button closes the dialog. Apply button is used in combination

with the "Show order" and the "Free select" methods. Unselect
button removes all selections.
4.3.9 Split Element
An element can be splitted by pointing it and clicking the left mouse

button. The element will be splitted in two at the clicked point.
4.3.10 Join Profiles
Use this tool to close an open profile or join two open profiles.
Follow these steps:

Press down the left mouse button.
Drag a rectangle around two start/end points of open profile(s).
Release the mouse button.
Note! If you draw the rectangle around more or less than two points,
this tool does nothing.
4.3.11 Leadins
Use this tool to change all leadins and leadouts in your nesting.
When you activate this tool, the following window opens.

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Select leadin and leadout types and length. Then click apply button
to apply new leadins and leadouts to the nesting.
4.3.12 Zoom In / Out
View can be zoomed in by moving the mouse button over the work
window and pressing the left mouse button down. A rectangle will
appear. This rectangle shows the area to be zoomed in. While the
left mouse button is pressed down, the area of the rectangle can be
changed by moving the mouse. If the right mouse button is clicked
the view will be zoomed out.
4.3.13 Reset View
This tool will reset the view. Which means that the view will be
resized in a way that all shapes and a possible plate will be seen as
large as possible.
4.3.14 Pan View
View can be panned by moving the mouse cursor to the editing area

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and pressing the left mouse button. The picture will follow the mouse
movement until the left mouse button is released.
4.3.15 Ruler
Use this tool to measure distances. Move the mouse cursor over
some point A and press down the left mouse button. Move the
cursor over some point B while you keep the left mouse button
down. You can see the distance between points A and B at the top
left corner of work window in a yellow box.
4.3.16 Copy
This tool allows user to copy different objects to the clipboard from
where she/he can paste them to any nesting. The object type, that is
to be copied, can be chosen from the "Options"-menu. There are
two kinds of objects that can be copied: shapes and nestings. An
object can be copied by pointing it with the mouse cursor and
clicking the left mouse button.
4.3.17 Cut
Use "Cut" to move shapes to the clipboard. You can paste shapes
from the clipboard to nestings.
Follow these steps:

1. Activate the "Cut" tool by clicking button.
2. Press the left mouse button and keep it down. A focus rectangle
appears.
3. Surround the shapes you want to cut with the focus rectangle and
release the left mouse button.

- 46 -
4.3.18 Paste
Use this tool to paste the copied/cut objects to a nesting. When you
click button, a dialog window appears (see below). If you want
more than one copy, change the paste multiplier in the dialog
window. The paste multiplier tells how many times the copied
objects are to be pasted. Now, click the editing area and the objects
are pasted.
4.3.19 Undo
Last editing can be undone by clicking the undo button.
4.4 Options Menu
The Options menu provides tools to configure the ProMotion Nest

software.

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4.4.1 Handling Options
Measurement
Measurement is either in millimeters or inches. This option defines
which.
DXF Options
Point Distance If two points are this close to each other, then
they are assumed to be the same point. Important! Change the
point distance before loading a file.
Ignore unit info from file When reading DXF-files, ProMotion
Nest tries to detect which measurement is used in the file. This
detection is ignored, if "Ignore unit info from file" is checked. If
detection is ignored, the DXF-file is read in millimeters or inches
depending on the measurement setting.
Move Shapes to Origin If this option is selected, then the shape
in DXF file is moved so, that it's minimum coordinates are at 0,0
point. If the DXF file contains a nesting (more than one shape),
then the nesting is moved so that it's minimum coordinates are at
0,0 point. All the shapes in the nesting are moved exactly the
same distance, so their relative position to each other do not
change.
Convert text to marking and Extended text search are
advanced features, which are only available in ProMotion iCNC

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units.
Scrap Cutting
Only available in ProMotion iCNC units.
Rotation Angle
Defines the rotation angle, that the Rotate tool uses. The angle is in
degrees.
Copy/Paste Target Type

Defines the target type of Copy/Paste tools.
CNC Options
These options are for older ProMotion controls. KAR CNC is state
of the art and these options are not needed in KAR CNC.
Marking Options
If "Skip Marking" is checked, then none of the markings are saved.
This is an useful option, if you just want to print the part names (on
paper), but not to really mark them.
If "Do all markings first" is checked, then all the markings are saved
first and after them the parts to be cut. "Go to origin after marking"
moves the machine to the zero point of the plate, when all the
markings are done. If "Stop after marking" is checked, then the
machine stops after markings.
Show Crosshair
If this box is checked, a crosshair will be drawn at the current cursor
position.
Vertical-Horizontal Bridging, Use Wide Bridges and Max

number of torches
These are advanced features, which are only available in
ProMotion iCNC units.
No area calculations
This option is useful only with some advanced features of
ProMotion Nest, which are not available in KAR CNC units.
Torch on right
Usually the origin is in the bottom left corner of the plate. If you

- 49 -
select this option, then it will be in the bottom right corner.
Software keyboard
If you don't have a keyboard, you can always use software keyboard
for text input. If you set this option, then the software keyboard is
automatically displayed, when text input is needed. Please note, that
you can use the mouse wheel for numerical input in ProMotion
Nest.
DNC enabled
This option sets the default download behaviour of ProMotion
Nest, when requested from ProMotion Cut. If this option is set,
then DNC download automatically activates, when you click
DOWNLOAD in ProMotion Cut. See more info about DNC in
chapter File Menu.
Default Leadins
In this section you can define, what kind of leadins and leadout are
automatically added to all profiles, when loading DXF or creating
macros. If you load EIA or ESSI files, no leadins or leadouts are
added, because they usually have programmed leadins and
leadouts.

- 50 -
4.4.2 EIA Options
These are options which affect the reading of EIA files.

Note: "Coding" and "I and J codes" affect to the nesting only when
they are not defined in the read EIA file.

- 51 -
EIA Codes:
These codes indicate some special action. For example code M09
means (in this case) that line marking is turned on.
Coding:
If coding is set to absolute, then all the X and Y coordinates are
absolute. Otherwise they are incremental.
I and J codes:
I and J codes are the coordinates of the center point of an arc or a
circle. If set to absolute, all I and J codes are absolute. Otherwise
they are incremental. If X and Y codes are set to incremental, then I
and J are also incremental.
Unit / Scale:
These options set the default units and scale used in EIA files. If an
EIA-file has unit definition, then that overrides this setting. The scale
is always defined here.
Program Rotation:
If the rotation is selected, all the new nestings, which are read from
EIA files, will be rotated 90 degrees counter clockwise.
Null G is linear:
This option sets ProMotion Nest to read those EIA-code lines,
which have no G-codes, but have some coordinates, as linear
cutting or rapid movement. If this option is not set, those lines are
considered as the same type, what the last given G-code indicates.
Ignore F codes
If this option is set, then all F codes (feed rate, speed) are ignored.
Ignore K codes
If this option is set, then all K codes (kerf) are ignored. If this is not
set, then you need to select, what does those codes mean. Are they
kerf width or kerf compensation.

- 52 -
Advanced EIA codes

These settings define, which codes set outbits on and off. For more
info about outbits, see ProMotion Cut manual.
4.4.3 Language Options
Change the language used in the user interface of ProMotion Nest.

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4.5 Help Menu
Help menu has following items:
Contents opens the help file on your screen.

About... shows you version info of your ProMotion Nest
software.
4.6 Toolbar
ProMotion Nest's toolbar looks like this:
Here is a list and short description of each tool:
Send to cutting This tool sends the current nesting to

ProMotion Cut and activates it.
File open This tool let's you open a file from KAR CNC's hard
drive or disk drive or from the network.
Save as This tool saves the current nesting for later use.
Macro This button starts the macro tool. See more info from
topic Macro under File Menu.
MicroCAD This button starts the MicroCAD tool. See more info
from topic MicroCAD.
New Plate This tool creates a new plate. See more info from
topic New Plate under File Menu.
Trash This tool trashes the current nesting.
Undo This tool undos the last editing you made for the current

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nesting.
Reset View If you have zoomed or panned your view, this tool
restores the default view.
NestInfo This button activates the NestInfo window. See more

info from topic NestInfo.
Help This button opens the help file.
4.6.1 MicroCAD
Use this set of tools to edit profiles. The tools are described below.
Add Circle
Type the diameter and the coordinates of the center point to the
corresponding text fields. Click the "Apply" button and the circle is

- 55 -
added to the shape. The new circle will be the first one in the cutting
order.
Add Rectangle
First select if you are going to use the center point or the bottom left
corner of the rectangle. Type length, width and the coordinates to
the corresponding text fields. Click the "Apply" button and the
rectangle is added to the shape. The new rectangle will be the first
one in the cutting order.
Round Corner
Insert the radius of the rounding to the "Radius" text field and click
the "Apply" button to verify the radius. When you move the mouse
cursor over a corner, the cursor changes to cross. Click the corner
and it will be rounded with the radius you just set.
Remove Rounding
This tool changes arcs to two lines. Move the mouse cursor over an
arc and it changes to cross. Click to remove rounding.
Add Point
This tool adds points (lines) to a shape. If the shape conatins open
profiles, the line is drawn from the last point of the first open profile
to the point you added. If there are no open profiles, then new line
(and profile) is created from the 0,0 point to the point you added.
Adding new points is simple. Just type in the coordinates and click
the "Apply" button.
Remove Point
This tool removes single points from a profile. Move the mouse
cursor over a point. The cursor changes to cross. Click and the point
is removed. If the point was the last or the first point of the profile,
then the whole element is removed. Other wise the previous and the
next point are connected with a line.
Move Point
This tool moves a point to another location. Click a point to select it
(a small box appears over the point). Enter the new coordinates to
the coordinate fields and click the "Apply" button. The point moves to
it's new location.

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4.6.2 NestInfo
NestInfo displays information about the current nesting. NestInfo

contains following information:
Plate
Plate name - the name of the current plate.
Area - the area of the plate. (square foot or square meters)
Plate width (inches or millimeters)
Plate height (inches or millimeters)
Collar width - this is defined in Nesting options, which is not
available in KAR CNC. (inches or millimeters)
Net usage (%) - the relation between the parts area and the plate
area in percentage.
Part
Parts nested - the number of parts in the nesting.
Nest width - the width of the nesting.
Nest height - the height of the nesting.
Parts area - the total area of all parts. (square foot or square
meters)
Piercings - the number of the piercing points in the nesting.
Nominal Areas
Parts - the total of all parts' nominal sizes.
Used Plate - nominal size of used plate. This is exactly (nest width
+ 2 x collar width) x (nest height + 2 x collar width).
Nominal Usage (%) - the relation between nominal size of all parts
and used plate.
Real Usage (%) - the relation between real area of all parts and
used plate.

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There is no data in the fields "Area", "Parts Area", "Real Usage" or

"Net usage". If you want to know these areas, click the "Calculate
Area"-button. Area calculation may take a while - depending on the
size of your nesting.
4.7 List Windows
There are two list windows on the right hand side of ProMotion
Nest user interface. Those windows are Plate List and Part List.
They both offer you several tools for your use.
4.7.1 Plate List

This window contains a list of all plates, which are opened. The list is
sorted alphabetically. The active plate has a blue bar on it (it is
selected). These tools are available in the plate window:
Activate - Click the name of the plate to activate it.
Popup menu - Right-Click the window to open a popup menu. The

menu contains following commans:

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New Plate
Change plate changes the plates size.
Trash
Rename, which renames the active plate.
Move Nesting to (see below)
Move Nesting to
This tool changes the position of the whole nesting. When you select
this tool, the window below appears.
Left is the nestings distance to the left side of the plate. If this
number is negative, it means that the nesting is over the plate's
edge. Right, bottom and top work in the same way.
You can change left and bottom values. When you click Apply
button, the nesting moves and the values (right and top) in this
window are updated. Ok is like Apply, but it also closes this window.
4.7.2 Part List

This window contains a list of all parts, which are opened. The list is
sorted alphabetically. The active part has a blue bar on it (it is
selected). These tools are available in the part list window:
Activate - Click the name of the part to activate it.
Copy to the active plate - Double-Click the name of the part.
Popup menu - Right-Click the window to open a popup menu. The

menu contains following commans:
Open
Trash

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Rename, which renames the active part.

Copy to nesting, which copies the active part to the active plate.
Move shapes to origin moves the nesting so that it's minimum x
and y values are equal to zero.
Add plate creates a plate, puts the nesting on that and moves the
job to the plate list (plate window).
4.8 Miscellaneous
4.8.1 Terminology
Nesting
Nesting is divided in the following way:
Element is the atom of a nesting. Element is the smallest part that

can be edited. There are three different kinds of elements: lines,
arcs and points.
Profile is a combination of one or more elements, which are

connected to each other. At the start point of a profile the sheet is
pierced and cutting starts. At the end point of a profile the torch is
raised up and cutting stops (for a while at least).
Shape contains one or more profiles. Shape is a logical part, which

has a boundary and possibly has some holes too.
Nesting contains all the shapes, but can also be an empty one.
Transferline
Transferline is a path, that the torch follows, when it is not cutting.
4.8.2 DXF
DXF format is supported by most of the present day CAD-softwares.
DXF files are an interface between CADs and ProMotion Nest.
There are some points in creating DXF to ProMotion Nest, which
should be noticed:
It is useful to put geometries on their own separate layer and
name that layer so that it is easily recognized (for example
PROFILES). ProMotion Nest detects different layers and lets the

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user to choose which ones will be loaded.

Line and point markings must be placed on their own layers. Use
POINT objects for point marking.
Use DXF version 12. Most CADs let you choose, which version of
DXF to export.
Splines and ellipses

Current version of ProMotion Nest does not support splines or
ellipses. The reason for this is, that they are not circular arcs and
KAR CNC can cut only lines or circular arcs. Same is true with any
CNC controller. If you think about EIA or ESSI cnc programs, there
are no codes for non circular arcs. Some CAD softwares allow you
to convert those curves to short lines. The result is not perfect, but
it's good enough in most cases. Future ProMotion Nest will also
have this feature, but before that, you just need to convert your
splines and ellipses to lines in your CAD software.
4.8.3 Improving DXF Loading Times

To improve the loading times of DXF files, keep your files simple. If
possible, use ProMotion Nest to make nestings. If you make the
nesting in your CAD software, that will increase the number of parts
in the file and will increase the loading times. We recommend, that
you put only part per DXF file. Please read below, what are the
differences between making the nesting in CAD software or making
it in ProMotion Nest.
Method - Nest in ProMotion Nest

1. Create the part(s) using a CAD software.
2. Load the DXF file(s) to ProMotion Nest.
3. Nest the parts in ProMotion Nest.
Method - Nest in CAD

1. Create the part(s) using a CAD software.
2. Nest the parts in CAD.
3. Load the DXF file to ProMotion Nest.
Comparison of methods
If you compare these two methods, you can see, that the first step is
the same in both methods. So you don't save any time during the
first step.

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If you can't use automatic nesting tools, then the manual nesting
process takes about the same time in CAD and ProMotion Nest.
However it's probably faster to do it in ProMotion Nest, because it's
a nesting software and thus has all the necessary tools quickly
available.
Where you can save lots of time, is loading the DXF file. If you nest
in CAD, you have all the parts in one file - it's a ready nesting. If you
are going to do the nesting in ProMotion Nest, then your DXF file
contains only one part. It's clear, that the loading times are faster
when you have only one part compared to many parts, but they are
actually faster, than you can imagine. Please see the following
examples.
Examples
The load times used in these examples have been measured by
using a Koike KAR CNC controller.
Part 1 Part 2
Example 1
Let's assume, that we need to create a nesting of 100 copies of part
1. Please see the flowchart below. There you can see the different
paths you can take to do that. Please note, that there are two
processes, which are the same for all paths and thus their time
consumption is not counted here. Those processes are Create part
and Prepare for cutting.

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If we do the nesting in CAD, let's say that it takes 10 minutes (600

seconds) to do it. In addition, it takes 407 seconds more to load it to
ProMotion Nest (in KAR CNC). That makes total of 1007 seconds.
If we just send the part to ProMotion Nest, it takes only 1 second to

load it. After that we have two different paths we can take. We can
use rows & columns nesting, which takes only 10 seconds. That
makes total of only 11 seconds. We can also do the nesting
manually in ProMotion Nest, which takes 400 seconds and total of
401 seconds.
If we do the nesting at office with a nesting software, let's say that it

takes 100 seconds (You can do this with ProMotion Nest office
version in 40 seconds). After that reading the ready cutting program
to KAR CNC takes 78 seconds. Total is 178 seconds.
Please note, that you can do all processes after and including the
process Read to CNC while the machine is cutting previous job.

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Thinking like that leaves you zero seconds of wasted time, when you
read the single part directly to KAR CNC and do the nesting there. If
you use office nesting software, you waste 100 seconds and if you
use CAD for manual nesting, you loose 600 seconds!
Example 2
Let's take 15 copies of part 2. Load time for all parts is 352 seconds
and for a single part it is 5.5 seconds. There are only 15 parts, so
you can do the manual nesting quite fast - even with CAD. We can
say, that the major time loss in this case is the loading time, if you try
to load a DXF file containing all the parts.
Conclusion
As you can see, you can save lots of time by making the nesting in
KAR CNC and that is why we highly recommend that.
Download times
DXF DXF CNC-2 EIA
(All parts) (Single part) (All parts) (All parts)
Part 1 407 s 1.0 s 78 s 98 s
Part 2 352 s 5.5 s 38 s 44 s
Size of the DXF file versus loading time

Accurate loading time cannot be given based on DXF file size.
Reason for this follows. In KAR CNC ProMotion Nest can read in
roughly 50 kilobytes of data per second. So it takes 20 seconds to
read in a file of 1 Megabyte. Unfortunately that is just the beginning,
because all the shape entities (lines and arcs) are in random order
in the DXF file. These entities must be organized in logical order
before they are usable for something else than just to be drawn on
the screen. When the data is read in, ProMotion Nest starts to
process it and how long that takes, depends on how many parts
there are in the file. Some large DXF files may contain only one
simple part and lots of other data, which is not used by ProMotion
Nest. That kind of data could be font definitions, drawing colors, etc.
That data is useful, if you read the file to CAD, but ProMotion Nest
is only interested about parts. If you have a file, which size is less
than 20 kilobytes, you can be pretty sure, that it loads quickly. If the
file size is 200 kilobytes, it can take anything from 10 seconds to
couple of minutes. The time range increases, when the file size

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increases. So you can estimate the load time, but the estimation is
not accurate.
Note: These guidelines only apply to DXF files. Other file types (EIA,
ESSI, CNC-2) fully support premade nestings and there are no
restrictions on how or where they should be nested. Naturally the
bigger your file is the longer it takes to load. In the table above you
can see load times for files of different types containing the same
nestings as used in above examples.
4.8.4 CNC-2
We have developed a new advanced CNC-language - Robotic CNC-
2. CNC-2 is more accurate than old Robotic CNC-, ESSI- or EIA-
languages.
CNC-2 is an excellent choice for making backup copies. It does not

save only the nesting, but the the plate too, if there is one.
4.8.5 Line and point marking

If a nesting contains line or point markings, they are merged to the
shapes of the nesting. You cannot add, move or alter the markings,
unless you also move the shapes. The only thing you can do to the
markings themselves is to remove them.
The line marking profiles are drawn in black color.

The point marking points are encircled by a black crossed circle.

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Koike KAR CNC Monograph Training Guide
5 Monograph Training Guide
5.1 Introduction
The Koike Monograph plasma-cutting machine consists of a highly

intelligent process controller, a stand-alone open loop arc voltage
controller and a programmable high-speed linear slide. The torch
lifter (linear slide) is integrated to the CNC. The CNC directly
commands raising and lowering of the slide until the plasma power
supply is started and the cutting process commences. The arc
voltage controller (torch height control) provides a means of
maintaining torch to work standoff distance during the actual cutting
process. The linear slide is integrated to the CNC through an
interface box located on the main rail behind the CNC. This interface
combines the functions of the CNC, height controller and linear slide
to work as one complete system. In addition this system includes an
IHS (initial height sensing) system to detect when the torch is in
contact with the material. The IHS system and arc voltage controller
are two completely independent systems. The only function of IHS
system is to initially sense the material and conversely the arc
voltage control system only maintains the torch to work distance
during the cutting process. The following details each independent
system separately.
5.2 Independent Systems
5.2.1 ATC - Arc Voltage Controller

The Arc Voltage Controller is commonly referred to as the height
control. It simply monitors the arc voltage potential between the work
(material being cut) and the electrode within the torch body. The
work is the positive or return ground path and the electrode serves
as the negative. Due to current flow between the positive and
negative a voltage potential will exist. The open circuit voltage (OCV)
of the power supply is reduced or divided proportionally to produce a
smaller overall voltage range that the height control utilizes. The
range is typically 3-13 volts DC. Dividing the actual arc voltage by a
20:1 ratio produces this voltage. This in done on the voltage divider
printed circuit board (VD PCB) located within the interface box. It is
the board mounted on standoffs in front of the Koike interface PCB.
The voltage divider PCB (printed circuit board) has two terminal

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Monograph Training Guide Koike KAR CNC
connections for connecting to the OCV within the power supply.

They are labeled PS+ and PS-. It is important that these are
correctly connected. PS+ is the work or ground return and PS- must
connect to the electrode.
Two terminals are provided on the VD PCB for the divided output
voltage to the height controller circuitry. These are labeled signal +
and signal -. This voltage is very important. The height control
functions based upon an input from the thumbwheel on the ATC
unit. The thumbwheel allows the operator to set the desired arc
voltage related to a specific torch standoff distance above the
material. A dial setting of 100 through the 20:1 divider will produce a
signal input of 5 VDC to the logic control board.
There are two terminals labeled 115VAC. These terminals have a

continuous supply of 115VAC to enable the logic functions of the VD
PCB. This voltage is supplied from the Koike interface PCB and is
fused at 2 amps.
The next two terminals are labeled logic + and logic -. This logic
output is activated when the material is sensed. The output activates
when the torch nozzle or tip becomes shorted to the work (material).
This is accomplished in two ways. First, a direct nozzle connection is
made from the power supply to the pilot arc terminal on the VD
PCB through a HV (high voltage) relay. The current state of the
normally open HV relay is energized, and therefore closed, making
this connection. The HV relay on the Koike interface PCB is used to
open this connection once the material has been sensed and before
the main arc has been established. This method only works when
non-shielded torch parts are used where the nozzle or tip can
directly contact the material. Secondly, when shielded torch parts
are used the sensing is done via means of an ohmic wire attached
to the shield cap on the torch. This signal is also connected to the
pilot arc terminal on the Koike interface PCB.
The Hypertherm Powermax G3 series units have the ability to use

both means of plate sensing. The Thermal Cutmaster units can only
sense via means of the ohmic wire connection due to its limitation to
shielded torch parts.
The height control only responds based upon three inputs and a
common reference to earth ground. The inputs are enable, THD
(torch height disable) and arc voltage signal level. The reference

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signal must reference the power supply work connection to the plate.
1. Enable/ Start: The enable signal is a contact closure supplied

by the Koike interface PCB once a main arc has been
established. The only time the height control becomes activated
is if the plasma cut has been initiated. The contact closure is
between pins 8 and 9 of the CNC connector. The unit sends out
24VAC, and it is returned through the contact closure, once the
main arc transfers starting the height control. There is a
potentiometer on the front of the unit which delays height control
activation after the main arc has been established. It is intended
for machines without CNC controls or machines, which are
sluggish or have response while cutting corners. The pot is
adjustable from 0-6 seconds. After a main arc transfer is
detected the timer begins and the height control is not enabled
until the timer expires. The use of this pot is not required with
the Koike MNM model due to the responsiveness of the
machine. Set to minimal value.
2. THD (freeze height): This contact closure is supplied directly
from the CNC when the machine speed has been reduced by a
percentage of the actual cut speed used to process the plate.
This contact activates during acceleration/deceleration motion
profiles when entering or exiting corners. As actual machine
speed decreases the natural process of the plasma arc will
remove more material due to increased kerf width. If the speed
slows too much a loss of material will occur causing a sudden
reduction in arc voltage. This sudden reduction results in a
quick torch adjustment downward. The purpose of the THD
contact is to only allow the height control to be activated when
at full cut speed, thus preventing the torch from diving toward
the material while cutting in corners or tight radius. The
activation of the input is indicated on the unit by illumination of
the AVC lamp. When the AVC lamp is illuminated the height
control is on and functioning. When the lamp is off the lifter is
frozen in its current position by the CNC or a main arc has not
been transferred. The THD inputs are on pins 4 and 5 of the
CNC connector.
3. Signal (arc voltage input): The signal input is taken from the
voltage divider PCB to the height control unit via a separate
control cable. This control cable must be shielded and of
conductor gauge no larger than 22 AWG. The cable must be
routed independently of other control cables, especially AC line
power supply cables. The signal cable cannot be joined with the

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CNC cable connections due to the 24VAC present for the

enable signal. The signal cable is the most important aspect of
a properly operating height control system. In the majority of
cases the signal input is the root cause of the problem. The
torch is raised or lowered based solely on this input from the
power supply.
4. Work Reference: The wire should be at minimum of 10 AWG
wire connected to the ground stud on the back of the ATC unit
to the star ground connection of the cutting table. The unit must
have a solid reference to the work piece and power supply
return in order for the arc voltage to be properly referenced.
This reference establishes the signal input to the unit. If the
reference is not solid and consistent the unit will not work
correctly.
The torch height controller simply raises or lowers the torch

positioning mechanism to a set point based upon the actual arc
voltage between the nozzle and the plate. The operator using the
thumbwheel on the front of the unit dials the set point in prior to
initiating the cut. In most cases the ability to control and maintain
proper torch to work distance is not the result of a faulty unit itself. In
most instances it is due to incorrect signal input being supplied to
the unit. Remember the unit only knows what to do based upon the
signal input it receives. It will process and adjust for bad information
just as well as good information with corresponding results. Many
things can impact the operation of the height controller and the
following trouble shooting section outlines the majority of those
issues. Also reference the ATC operator and technical reference
guide shipped with your equipment.
5.2.1.1 Trouble Shooting AVC

Problem 1: The torch to plate distance varies up and down as the
part is being processed.
Solution(s):
1. The signal input to the unit is unstable. RF noise may be

attenuating the signal. Use shielded cable. Tie external shields
to case grounds at both ends and internal shields only to earth
ground within the Koike interface box.
2. DO NOT coil the signal cable. The signal is a very low voltage

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level and drives no current. Coiling this causes inductance and

will adversely vary the signal input entering the unit.
3. DO NOT coil extra torch lead. Lay extra torch lead out flat back
and forth on the floor and place under the table.
4. DO NOT coil the work cable. This will greatly affect the arc
voltage at the torch and therefore affect the signal input to the
unit.
5. Loose connection on the PS + or PS- terminals of the VD PCB
or the signal + or signal - terminals. Ensure terminals have not
loosened from the VD PCB.
6. Phase loss on primary input power connection to power supply.
7. Poor or missing connection of the work reference connection
from the ATC unit to table star ground.
Problem 2: The height control works, but I have to increase the

AVC set point reference much higher than the manual states.
Solution(s):
1. DO NOT coil up the power supply work cable. This creates an

inductor and reduces the actual arc voltage between the nozzle
and the plate causing less output from the VD PCB therefore
commanding the torch to lower. Increasing the set point allows
it to work but with poor response. This can cause the torch to
wander or vary.
Problem 3: As soon as the arc transfers and the AVC lamp (located
on the front of the ATC) illuminates and the torch drives into the
plate.
Solution(s):
1. Arc voltage set point set too low on ATC.

2. Signal + and - reversed on the VD PCB (Located in Interface
Box)
3. Incorrect consumables or current setting for consumables used.
4. The nozzle orifice is not round (Bad Nozzle).
5. Poor work reference connection
6. Look for loose terminal connections on the VD PCB or broken
solder joints of terminals into board.
7. Check air pressure on Plasma Power Supply. Set to
parameters established in the Plasma Power Supply manual.

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Problem 4: As soon as the arc transfers and the AVC lamp

illuminates the torch goes up.
Solution(s):
1. If the enable signal to the unit is closed, and THD signal contact
is open the lifter will raise immediately. This is normal. Lack of
arc voltage or signal input to the ATC unit will cause it to rise.
Refer to the ATC operator's manual supplied with the

equipment and perform the Voltage Divider checkout
procedure.
Problem 5: The torch can't be raised or lowered from the up/down

switch on the ATC unit, but torch raises and lowers from the CNC.
Solution(s):
1. Replace 3-amp motor fuse on rear of ATC unit.
Problem 6: The power on LED on the ATC unit is not illuminated:
Solution(s):
1. Check and replace 1 amp fuse on rear of unit. Check and

replace 2-amp fuse on the Koike interface PCB located in the
interface box mounted on the main rail. Power to the ATC unit
comes from the plasma interface box.
5.2.1.2 Other Issues Which Influence Proper Arc Voltage Control

1. Plasma gas quality. If the plasma arc is varying the arc voltage
control will follow the arc. Clean, dry air is a must to maintain a
consistent arc.
2. Machine grounding. A poor connection will cause arc voltage
controller variations. Do not create grounding loop. Ground your
machine according to Koike recommendations. Ensure paint is
removed prior to connection to the cutting table.
3. Coiling of cables. Do not coil cables.
4. Bad consumables in torch. The arc voltage changes drastically
when the nozzle becomes distorted. The orifice of the nozzle
must be round for the arc voltage to remain consistent.

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5. Cutting speeds incorrect. Ensure that speed is correct for

material thickness and amperage selected. To slow or loss of
material under the torch will cause the torch to lower.
6. Leak in gas supply lines. This will usually cause the arc voltage
to wander.
5.2.2 Torch Lifter/ Linear Slide

The lifter consists of a linear slide and ball screw. The slide is
actuated by the DC brushless amplifier and motor, which mounts to
the top of the slide. A spring coupler connects the motor shaft to the
lead screw. The motor/amplifier is programmable. A program, which
resides within the motor, is initiated each time the machine is
powered on.
Upon powering the machine, the lifter is commanded upward at a

preset torque limit. Once the upper limit of the slide is reached the
motor is stopped and commanded downward a preset distance.
After this move the lifter is considered to be at absolute home
reference. The lifter has 5 inches of travel from the home position
and always knows its position from home. The motor does not
incorporate a holding brake. The screw itself serves as the brake
once power is removed, however due to reduced friction the lifter
may drift down when powered off. Always make sure the torch is
over an open area of the cutting table when the machine is powered
off.
Functionality of the lifter is based on fail-safe input/output logic

commanded by the CNC through the plasma interface box. The
motor I/O is isolated from the CNC through the plasma interface
PCB. All I/O is 5VDC sourcing and is held at a logic high level.
The following I/O is supplied to the lifter from the CNC as stated
below. Each I/O is in the off state when 5VDC is present.
1. Torch Up: Can be commanded by the CNC or ATC by

automatic function or by use of the manual raise/lower switches.
2. Torch Down: Can be commanded by the CNC or ATC by
automatic function or by use of the manual raise/lower
switches.
3. Cut: Is initiated by the CNC control through program execution
or by the manual plasma enable switch being placed in the on

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position.
4. IHS Auto/Man: The IHS switch located on the CNC control
panel selects the state of this input. If IHS is in the auto position
the lifter will retract to the full upper position of the slide between
each and every cut. When placed in the manual position the
user time for ED1 (end delay) will determine how far the lifter is
to retract in-between cuts.
The lifter itself is a preassembled unit, which should not be

disassembled. Disassembling of the slide will void all warranty. The
lifter needs to be lubricated from time to time to ensure maximum
life of the unit. This can be done without disassembly. The spring
coupling should also be checked on occasion to ensure that the
motor shaft is securely coupled to the lead screw. Slippage will
cause lifter and height control problems. The recommended
lubricant information was shipped with the documentation for your
specific equipment. The lubricant is recommended directly from the
supplier of the unit.
5.2.2.1 Lifter Check Out / Setup Procedure

The following procedure should be performed during initial setup of
the equipment, and each time the torch is removed from the torch
holder or any time the lifter is suspected of having a problem. It is
important that the initial torch to work distance be set properly.
LIFTER CHECKOUT:
1. Power-up the machine and observe the lifter homing sequence.

The lifter should move upward to the upper limit and move
down a short distance. After this move the lifter is considered to
be at absolute home reference. To test the lifter hold down and
maintain the raise or lower switch to ensure that the lifter stops
at the upper and lower limits.
2. Lower the lifter to the lower limit position. Place the IHS switch
in the auto position. The lifter should rise to the home position.
3. With the IHS switch in the auto position and the torch positioned
over an open section of the cutting table between table slats,
hold down and maintain the torch lower switch. The lifter will
traverse at high speed for approximately 3 inches then drop into
slow speed. When the lifter reaches the lower limit turn off the

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drive enable switch on the CNC and apply the E-stop to

remove power to the lifter. Note the lifter will not fall due to the
lead screw pitch.
4. Remove the torch from the torch holder.
5. Check to ensure that the spring coupler, which joins the lead
screw to the motor shaft, is secure. This is done by tightening
the two 2 mm socket head screws in located the coupler. Make
sure the coupler is centered between lead screw shaft and
motor shaft.
6. Manually rotate the spring coupler to lower the slide until it
reaches the lower limit of travel.
7. Place the torch into the torch holder. Move the torch down in the
holder until the shield cap or nozzle is level with the table slats.
It is imperative that the torch always makes contact with the
thinnest and the thickest materials being cut during the slow
portion of the lifter cycle. This slow speed portion of the lifter
cycle is required for detection of the material. Proper adjustment
of the torch position for material thickness to be processed will
insure the slow speed portion of the cycle is achieved.
Adjusting the torch to a lower position in the holder can reduce
cycle times, however the slow speed portion of the cycle must
be achieved to obtain proper ATC function. Secure the torch in
the holder.
Example: With the lifter in its lowest position and the torch
adjusted as described in step 7 the lifter will drop into slow
sensing speed and travel approximately 2.0" before a 24 gage
plate is detected. This increases cycle time between cuts. If you
set the torch 1 inch below the table surface the lifter will only
need to travel .5 inch at slow speed before detecting the
material. This will decrease cycle time by 1-second in-between
cuts. In other words by increasing the torch set height below
the table top you decrease the slow speed travel distance.
Note: Increasing the distance below the plate will reduce
the slow speed portion of the cycle. Reducing the slow
portion of the cycle too much will affect proper functioning
of the ATC. The slow speed portion of the cycle must be
achieved to obtain proper ATC function.
Important: The torch is installed at a preset distance of 7.5

inches from the top of the gear rack, on the torch body, to
the top of the torch holder. This distance always ensures

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that the torch will properly detect materials that range is

thickness from 24 gage to 5/8 inch thick A label is attached
to the torch body which identifies this distance. This
distance however does not minimize torch cycle time
between cuts. Adjust torch accordingly to minimize cycle
times.
8. Remove the E-stop to apply power to the lifter motor.

9. The lifter will rise to the upper limit of the slide. The motor will
stop when the physical mechanical limit of the slide is reached
and the preset homing torque limit of the motor is exceeded.
The lifter will then automatically lower for a short distance. The
lifter is now considered to be at absolute home position. Once
homed the lifter has five full inches of travel.
10. Position the carriage so that once lowered the torch will travel
in-between two table slats and reach the lower limit of the slide.
Place the IHS Auto/Man switch on the CNC switch control panel
into the manual position and maintain (hold down) the torch
lower switch. With the switch maintained the lifter should lower
to the lower lifter software limit and stop. If the raise switch is
maintained the lifter will go back to IHS sensing speed for the
remaining 2 inches. Once the lower limit is reached the lifter will
rapidly rise for two inches then begin to slowly lower again. This
sequence will continue until the lower switch is released. Upon
release, the lifter will return to home position.
Important: If the lower limit is reached before the torch is able

to contact the material, the lifter will reach the lower limit, retract
to the home position and the torch will fire in the air. This
condition requires lowering the torch within its holder. Follow
the Example in step 2.3.1 step 7.
5.2.2.2 Koike HS-5 Lifter Technical Information

Components/Devices: Koike H5 Lifter / Linear Slide
Programmable Motor Interface
Height Control w/ Plate Sensing Logic

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System Overview:
The complete system consists of stand-alone arc voltage controller

(AVC), a high-speed linear slide and a programmable lifter for
positioning and setting of the initial pierce height. The arc voltage
controller and the intelligent lifter are integrated to act as a complete
system although each operates independently. The intelligent lifter
provides the initial height sensing ability, referred to commonly as
IHS, while the automatic voltage controller maintains torch to work
distance during the cutting process.
CNC Functionality:
When a plasma start cycle is started, the torch first raises for the
duration of torch up timer. This time is set in a user parameter within
the CNC. This time is used to delay motion until the torch is fully
retracted. This prevents the torch from contacting any parts, which
may have tipped up, when traversing to next pierce location. This
output will only activate when a time value in seconds is present in
the primary plasma torch up time parameter field located in the
plasma setups and the IHS auto/man selection switch is placed in
the auto position. The timer value is overridden when IHS switch in
selected in the manual position.
Torch Up = typically.25-.5 seconds. Allows lifter to retract to full

upper position before traversing between parts. If the timer is not set
the torch will raise during the traverse to the next pierce location.
The timer is used to delay motion to next pierce location, until the
torch is partially or fully retracted. Not required with KAR CNC
controller.
As soon as the Torch Up timer elapses the Torch Down Timer

starts. The lifter is commanded down at a high speed (700ipm).
After a specific travel distance is reached the lifter slows to a lower
speed (30ipm) at which the initial height sensing takes place. The
torch down timer is initially set for a time, which exceeds the limits to
completely cycle the lifter for the full stroke. When TDS, Torch Down
Sense, input to CNC is activated and the Torch Down Timer has
expired the start sequence advances within the CNC. Once TDS
input to the CNC becomes activated, the downward motion stops.
TDS input is activated by shorting the torch nozzle or tip directly to
the material to be processed. When shielded consumables are

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used, where the nozzle or tip is prevented from directly contacting

the material, an ohmic wire connection must be provided and
attached to the shield cap. The torch shield is then used as the
sensing means, directly contacting the material.
Torch Down = typically 2-3 seconds
The lifter is then raised for Plasma Pierce Up Time. This timer is
user settable within the CNC and determines the height of the torch
above the material when the torch is started. Once TDS input
activates, torch down output deactivates and torch up output
activates once again for the duration of the Plasma Pierce Up
Timer.
Typically set for .08-.2 seconds. Default is .15 seconds, which

equates to approximately 1/8 inch of travel. Minimal value allowed is
.08 seconds, which prevents the torch from firing when in contact
with the material.
After the Plasma Pierce Timer expires the CNC plasma start
output is activated. This starts the actual torch. Once the main arc
transfers to the material the Cut Sense input to the CNC is activated
and motion along the programmed path is started. The Arc On
Feedback parameter must be set to on or enabled for this to take
place. If Arc On Feedback is set to off the machine motion will take
place immediately following the Pierce Time timer. Following
expiration of the user adjustable delay timer (0-6 seconds) on the
ATC height control, arc voltage control takes over and maintains
torch standoff to material based on arc voltage generated from the
electrode to the plate. See ATC instruction manual for detailed use
of ATC height controller.
5.2.2.3 Lifter Sequencing Conditions

1. If during the IHS sequencing the CNC stop key is pressed the
lifter will raise to home or position = zero based upon certain
events (top of the stroke). During a trajectory the state of torch
up, torch down, ignition (cut) and IHS select inputs to the lifter
motor are therefore continuously being monitored.
2. Once the CNC ignition output (cut on input to lifter) is activated,
and then de-activated the lifter will return to home after one
second. This one-second allows the plasma arc to fully

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extinguish before the torch is raised preventing the arc from

extending from the material.
3. When the IHS switch is in manual position it sends an input to
the motor placing the lifter in manual mode. This is a contact
closure from CNC. The contact is closed in manual mode and
the operator can manually raise and lower the torch at a preset
velocity or the height control can output to raise or lower the
torch when necessary. In manual mode the lifter will retract to
operator specific height at the end of the current cut cycle.
4. If the IHS switch is placed in the Auto (on) position the lifter will
retract to home position if the ignition output is lost. IHS
sequencing selection can only be selected when the torch is
not actually cutting. Lifter always returns to home upon selection
of the mode of operation.
5.2.2.4 Sequence of Operation Manual mode

When the IHS Auto/Man switch is placed in manual selection the
lifter operates at two defined speeds. Speed range 1 is at a slow
inching speed of 30 IPM. Speed range 2 is at the maximum lifter
speed of 700 IPM.
When the lifter manual lower switch is first activated the lifter
moves at speed range 2 for a specific distance, then switches to
speed range 1. If the raise or lower switch is released during motion
at speed range 1 or speed range 2, the motion is immediately
stopped.
When the lifter manual raise switch is first activated the lifter
moves at speed range 1 for two seconds, then switches to speed
range 2. Further upward motion is prevented when the home
position is reached.
1. Operator selects IHS in manual using selector switch.

2. Operator lowers torch to desired height above material.
3. Operator presses cycle start (on the CNC) to execute desired
program.
4. Torch lowers from current position, detects plate, retracts to
pierce height and fires. This occurs just as it does in automatic
mode.
5. After the main arc transfer occurs, motion along the
programmed path begins.

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6. The operator or the height controller if selected active, can raise

or lower the torch as required.
NOTE: If cut sense is lost, safety device tripped, or cycle stop

is activated the arc extinguishes and lifter motion freezes
unless commanded by the operator using the manual
raise/lower switch. The lifter will rise for the programmed torch
up time set prior to initiating the cut cycle.
NOTE: The lifter responds only to torch up or torch down

commands by manual raise/lower switch or up/down
commands from the height control.
NOTE: At any time if the IHS selector switch is placed in the

auto mode from the manual position, the torch will rise to the
full upper or home position. Auto mode therefore cannot be
selected during a cut, which was initially started with the IHS in
manual mode.
5.2.2.5 Sequence of Operation Auto mode

Note: IHS selection switch placed in the auto position.
1. Operator selects IHS auto mode using selector switch. Lifter

immediately moves to home position or holds if currently at
home. This occurs 1 second later if ignition/cut output is
currently on and then switched off, ensuring that the arc has
extinguished prior to raising the torch.
2. Operator initiates a cycle start command.
3. Lifter rises for torch up time or until position equals 0 (full up).
No actual lifter motion occurs since position is currently the
home position.
4. After torch up timer elapses torch lowers for the torch down
time or until TDS becomes activated.
Note: Torch initially lowers at rapid speed (speed 2) for 2/3rds of

the stroke of the lifter, and then changes to a slower speed
(speed 1) for sensing of the material.
Ohmic Contact Plate Sensing: If during the slow speed

portion of the IHS sequencing the torch nozzle or shield cap
directly contacts the material, the TDS input is immediately

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activated. The torch down output is then de-activated and the

torch up output is activated.
5. Torch up output activates for Plasma Pierce Up Time

6. Ignition on. Plasma torch started.
7. After main arc transfers and the cut sense input is activated,
motion begins along the path.
8. ATC height control amends torch standoff if auto mode is
selected. If manual mode is selected, the operator using the
manual raise/lower switch on the ATC or CNC operator panel
amends the torch height.
5.2.2.6 State of Lifter Motion Trajectory

State 1/ IHS Switch: Lifter always responds to current state of the
IHS selection switch when placed in auto mode from the manual
position and vise versa.
When the IHS selection switch is placed in the manual mode the
lifter can only be raised or lowered by use of the manual raise/lower
switches. Switch #1 is located on the CNC control panel and will only
function when the plasma torch station select switch is enabled.
Switch #2 is located on the height control console and will only
function when the auto/man switch is placed in the manual position.
If the switch is in the manual position and then switched to auto

mode position, the lifter will return to home position or top of stroke.
If the lifter is currently at home position and the mode is switched
from manual to auto, no motion will take place.
If the switch is in the auto position the lifter will be at the home
position. Switching to manual mode will enable manual motion.
If the switch is in auto position, the machine is in the cutting process

and the manual position switch is selected, the lifter will return to
home position after 1 second.
State 2/Manual Mode: Manual motion of the lifter is allowed when

the IHS selection switch is placed in the manual mode. The lifter can
be commanded to move using two defined speeds. Speed 1 is slow
inching speed (30 IPM) and speed 2 is rapid speed (700 IPM).

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When commanding manual motion using raise/lower switch the lifter

moves at speed 1. After the switch is maintained for 1 second the
speed is increased to the speed 2. Whenever the raise/lower switch
is released the lifter motion stops immediately.
When the lifter is at the home position no further motion can be

commanded of the lifter upward. Home is therefore the upper limit of
the lifter.
The lifter position relative to the home position is being constantly

monitored. The lower limit of the lifter is therefore set based upon
the overall length of the slide. The lower limit cannot be exceeded in
manual or auto modes of operation. The lower limit is set
approximately .25 inches before end of slide.
State 3/Lifter Homing:

When control power to the CNC is first applied the lifter homing
routine is immediately implemented. The lifter is commanded
upwards at a predefined torque and speed towards the linear slide
upper limit. Once the end limit (physical hard stop) is reached the
motor is reversed and commanded off the end limit 1/8 inch. This
point then becomes lifter home or absolute position 0,0. The lifter
has a 5-inch stoke from the home position.
5.3 IHS (Initial Height Sensing)
The IHS is the means for detecting when the torch nozzle or tip is in
direct contact with the process material. When the torch is fired with
the torch nozzle or tip in direct contact with the plate the
consumables are almost always destroyed. Once this occurs
problems relating to height control begin to occur and the cut quality
diminishes. All it takes is one occurrence to destroy the consumable
set.
The Koike system implements automatic ohmic contact plate

sensing to prevent this from happening. With the MNM model
machine the feature is always active. The procedure below ensures
that the system is functioning properly.
The system works by detecting a short circuit between the torch

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nozzle and the work lead of the power supply. Circuitry is then
actuated on the VD PCB and Koike plasma interface card, which
stops further motion downward and commands the CNC to advance
to the next instruction in the plasma starting sequence.
Detection occurs in two ways. First, a direct connection is utilized

from the nozzle connection, directly off the control board, within the
power supply. With this connection the use of non-shielded
consumables is allowed. This includes such consumable sets as the
new Finecut for use with the Hypertherm G3 series units. Certain
consumables sets are not offered non-shielded, where the nozzle is
exposed. With these consumables a special ohmic cap or clip is
attached to the shield cap. The clip contacts the shield used to
protect the nozzle. One end of a high voltage wire is attached to the
ohmic cap by a tab, while the other end connects the sensing input
to the voltage divider PCB. When the shield contacts the plate, the
plate is sensed in the same manner as if the nozzle directly
contacted the plate.
The IHS system and the ATC systems are completely independent
of one another. The IHS is used to sense the material and the ATC
is used to maintain a constant torch to work distance above the plate
during the cutting process.
5.3.1 IHS Checkout Procedure

1. Verify proper lifter functionality. See lifter checkout procedure.
2. Place a piece of slightly crowned 16-20-gauge material under
the torch with the crown facing upwards.
3. Place the IHS Auto/Man switch in the manual position and
lower the torch into the material. The lifter speed must
decrease before the material in encountered. If not, see section
2.3.1 step #7 of the lifter checkout procedure. Once the material
is contacted the lifter will stop and no further downward motion
can be commanded.
4. Remove the cover from the plasma interface box located on the
main rail behind the CNC. Observe the RED LED on the voltage
divider PCB. The LED should not be illuminated when the torch
is contacting the material. Raise the torch to break contact and
observe that the LED is now illuminated.
5. Repeat item #4 using both shielded and non-shielded
consumables installed within the torch. Note that Thermal

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Dynamics systems do not have the ability to sense the nozzle

directly and will always require the use of the ohmic clip and
wire to the torch body. See Plasma section for complete details
for your system.
6. Place the IHS Auto/Man switch in the auto position. Maintain the
plasma lower switch in the lower position. The torch will rapid
traverse from the home position, then drop into slow speed prior
to detecting the plate surface. Once the plate is detected the
torch will immediately retract back to the home position. The
cycle will repeat as long as the lower switch is maintained.
7. Turn the Plasma power supply off. Place material on table
under the torch. On the CNC control select setup, then
advanced setup, cutting table #6. Ensure that the torch down
(SD2) and plasma start (SD4) timers are set for at least 5
seconds. Program a small part to perform cut signal test.
Place the plasma on/off/auto switch in the lower or auto

position
Press green program start button to start the program
After torch contacts the material and retracts to the pierce
height the torch is started and the plasma start timer begins
to count down. The torch should remain at this position while
the plasma start timer counts down.
Press the torch on/off button to stop the sequence before the
timer expires. If you do not stop the start sequence before the
time expires the external stop input may activate. This
depends on if the parameter Main Arc Lost During Cut was
set to activate if the main arc is lost during a cut.
Repeat the same starting sequence except place the
on/off/auto switch in the center off position. With the cut
switch in the off position the torch will retract to the piercing
height and should then immediately retract to the home
position.
Cut sequence is fully functional.
5.3.2 Initial Height Sensing Troubleshooting Guide

Problem 1: The torch lowers to the plate, but then retracts back
towards the home position. At some point the torch fires on its way
back home.

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Solution: The torch has never actually contacted the material. The
lower limit of the slide has been reached prior to the torch contacting
the material. The torch has to be lowered within the holder or the
spring coupling joining the motor shaft to the lead screw is slipping.
Reset the torch in the holder per instruction in section 2.3.1 step #7.
Check coupling screws per instruction in section 2.3.1 step #5.
Problem 2: The torch lowers and senses the material then retracts
to piercing height. As soon as the pierce height timer expires the
torch retracts back to the home position. The torch does not fire.
Solution: The plasma on/off/auto enable switch is placed in the off

position. Place the plasma on/off/auto switch in the auto position.
Problem 3: The torch contacts the material hard and pushes the
material down.
Solution: The material can only be sensed when the motor speed is
reduced to the IHS sensing speed. The torch is contacting the
material in high speed. Re-adjust the torch in the holder. Torch is too
low for material being processed. See instruction in section 2.3.1
step #7.
Problem 4: I am using non-shielded parts in my G3 torch, but the

IHS is not working.
Solution 1: The work cable from the power supply is not connected
to the table or the plasma interface cable is not plugged into the unit.
Check these cable connections.
Solution 2: The HV (high voltage) relay has failed on the Koike

Plasma Interface PCB. Replace the PCB or relay.
Problem 5: I am using shielded consumables and the IHS is not

working, but the torch raises and lowers fine.
Solution:
1. The ohmic wire connection from the torch shield cap to the pilot
arc connection on the voltage divider PCB may be broken or
loose.
2. Remove the cover of the plasma interface box located behind
the CNC control mounted on the main rail. Confirm that the

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RED LED on the VD PCB is illuminated.

3. Locate the terminal labeled pilot arc on the voltage divider
PCB. It will have a colored wire attached to it labeled nozzle.
Using a jumper wire short this pilot arc terminal to the key
stock on the main rail or to other good ground point.
4. Observe the RED LED on the VD PCB. The LED should go out
when pilot arc terminal is shorted to power supply work
connection.
5. If LED goes out when shorted replace or correct the problem
with the ohmic wire. Check for poor connection at torch or at
terminals TB2- 20 and 21 of the Koike Plasma Interface PCB
located behind the VD PCB in the interface box.
Problem 6: The torch will not lower, but raises fine.
Solution: Check the status of the red LED on the VD PCB. If the
LED is out remove the connection from the pilot arc terminal. If the
LED illuminates then the ohmic wire is shorted to ground or the torch
shield is shorted to the nozzle. Replace the ohmic wire or
consumables.
5.4 Process Controller
The Koike KAR CNC through its user switch control panel and
sequential I/O platform is the executive control of the machine. It
executes the sequence of events once the operator commands a
program start. The I/O logic is sequential and interrupt bits can be
set to override a set output bit. An interrupt bit is used to cancel the
remaining time of a timed output. If an output bit is activated for a
specified time an input bit is therefore used to advance the
sequence by interrupting the current function.
The Koike KAR CNC process controller incorporates a user defined

graphical sequential timing chart. This allows the user to determine
exactly what will occur once the program start button is pressed
(Execution of the program). The KAR CNC utilizes the plasma
process control-timing chart. The timing chart is illustrated below.
The timing starts at SD1 once the program start button is pressed. A
SD stands for a program start delay time and an ED stands for a
program end delay time. A move delay is simply a delay in which no
output is activated. It is just a time delay before the next event is

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commanded to begin. A start move delay is generally used for the

plasma piercing time and an end move delay is used to ensure the
arc has extinguished before rapid traversing to the next piercing
location. Cutting represents when the actual cutting is taking place
and rapid is the torch off move to the next pierce point location.
5.4.1 Plasma Cutting (Tab 0)
All inputs and outputs are sinking to 24VDC supply common. This
means a 0 volts potential is present on the output pin when an
output is turned on and a 0 volt reference must be supplied on an
input pin to activate and input.
In Tab 0 (table 0) only output 7 is required. SD1 is not required and

the starting sequence begins at SD2. At the beginning of SD 2,
output 7 of the controller is turned on. This output is the Plate Down
output and remains on for the entire duration of the cut. This is
indicated by the highlighted red bar graph. All other sequencing is
set in table 1. As with the Plate Down output the Torch Down and
Hold outputs also activate at the beginning of SD2. The Torch Down

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output starts the lifter lowering cycle and the HOLD output simply
disables the height control. At the start of SD2 you will also notice
that an inbit (input) interrupt is set by the check mark in the box at
SD2. A bit number dialog box prompts you for the desired input
number and the interrupt value which is the current state of the
input. 1 represents waiting for input to be activated or 0 representing
waiting for input to be deactivated. This input 10 becomes activated
once the nozzle of the torch is shorted to the work lead and tells the
controller that the torch is in contact with the plate.
5.4.2 Plasma Cutting (Tab 1)
5.4.3 MNM Model Plasma Cutting Sequence of Operation

Program start is executed by operator
Torch lowers for SD2 (start delay #2 time) or until input 10
activates. SD2 is the torch down timer and must be set to a
minimum value of 3- 4 seconds.
Once input 10 (torch down sense) activates the torch down timer

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immediately expires and the sequence advances to SD3 (start

delay #3 timer). The torch then rises for SD3 time. SD3 time is the
pierce height up time for the pierce height and is determined by
the operator based on material thickness.
Once SD3 expires the torch is now at the pierce height, the
plasma start output 9 is activated. It activates for time SD4 or
until input 4 (main arc input) activates interrupting SD4 timer.
Input 4 is the main arc transfer input from the power supply and
indicates that the main arc has transferred to the plate.
Once input 4 activates the sequence advances to the move delay
(pierce timer). The move delay is used for the plasma pierce time
and causes the machine to hold position with arc on until the time
expires.
After the move delay expires motion along the programmed part
path begins. If input 4 is lost during the cutting process the
external stop is activated stopping the machine motion and
turning off output 9 (plasma start). This is determined by the state
of a parameter in the advanced setups.
After the cutting has finished the torch is raised for ED1 (torch
up) time. This allows the operator the ability to select how far the
torch raises after each cut. This timer only functions when the IHS
switch is placed in the manual position prior to initiating the cut
cycle. In the automatic position the lifter is retracted to the home
position in-between cut cycles.
After the torch up timer ED1 expires and the torch has retracted to
the specified height, the machine rapid traverses to the next
piercing position. The entire cycle then is repeated starting at
SD2.
Plasma Default Timing Parameters for MNM Model Machine:

The basic plasma setup parameters are displayed when the SETUP
software key on the KAR CNC is activated. In the menu the basic
parameters that are most frequently required to change are
displayed.

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5.4.4 BASIC SETUPS
Kerf Width: The width of the cutting tool. This will be the amount of
material, which is removed by the cut process. The amount must be
offset to have the part be the correct dimension once processed.
The kerf is the orifice size of the nozzle. Typically the kerf is .040 for
40 amps nozzles and .070 for standard tips. The Hypertherm
Finecut nozzles have an orifice diameter of .032.
Cutting Speed: The actual speed when processing the part

program. Rapid speed is the speed when the torch is off and cutting
speed is the speed when the arc is on. Trial speed is simply a dry
run speed without actuating any I/O.
Program Rotation: Indicates if any rotation was assigned to the

part program. Any rotation caused by the plate alignment feature will
appear in the window.
Pierce Height: This is the height to which the torch will retract after
the plate is sensed. The range is in seconds from .1 to .2 seconds,
typically .15 seconds. The lower the time the closer the torch will be
to the plate once the piercing begins. The time is SD3.

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Pierce Time: This is the time that the torch will stand still during the
plate piercing before machine motion begins. This time is the start
move delay.
5.4.5 ADVANCED SETUPS
The top of the window will display the current process, which will be
performed. This is shown as Parameters (Plasma). The Koike
MNM will only function in plasma mode. Select the Plasma software
key from the Gas /Plasma/ Plasma 2 selection window.
A bitmap of Parameter group 1 is currently displayed. The

parameters are as follows:
Kerf: Orifice diameter of nozzle or tip.
Cutting Speed: Actual cutting speed.
Creep Speed: A reduced cutting speed for the creep time value
specified in parameter group #6. After time expires machine

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proceeds at the cutting speed. Not required with MNM machine.

Make creep time minimum value of .01 seconds. Creep speed will
default to 5 IPM or minimum based on maximum machine speed.
Pierce Height: This is the distance based on time in which the torch
will retract once the material in sensed. It is SD3 in parameter group
six and is set, so it can be displayed in parameter group 2 Aux
Parameters.
Pierce Time: Hold time before motion with arc on. The value is the
start move delay set in parameter group #6 and marked for display
in parameter group 2.
Program Rotation: Displays current rotation after performing a

plate alignment function or allows operator to rotate the plate
manually. +90 will rotate the plate at 90-degree increments and zero
will return the rotation.
Mirror: Flips the part creating a mirror of the original.
Tool Location: Tool location prompts for and X and Y value. This
tool location would be in reference to a laser pointer device used for
orientation of the torch to the corner of a plate. The values are from
the laser device to the plasma torch. It wants to know the location of
the cutting tool relative to the lasers fixed position. The MNM is not
offered with a laser pointer. A battery powered laser pointers may be
used if so desired.
Gas/ Plasma/ Plasma 2: The Koike MNM only supports the plasma
mode of operation.
MTT Tables: The MTT tables allow operator to establish preset

parameters based upon the material, material thickness and the tool
used in the process. Once the tables are created the operator simply
selects the material, thickness and tool and all relevant parameters
to process the plate are automatically recalled.
To access the MTT tables and configure data the ADD/REMOVE

dialog box must first be checked. When the ADD/REMOVE window
is checked the NEW software keys are highlighted and therefore
enabled for use in data entry. When the new button is selected a
dialog box will be displayed and OTHER is displayed. When you

- 91 -
click on OTHER a command line will appear. Type is the text you
wish for the material, thickness or tool. Once the new MTT dialog
has been prepared use the dropdown arrow for the material,
thickness or tool to select and highlight you new data entry. Once
the desired material, thickness and tool are highlight enter all
relevant data required for the new MTT and SAVE the new MTT.
Once new MTT sets, other than the default set, have been created
the REMOVE button will become activated allowing user to delete
unwanted data. Once all MTT data has been created the
ADD/REMOVE window should be unchecked before the final save is
implemented. The next time the controller is restarted the system
will prompt for the password to save this data permanently. Enter the
password "rbtc" in lower case when prompted to do so.
Caution: The default MTT parameter group must remain. This

group must not be removed or the controller will not function
correctly.
It is very important to recognize that each time the material,

thickness or tool is changed the system will considered a change to
become a brand new MTT group set. Each time a new MTT group
set is created all relevant data must be updated for the new group
set. Any parameter field highlighted in red requires data input. Such
fields will be the creep time field. This includes sequence timing in
parameter group #6, all cutting and rapid speeds, kerf values, etc.
Once all data has been created for the new MTT group set the
SAVE software key must be applied. The system will prompt for the
password
Edit Delay Names: This check box allows user to edit the name of
the delay set in parameter group #6 cutting parameters.
A bitmap of parameter group #6 cutting parameters is displayed

below. The parameters are as follows:
Cutting speed: Desired cutting speed.
Rapid speed: Traverse speed between cut cycles. Usually set to

the maximum speed of the machine.
Creep speed: Reduction of actual cut speed for time allocated by

creep time. Creep speed will have a minimal allowed default value

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based on machine maximum speed.
Creep time: Time in which the reduction of cutting speed will occur
at the creep speed.
Prestop distance: This parameter is used with power supplies,

which ramp down the current at the end of a cut cycle. It allows the
plasma to shut off just prior to the program completing motion. As
the power supply ramps down the arc remains on long enough to
finish the cut. This prevents dimpling when the plasma ramps down
normally after the motion has ended. It is not usually required with
Inverter Type power supplies such as the Powermax G3 series and
Thermal Cutmaster installed on the MNM machine. The parameter
must be set in the Advanced Plasma Setups through the KAR CNC
Setup Parameters, before it will function. Typical values range from
.040 to .1 inches.
Piercing Up/Down Routine Window: The plasma pierce up and

pierce down feature is not implemented for use with the MNM model
of machine. The MNM model uses a more advanced method of
starting the torch cycle. The Start should be set for not activated.
Start: Selects at which start delay the sequence is to begin.

Piercing up: Time to raise the torch for piercing.
Stay up: Time torch remains at piercing height.
Piercing down: Time to lower to cutting height after stay up time
has expired.
5.4.6 Show Delay Names In Readjust Field

This check box simply allows the name assigned to each delay to be
displayed in the On-The-Fly parameter readjust window dialog
window when prompted.

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Sequential Event Timing: When the checkbox for a particular

delay is checked, this delay will be shown in the readjust parameter
window for changing "On-The-Fly", during the cutting process.
SD#1 (Start delay 1): Not required
SD#2 (Start delay 2): Starts torch down for SD2 time or until torch
is sensed making contact with the plate. Once plate contact is made
torch down output time immediately expires. Minimum value is 3-4
seconds.
SD#3 (Start delay 3): Raises torch for time duration to piercing
height.
SD#4 (Start delay 4): Output to start the power supply. Allows time
for plasma to fire and receive arc transfer input to begin motion. If
start timer expires before the main arc transfer is received the
external stop input will activate.
Move delay: Time to expire with arc on and before motion begins.
Used for piercing of the material.

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CUTTING: Actual cutting of the part or program nest. The height

control AVC LED indicator should be illuminated if placed in the auto
mode of operation. The up/down LED indicators should blink at
random as the torch requires amendment to the standoff between
electrode and work. The AVC LED should blink briefly as the
machine accelerates /decelerates to and from corners. At very slow
cutting speeds, where the actual machine speed remains constant
during cornering, this LED may remain illuminated. Amendment to
the standoff can be made at any time using the thumb dial on the
height control unit. Increasing the threshold voltage will increase the
standoff from the plate.
ED#1 (End delay 1): Turns on the torch up output after the cut to
raise the torch before traversing. The distance the torch raises is
determined by this time value. More time allows more distance. 2.5
seconds is the maximum value before the lifter will switch into high
speed and traverse back to full upper home position. The IHS switch
must be placed in the manual mode for this timer to be functional.
ED#2 (End delay 2): Not required.
Move delay: Not required.
5.4.7 Aux Parameters

A bitmap of parameter group #2 cutting parameters is displayed
below. The parameters are as follows:
Scale: This parameter allows the part to be scaled larger or smaller

than the size originally created. 100 percent is actual size as
created. A scale factor of 200 doubles the size. A scale factor of 50
will reduce the size by half. If a part is scaled a message window will
appear stating that the scale is not at 100 percent before running the
part.
Delay nr 1: This allows the operator to display by name one of the

most common delays, that requires frequent changing, on the basic
setup screen. This delay is set to display the pierce height time.
Delay nr 2: This allows the operator to display by name one of the

most common delays, that requires frequent changing, on the basic
setup screen. This delay is set to display the pierce time.

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Parameter group #7(Information) is simply a notepad. It allows a

place for the operator to save information he deems important to the
process.
Plate Alignment: This feature allows the operator to align parts on a

plate, which is not parallel to the main rail. It corrects for skewed
plate. See KAR CNC operation manual for detailed instructions.
General: Checking this check box allows system to correct for

kerfing error's created when program contains small arc segments.
OK: This button applies the current data to the process but does not
retain the data permanently. It is a temporary save.
SAVE: This button applies the current data to the process and
prompts for the password to permanently save this new data.
Password is lower case "rbtc".
CLOSE: Simply closes the window and makes no changes.

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5.4.8 Floating Head Setup Tables

Floating Head: Tab 0
Floating Head: Tab 1

- 97 -
Floating Head Plasma Advanced Parameters:

- 98 -
5.5 Plasma Power Supply
5.5.1 General Information

Only inverter output contact start type power supplies are equipped
on the Koike MNM plasma-cutting machine. The available power
supplies are the Hypertherm 1000, 1250 and 1650 rated at 100
amps. A one hundred amp unit is the largest available on the MNM
model. This MNM can also be equipped with the Thermal Dynamics
Cutmaster 101, which is rated up to 80 amps. The table is rated up
to 5/8-inch plate over the perimeter of bed.

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Hypertherm 1250 Cut Chart for 25-55 Amp Fine-cut nozzles:

KAR CNC parameter setup
MILD STEEL
Thickness Amps Speed Kerf Pierce T Pierce H Arc V
(Inch) (IPM) (Inch) (sec) (sec) (Volts)
.25 50 36 .032 .3 .18 85
.187 50 52 .032 .2 .17 80
.125 50 63 .032 .2 .16 75
12 Ga. 50 75 .032 .2 .15 75
14 Ga. 50 80 .032 .17 .15 75
16 Ga. 40 85 .032 .15 .15 75
24 Ga. 45 300 .032 .1 .12 75
T = Time in seconds
H = Height based on time in seconds.
ARC = Arc voltage (torch to work distance during the cutting
process)

- 100 -
Connector Review Koike KAR CNC
6 Connector Review
Main Supply Power Input: Supply power to KAR CNC

CONN J1:
1. Line 115VAC only.
2. Neutral
3. PE-Ground

- 101 -
Koike KAR CNC Connector Review
MOTOR: Motors connections using DC amplifiers will use a 4-

pin amp circular AMP connector.
AMP mating PN# 206429-1 Plug, 4 Pin, CPC
Backshell PN# 0868-8756-00
Koike PN# 0866-6068-00
CONN-J7/J8:
1. Motor
2. Motor +
3. Tach +
4. Tach

- 102 -
ENCODERS: Encoder will use a 9-pin circular amp.

AMP mating PN# 206708-1 Plug, 9 socket, CPC,
Koike PN# 9948-6720-00
CONN-H10 X/Y:
1. Enc power supply. 5 VDC using HS CMC 250 Line count
encoder.
2. Enc. Power supply common.
3. CHA-A
4. CHA-A Compliment
5. CHA-B
6. CHA-B Compliment
7. Not Used
8. Not Used
9. Enc Shield wire termination.

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J16 Limits:
Amp 211768-1
Koike PN 9948-9874-06 (9-Pin large connector)
1. Input 0 to FET card. Actual signal to indicate limit switch trip.

Fail-safe NC or activated through limit switches placed in series
circuit.
2. Jumpers to pin 3 internally.
3. Jumpers to pin 2 internally.
4. Connects to logic ground of FET card. Common reference for
limit input.
5. Not used.
6. Not used.
7. Not Used.
8. Not Used.
9. Keying pin.

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J25 I/O:
Mating Connector: AMP PN# 206305-1 Plug 37 Pin (reverse sex)

CPC
Koike PN# 0866-6339-00
1. C supply for user

2. C user supply neutral
3. PE Ground for user supply
4. THD (hold) signal. Dry contact closure from CNC.

9. THD user common.
5. Floating head lower 115VAC output

6. Neutral for floating head valve
7. PE ground for floating head valve
8. Not Used
10. C torch down output for G-lifter

11. Neutral for G-lifter

- 105 -
12. PE Ground for G-lifter

16. C torch up output for G-lifter
13. User DC Common for supply.

14. +24VDC user supply rated at 2 amps. To Interlogic VD PCB.
20. Collision detection/safety mount device sense reference (DC

Common)
21. Collision sense input.
15. Plasma enable normally open set of contacts RL5

22. Plasma enable common N.O Contact RL5
17. IHS Switch. Outputs 24VDC in manual mode. Used with

Smartmotor interface only.
18. Keying Pin

19. Keying Pin
23. +37VDC user supply rated at 3.3 amps.

24. +37VDC Common
26. Torch up sense input
28. Not Used
31. Not Used
25. Torch up sense common.

27. 24VDC spare common.
29. Plasma enable +24VDC output. Used with Smartmotor

Interface.
30. Plasma enable DC Common.
32. Arc Transfer (CSR) input. Contact closure from outside world
required.
33. Arc Transfer DC Common.
34. +24VDC user supply at 2 amps.

35. User supply common.
36. Torch Down Sense Common. (DC Common for 24VDC supply)
37. Torch down sense input to CNC. From VD PCB SEN Relay
output.
NOTE: Activates pierce height timer to raise to pierce height.

- 106 -
RS232
Keyboard
Mouse
LAN
These connectors are from left to right: RS232, Keyboard (PS2),
Mouse (PS2), LAN (RJ45)
RS232 is for DNC data transfer.

Keyboard connector is a standard PS2 connector.
Mouse connector is a standard PS2 connector.
LAN connector is a standard RJ45 connector.

- 107 -
Koike KAR CNC
holes 42
Index
-I-
-C- iLink 38
import 39
change compensation side 41
change cutting direction 42 -J-
change cutting order 42
change piercing point 41 join profiles 44
cnc2 65
copy 46 -L-
cut 46
-D- language 53
leadin 44
leadout 44
dnc 38 list windows 58
dxf 60 lock first object 42
-E- -M-
eia 51 macro 34
element 60 marking 65
ellipse 60 MicroCAD 55
exit 39 mirror 41
export 39 move one step 42
move shape 40
-F-
-N-
File menu 32
Nestinfo 57
-H- nesting 60
new plate 32
handling options 48

- 108 -
Koike KAR CNC
-O- -T-
open 32 terminology 60
options 47 toolbar 54
Overview 3 tools menu 40
transferline 60
-P- trash 34
pan view 45
-U-
part list 59
parts 42 undo 47
paste 47
plate 32 -V-
plate list 58
plate options 32
view menu 39
print 38
profile 60 -Z-
ProMotion Nest 30
-R- zoom 45
remove 41
reset view 45
rotate shape 40
ruler 46
-S-
save as 34
shape 60
show order 42
spline 60
split element 44
swap 42

- 109 -

Kar CNC

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What are the main sections covered in the manual?

What are the main sections covered in the manual?

What are some of the main buttons/controls on the operating panel?

What are some of the main buttons/controls on the operating panel?

Operation Manual

Manufactured by ProMotion Controls

Part III Setup of KAR CNC 22

1997 - 2005 Robotronic Oy

Part IV ProMotion Nest 30

1997 - 2005 Robotronic Oy

Part V Monograph Training Guide 66

1997 - 2005 Robotronic Oy

Lifter Sequencing Conditions

Part VI Connector Review 101

1997 - 2005 Robotronic Oy

ProMotion Controls Inc. warrants to the purchaser that products

Improper use, modification, mishandling, or incorrect installation by

ProMotion Controls, at its option, shall repair or replace free of

Replacement or repaired parts will be sent standard ground delivery

The applicable warranty expressed in this section constitutes the

DO NOT CONNECT the controller directly to a computer through the

1997 - 2005 Robotronic Oy

1.2 Contact Info

Koike Aronson, Inc.

780 W. Smith Rd. Unit F

Tel: +1 330 721 1464

Tel: +358 3 276 0500

1997 - 2005 Robotronic Oy

The KAR CNC controller is designed to be user friendly and simple

1997 - 2005 Robotronic Oy

2.1 Main Screen

The main screen is divided in three parts.

2.1.1 Info (System Status)

Speed IPM (or metric) indicates machine speed.

1997 - 2005 Robotronic Oy

Potentiometer. If the speed pot is turned completely 100% CW the

2.1.2 ProMotion Cut - Next Job

1997 - 2005 Robotronic Oy

Selecting the Shapes button will automatically open the Macro

1997 - 2005 Robotronic Oy

The Download button opens the Windows Open File to select a

2.1.3 Current Job

1997 - 2005 Robotronic Oy

Normally this button is grayed out. Activated when a cutting program

1997 - 2005 Robotronic Oy

Normally this button is grayed out. Activated when a current program

Normally this button is grayed out. Activated when a current program

Refresh the current job screen.

1997 - 2005 Robotronic Oy

2.2 KAR CNC Operating Control Panel

1997 - 2005 Robotronic Oy

2.2.1 Emergency Stop - Off Button

2.2.2 Input Power Switch

1997 - 2005 Robotronic Oy

The power switch is a momentary switch. Toggle the switch up and

The proper way to switch power off is using Windows

In case Windows shutdown is not available, it is possible to force

Note: After switching off the controller it is advisible to wait at least

2.2.3 Drive Enable Switch