Connectors

This is the Rev A version of the WarpRunner hardware.

The green connectors are unplug-able as a group, for each connector. Gently pull with your hand to remove the group you need, DO NOT PRY with a metal object!

 

The 26 pin Port 3 Connector to the ESS

The WarpRunner uses the Ethernet SmoothStepper's Expansion port and SOME of the pins on Port 3. While you will only plug this into the ESS, you may need to configure the Pins on Port 3 differently that what is provided in the default profile. (There are no configuration options for the 16 pin expansion port.)

Port 3 pins are assigned as follows:

  1. Port 3 Pin 1: WarpRunner RESERVED output (DON'T assign to anything)
  2. Port 3 Pin 2: J4 - M0 STEP (or other generic output)
  3. Port 3 Pin 3: J4 - M0 DIR (or other generic output)
  4. Port 3 Pin 4: J4 - M1 STEP (or other generic output)
  5. Port 3 Pin 5: J4 - M1 DIR (or other generic output)
  6. Port 3 Pin 6: J4 - M2 STEP (or other generic output)
  7. Port 3 Pin 7: J4 - M2 DIR (or other generic output)
  8. Port 3 Pin 8: J4 - M3 STEP (or other generic output)
  9. Port 3 Pin 9: J4 -M3 DIR (or other generic output)
  10. Port 3 Pin 10: Arc Okay (THC ON), REQUIRED input signal.
  11. Port 3 Pin 11: J6's generic Input #1
  12. Port 3 Pin 12: J6's generic input #2
  13. Port 3 Pin 13: WarpRunner RESERVED input for the velocity commands (DON'T assign to anything)
  14. Port 3 Pin 14: REQUIRED output for Anti Dive Mode 2 - Enable/Disable THC with M62/M63. Assign to one of the Output signals 0 through 63. You will use this output number instead of the pound sign in your GCode's "M62 P#" if you want to enable THC or "M63 P#" if you want to disable THC.
  15. Port 3 Pin 15: WarpRunner RESERVED input for the velocity commands (DON'T assign to anything)
  16. Port 3 Pin 16: XY PWM Velocity signal, a REQUIRED output for Anti Dive Mode 3 - Velocity. Assign to one of the Output signals 0 through 63.
  17. Port 3 Pin 17: Torch Relay, REQUIRED output. Assign to one of the Output signals 0 through 63. You will also need to enter this Output Number in the ESS Config -> H.C. -> Torch Relay Options. You will use this output number instead of the pound sign in your GCode's "M62 P#" if you want to turn the Torch relay ON or "M63 P#" if you want to turn the Torch relay OFF.

 

Height Control will adjust Motor 2, so use Motor 2 as your Z axis. Your Z axis MUST use Motor 2 for Height Control to work. Your X, Y and Z motors may use the designated output pins on Port 3 (as noted just above) or you may move them to Port 1 or Port 2 - any output pin is fine for any of the motor output signals. If you move your motor outputs to another port, then you may use the Port 3 Pins 2 through 9 as generic outputs.

 

Please read and following the installation and wiring photos, an incorrectly wired input can damage the WarpRunner!

 

Power 

The WarpRunner requires a 12V or 24V (10.8V minimum to 26.4V maximum)input power source on J1, a Wurth Pluggable 2-pin 5.08mm Right-Angle header (connector). This will power the WarpRunner and the ESS.

  • DO NOT apply power to the ESS's 5V J6 connector
  • DO NOT use a Break Out Board (BOB) on port 1 or port 2 to feed power back into the ESS.

J1 Power Plug, Bottom and Top Views

Plasma Manufacturer’s CNC Connection

In the last 15 years, almost 95% of all major plasma supply manufacturers have incorporated (or have an option) for a CNC connection from their machine to CNC electronics. All of the major names such as Hypertherm, Thermal Dynamics (Victor/ThermoDyne), and ESAB do.

Below are examples of some of the connectors used on major plasma brands for CNC connection to the WarpRunner. You will need to consult your own plasma cutter owner’s guide for wiring information or contact your plasma representative. Many offer a “CNC cable option” and it plugs into the back of the plasma power supply. The other end has wires that can be connected to the J7 Torch connector of the WarpRunner (next section).

 

 

 

Torch Interface - J7

J7 THC Signals, Bottom and Top Views

The 8 pin connector J7 requires the following connections with your plasma unit:

  • .Arc Okay, isolated input - this input will let the WarpRunner, ESS and Mach know when the torch arc is stable. Arc Ok or “Ok to Move” is an input to the WarpRunner. It is a closed contact that is sensed by the THC. Being non-polarized, either wire can be installed in pin 1 and pin 2.
    • Connect one arc okay wire from your plasma unit to ARC OKAY 1 (J7 Pin 1)
    • Connect the other arc okay wire from your plasma unit to ARC OKAY  2 (J7 Pin 2).

  • Tip Voltage, isolated input - this will measure the voltage of your plasma arc. It must be a divided tip voltage of:
    • 50:1
    • 40:1
    • 30:1
    • 20:1
    • 16.67:1 or
    • 15:1

    The tip voltage is only connected to the SINGLE V IN pins. Wire polarity is CRITICALLY important here! The + and - symbols my be reversed for your unit.

     

    • For a plasma unit with a POSITIVEtip voltage, like a Thermal Dynamics unit:
      • Hook the positive wire to '+' (J7 Pin 4) above SINGLE V IN.
      • Hook the negative wire to '-' (J7 Pin 3) above SINGLE V IN.

     

    • For a plasma unit with a NEGATIVEtip voltage, like a Hypertherm unit:
      • Hook the positive wire to '-' (J7 Pin 3) above SINGLE V IN. This is the opposite of the silk screen, but it is correct!
      • Hook the negative wire to '+' (J7 Pin 4) above SINGLE V IN. This is the opposite of the silk screen, but it is correct!

     

    • If your WarpRunner's tip voltage input is not connected to a driving source (J7 pins 3 and 4 are unconnected OR your Plasma unit is not powered), you will see the tip voltage slowly creep up over time.  This is normal and will go to the correct voltage as soon as a voltage is driven into the Tip Voltage input.

 

  • Technical notes for the SINGLE V IN pins:
    1. The WarpRunner will accurately measure up to approximately 8.15 V at the Single V IN terminals (a tip divider of 50 would result in about 407 V being displayed on the screen set). After the 8.15 there may be linearity issues, so we cap the displayed voltage at the 407 V and just say Over Limit on the screen set.
    2. The analog voltage circuit input has internal diodes to protect against over voltage conditions, as noted here:
    3. Input Protection: The input terminals are protected with internal diodes connected to VSP and VSN. If the input signal voltage exceeds the power-supply voltage (VSP and VSN), limit the current to less than 10 mA to protect the internal clamp diodes. This current-limiting can generally be accomplished with a series input resistor.
    4. We are supplying a VSP of 14.0 V to 18.0V and a VSN of -14.0 V to -18.0 V
    5. The input voltage pins are protected with 33 kOhms of current limiting resistance that it was eluding to, yielding a max current of 0.5 mA or 1/20 th of the rated current for the diodes. Your setup would also limit the current some more too, with the voltage divider resistors.
    6. Ideally, your supplied voltage would not exceed +/- 11.5V, but this is fairly well protected (unless very high voltages are applied to the terminals or random wires start touching the board itself).

 

  • The DIFF V IN pins are RESERVED, and you should not connect anything to them. (J7 Pin 5 and (J7 Pin 6)
  • Torch ON Relay, isolated output - the Torch ON Relay output will tell your plasma unit to turn on and off. This is a closed contact that triggers the torch to fire and is non-polarized so either wire can go into J7 Pin 7 and J7 Pin 8.:
    • Connect one torch relay lead wire your plasma unit to RELAY 1 (J7 Pin 7)
    • Connect the other torch relay wire from your plasma unit to RELAY 2 (J7 Pin 8).

 

Here is a sample guide for Hypertherm units.  Please make sure your unit uses the same cable as documented here! If using a Termal Dynamics or other positive tip voltage based units, the Single V in tip voltage will be wired differently as mentioned above.

 

 

 

Isolated General Purpose Inputs

J6 Inputs 1 and 2, Bottom and Top Views

The WarpRunner provides 2 general purpose opto-isolated inputs:

  • There are two LEDs (green and Blue) on the board to indicate when an input is active or not.
  • These inputs are well suited for home switches, limit switches or probe switch inputs, or an EStop input.
  • Each of these inputs contain at least 4.8 kOhms (in forward bias saturation) or up to 7.2 kOhms (reverse bias or non-saturated forward bias) of internal series resistance.
  • These components are only rated for a working voltage of 24V ( 26.4 V DC maximum).
    • If you try to probe directly (where the 24V signal attached to your Torch tip), the 200+ V arc will also be applied across this circuit - greatly exceeding the working and maximum voltage ratings of the components and likely destroying this input.
  • These opto-isolators will fail to activate if the input voltage is below 11V DC.
  • Input 1 will activate Port 3 Pin 11 of the ESS.
  • Input 2 will activate Port 3 Pin 12 of the ESS.

You will need to use your Vin source (12V to 24 V DC) to generate a current through the opto-isolator. The current through the opto-isolatorwill generate the input signal for the ESS. You will ALSO need to hook up the ground (GND), of your Vin supply, to complete the circuit. Without this complete return current path, there will be no current flow. Without current flow, these inputs will not activate

Here are example schematics for wiring Normally Open and Normally Closed switches into the pins of J6. These only show how to do this on pin 3 to pin 4 (Input 2), but it is identical for what you would need to do for pin 1 to pin 2 ( Input 1).

  • Single Normally Open (NO) Switch This will use positive logic (Active High) on the ESS Pins Config tab.

  • Multiple Normally Open (NO) Switches This will use positive logic (Active High) on the ESS Pins Config tab.

 

  • Single Normally Closed (NC) Switch This will use negative logic (Active Low) on the ESS Pins Config tab.

  • Multiple Normally Closed (NC) SwitchesThis will use negative logic (Active Low) on the ESS Pins Config tab.

 

 

Common Select

The 3 position jumper J10, allows you to select which voltage reference you wish to use for the two COM (commons) provided in the J4 connector.

  • You can tie all of the commons to ground at J10, at which point the ESS will need to Drive Active Highs for all of the J4 Pins.

  • You can tie all of the commons to +5 V DC at J10, at which point the ESS will need to Drive Active Lows for all of the J4 Pins.

  • You can leave J10 un-jumpered, at which point you will have erratic functionality(VERY JUMPY MOTORS) or no functionality from your J4 Pins.

The COMs are located so that each pair of axes adjoining them can share the same terminal (i.e. the two common wires will both need to go into the same COM screw terminal).

 

General Purpose Outputs

These 8, non-isolated 5V signals, come directly from port 3 of the ESS. You may use them for general purpose outputs or to hook up to 4 motor drivers (which have their own isolation) to run your system.

The 10 pin connector J4 allows for you to connect up to 4 motor drivers, or you may use these pins for generic 5V non-isolated outputs.

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