Power Supply and Remote User-Interface Communication Specification Version 2.0 Introduction This specification is version 2.

0 of a specification for the communication between the plasma power supply and the remote user interface running on the CNC platform.

Guidelines (1) The power supply software (!") and the remote user interface software (#$%) will use a &home grown' protocol. %f in the future we need additional capabilities( we can then wrap our messages in a formal networ) protocol.

(2) The power supply is always &in charge of' the serial lin)* the power supply (!") software can decide at any time to ignore input from the remote user interface (#$%) and ta)e commands from its local console instead. (+) The #$% initiates all message e,changes* the #$% sends a command or -uery message to the !" and the !" returns a response message. The #$%.s wait for a response may time out( in which case the #$% can resend the message. (/) 0ll messages are brac)eted with a start of message1end of message character pair. (2) 0ll messages( including data( are guaranteed to be shorter than a specified compile time constant. (3) 4nly 0"C%% bytes will be transmitted. Chris uses a third party library that imposes this restriction. (5) No te,t for display will be transmitted. 6rror messages and process descriptions will be enumerated in a header file shared between the !" and #$% software.

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PS Operation The !" operates in either local or remote mode. %n local mode it accepts input from the local console. %n remote mode the !" will wait for commands arriving at the serial port. %t can decide at any time to switch modes. 7hen the power supply is set up with a serial lin) to a remote CNC computer( normal operation consists of these steps* (a) awa)en in local mode8 (b) perform any local initiali9ation8 (c) switch to remote mode8 (d) process messages8 (e) on receipt of an &all done' message or loss of serial communication( perform local shut down procedures. The !" should try to respond to #$% messages in either mode. %n local mode the !" can send a &local mode' message. The #$% should wait a polite time before trying again. The !" guarantees a response time. %f the !" is going to respond to a command the first character of the response will occur within a fi,ed time of the receipt of the command.s end of message character. 0t present( the guaranteed response time is one second. The !" also guarantees that each character of a message will be sent within a specified time of the previous character. 0t present the guaranteed character rate is one per second. These two constants will be specified in the CNCserialmsg.h shared file. RUI Operation The #$% interacts with the !" parameters at three levels* "ee( "et( and "ave. "ee means that the operator can e,plore the information in the plasma database( but no changes occur at the !". 0fter the current version of the database is transferred to the #$% this e,ploration can continue off line. No action occurs at the !". "et means that the #$% re-uests that the !" change a parameter setting( so a set parameter command is transmitted to( and ac)nowledged by( the !". The !" decides when and how to ta)e physical action based on the new setting. :or e,ample( if the operator ;sets; a gas pressure the !" may ad<ust a gas valve immediately( may wait until a subse-uent load process command( or may wait for a hardware signal from the CNC controller. The resulting indeterminate latency is of no direct concern to the #$% now( but will be significant later when we try to implement non interactive operations such as the 46= <ob -ueue. "ave means that the !" should store the current settings as a customi9ed version of the currently selected process( so the formatted te,t files of the database will change. To )eep the #$% and !" synchroni9ed we will re-uire that the #$% reload the affected database from the !" after a "ave. essa!e "ormat

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>aud #ate ? 1@200 Aata bits ? B !arity ? No parity "top bit(s) ? 1 The generic message format will be* start of message character (1 byte)8 message identifier ("="CDCE0#"D%ND="CD%A ? + bytes at present)8 data (variable length)8 chec)sum (2 bytes)8 end of message character (1 byte).

=a, length of a message is defined by "="CD=0FDG6NCTE. 0ll bytes are 5 bit 0"C%%8 the most significant bit is always 9eroed. The shortest message is a message with no data( so is seven bytes long at present. The start of message and end of message characters are guaranteed not to occur in the body of the message. The chec)sum is computed by adding all the bytes in the message identifier and the data. The least significant byte of the resulting sum is transmitted as two he,adecimal characters. :or e,ample( if the chec)sum is 0,162: the two bytes transmitted will be the 0"C%% characters H2I and H:I. #eader "iles The power supply software and the remote user interface software will share three header files. The files will be in standard C format so they can be used directly by both the !"" C compiler and the #$% CJJ compiler. The file ;CNCserialmsg.h; contains the message construction parameters such as "="CD=0FDG6NCTE and "="CD"T0#TDCE0#. This file also contains an enumeration of legal messages as described under ;=essages; below. The file ;CNCdatadefs.h; contains the enumeration of plasma database parameters that need to be shared. :or e,ample( the file contains the lists of materials( thic)nesses and gasses that can be selected from the #$%. essa!e Set

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The response to any command accepted by the !" will be specific to the command. These affirmative responses are listed under the provo)ing #$% command. The !" will echo the message identifier of a command that it accepts for processing. #esponse specific data may be appended. 0ny command to the !" can elicit one of the generic error responses (e.g.( ;bad chec)sum;) shown at the end of the following list. The mnemonic names below (from file ;CNCserialmsg.h;) are entries in the enumeration !"CNCD=6""0C6. The message identifier will be the numerical value of the enumeration( e,pressed as a string of 0"C%% digits. :or e,ample( the K6#"%4N command has an ordinal value of 1 as the second command in the 9ero based list of messages. %t is transmitted as the 0"C%% string ;001;. The phrase ;blan) delimited; in the descriptions below means that individual data are separated by a single space. 0 space is the 0"C%% character with the numeric value of +2 (decimal) or 0,20 (he,adecimal). "or t$e documentation %elow CS & 2 %yte c$ec'sum and refer to C(Cserialms!.$ for t$e numeric e)ui*alent for t$e essa!e I+. ,$e num%ers used in t$e samples are accruate as of --.-/.00. Commands from #$% to !"
=essage %A Aescription Command Aata #esponse Aata "ample Command "ample #esponse =essage %A Aescription Command Aata #esponse Aata "ample Command "ample #esponse =essage %A Aescription Command Aata #esponse Aata "ample Command "ample #esponse =essage %A Aescription Command Aata #esponse Aata "ample Command "ample #esponse E6GG4 as) !" to indicate that it is responding to serial messages. (none) hardware identification string( e.g. ;EA/050; L000C"M L000EA/050C"M K6#"%4N get current !" version information. (none) (code version) (database version) blan) delimited L001C"M L0010.0 0.0C"M C6TD"T0T6 get the state of the !" (none) number representing the machine state8 see enumeration in CNCdatadefs.h L002C"M L002+C"M G0"TD6##4# get most recent error code (none) error code from Chris.s list of triaged warning1error conditions L00+C"M L00+2C"M

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=essage %A Aescription Command Aata #esponse Aata "ample Command "ample #esponse =essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata "ample Command "ample #esponse =essage %A Aescription Command Aata #esponse Aata "ample Command "ample #esponse

#6=4T6D=4A6 re-uest a change to remote mode (none) respond with actual mode achieved( see G4CD#6=4T6 enum in file CNCdatadefs.h L00/C"M L00/1C"M C6TD"TAD!#4C"( C6TDC$"TD!#4C" re-uest for up to + NstandardOcustomP processes for specified material and thic)ness. Not while cutting. C6TDC$"TD!#4C" will respond with a line feed (0,00) 4NGQ( no process data( for each standard process that has not been customi9ed. (material) (thic)ness)( blan) delimited( e.g ;+ 2+; re-uests material +( thic)ness 2+ process description(s) separated by carriage return (0,0A) and line feed (0,00) C6TD0CT%K6D!#4C re-uest for process currently active on power supply. Not while cutting. (none) process description (see process description below) if there is no active process( the #esponse Aata will have a process number of 9ero #60ADCT#1( #60ADCT#2 read counter1timer number 1 or 2 only the counter for the active torch can be read (none) si, fields of counter1timer data (see CounterDTimerDTe,t below) blan) delimited R6#4DCT#1( R6#4DCT#2 clear specified counter1timer to 9ero can only clear the counter for the active torch. (none) (none) L010C"M L010C"M G40AD"TAD!#4C( G40ADC$"TD!#4C Goad specified process. 7ill be ignored if cutting. (material) (process number) blan) delimited (process number loaded) !rocess number 9ero is reserved to indicate an error during the attempt to load the process. L0121 51C"M L01251C"M

=essage %A Aescription Command Aata #esponse Aata =essage %A Aescription

"0K6D!#4C save current settings to custom database8 ma)e this the active process (none) (procDnumber loaded) or 9ero on error C6TDC4N:%C re-uest description of current hardware configuration

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Command Aata #esponse Aata

(none) (torches installed)(TEC installed)(slave installed0

as for "6TDC4N:%C command data "ample Command L013++0C"M =essage %A Aescription "6TDC4N:%C send description of current hardware configuration to !" setup mode Configuration cannot be changed while cutting. The present EA/050 does not allow a slave configuration.

Command Aata (torches installed)(TEC installed)(slave installed) as a single three digit decimal number( i.e.( no spaces torches installed* 0?neither( 1?first( 2?second( +?both TEC installed* 0?neither( 1?first( 2?second( +?both slave installed* 0?no( 1?yes e.g.( ;110; means Torch S1 with a TEC is installed #esponse Aata (none) "ample Command L015++0C"M "ample #esponse L015C"M =essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata =essage %A Aescription C6TDT4#CE determine currently selected torch (none) (number of active torch) number* 0?neither torch( 1?first torch( 2?second torch "6TDT4#CE1( "6TDT4#CE2 select specified torch !ower supply will not allow a torch change while cutting. (none) (number of torch selected) number* 0?neither torch( 1?first torch( 2?second torch TECD=0N$0G( TECD0$T4 put TEC for current torch into manual or automatic mode 4n power up( the power supply puts the TEC into 0$T4 mode. 0fter power up( the TEC mode changes only by operator command. The TEC does not automatically return to 0$T4 mode when a cut is started. (none) TEC configuration enum from CNCdatadefs.h #esponse is either TECD=0N$0G or TECD0$T4. TECD"G67D$!( TECD"G67DA47N start slew on active TEC Eardware protection e,ists and may terminate a slew command prematurely. (none) TEC configuration enum from CNCdatadefs.h TECD"G67D"T4! stop TEC slew (none) TEC configuration enum from CNCdatadefs.h

Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata

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=essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata

TECDT4CD$! move TEC up (away from wor)piece) a fi,ed increment (none) TEC configuration enum from CNCdatadefs.h TECDT4CDA47N move TEC down (toward wor)piece) a fi,ed increment Eardware protection may void this command. (none) TEC configuration enum from CNCdatadefs.h #60AD!G0"=0D0=!" get actual arc current (none) arc current in amps arc current is 9ero when the torch is not cutting #60AD!G0"=0DK4GT" get actual arc voltage (none) arc voltage in tenths of volts arc voltage is 9ero when the torch is not cutting arc voltage is 9ero if there is no TEC installed on the active torch "6TDC$T"!66A set the #6C4==6NA6A cut speed( useful for customi9ation new recommended cut speed in inches per minute recommended cut speed in inches per minute C6TDC$T"!66A Nnew 10123100P get the #6C4==6NA6A cut speed (none) recommended cut speed in inches per minute C6TD%NG6TDC0"D n( (n?1(2(+) get type and inlet pressure of specified gas (none) (gas type) (gas pressure in psig) blan) delimited gas type is an enumeration from CNCdatadefs.h8 it could be N4DC0" gas pressure is the manifold supply pressure8 it could be 9ero C6TDC0"D:G47DFFDn( (FF?!reCut( CuT( !re"hield( "Eield)( (n?1(2) get gas flowrate of specified gas (none) gas flowrate as a percent of full( e.g. ;20; means half flow C6TDC0"DTQ!6DFFDn( (FF?!reCut( CuT( !re"hield( "Eield)( (n?1(2) get type (eg o,ygen) of specified gas (none) enumerated gas type see CNCdatadefs.h "6TDC0"D:G47DFFDn( (FF?!reCut( CuT( !re"hield( "Eield)( (n?1(2) set gas flowrate of specified gas receipt of this command will terminate any gas flow tests in progress gas flowrate as a percent of full( e.g. ;20; means half flow gas flowrate as a percent of full( e.g. ;20; means half flow

=essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata

=essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Comment Command Aata #esponse Aata

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=essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata

"6TDN4=%N0GD0=!" change arc current setpoint desired arc current setpoint actual arc current setpoint in amps "6TD N4=%N0GDK4GT" change arc voltage desired arc voltage achieved arc voltage in tenths of volts if no TEC installed( arc voltage will always be 9ero "6TDTECD!0#0=" set all TEC parameters Not while cutting. TEC parameters as blan) delimited integers pierce height factor( percent pierce delay( tenths of seconds %E" speed( 1 to 10 (arbitrary scale) %E" stall force( 1 to 10 (arbitrary scale) retract speed( 1 to 10 (arbitrary scale) retract height( thousandths of an inch no99le contact( 0?off( 1?on cut height( thousandths of an inch auto)erf( 0?off( 1?on machine accel delay( thousandths of a second (0 @000 ? 0 to @.000 seconds) TEC configuration enum from CNCdatadefs.h C6TDTECD!0#0=" get all TEC parameters (none) TEC parameters actually set( in "6TDTECD!0#0=" format a pierce height (the first parameter) of 9ero indicates that the parameter list is invalid TECD%E"DT6"TD"T0#T initiate a test of the %E" setting* TEC moves toward wor)piece until contact is sensed (none) (none) TECD%E"DT6"TD"T4! stop the test (none) (none) C0"DC$T:G47DT6"TD"T0#T initiate a test of the cutflow gasses (none) (none) C0"DC$T:G47DT6"TD "T4! stop the test (none)

#esponse Aata =essage %A Aescription Command Aata #esponse Aata

=essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata

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#esponse Aata =essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata =essage %A Command Aata #esponse Aata Aescription =essage %A Aescription

(none) C0"D!#6:G47DT6"TD"T0#T initiate a test of the preflow gasses (none) (none) C0"D!#6:G47DT6"TD "T4! stop the test (none) (none) "Q"T6=D#6"6T %f the power supply is in the "E$TA47N "T0T6 because of an error( the system will recover to a safe state. 0ppropriate error chec)ing will immediately resume. (none) 1 ? reset( 0 ? no reset allowed "6TDC4#N6#DC$##6NT 20 100U actual value set 7hile the CNCDC4#N6#DE4GA signal is asserted( the power supply switch the current setting.

Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata

=0N$0GDC4NT#4GD!$=! %f the power supply is in the %AG6( 70%TD:4#D!#4C6""( or %AG62 "T0T6 the pump can be manually turned on or off. :or safety reasons the power supply will ;unload; the active process( forcing a new process to be loaded. This is one way to ensure that a start signal will not be accepted. 7hen the pump is turned on( the /050 will activate the coolant path for e*ery torch that is installed. 1 ? on( 0 ? off 1 ? on( 0 ? off( or will return >$"Q if not in one of the states listed above C6TDC4NT#4GDK4GT0C6 #eturns the voltage from the 120v coil of the control transformer. $sed as relative measure of the incoming line voltage. (none) #eturns voltage in tenths of a volt

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=essage %A Aescription

A47NG40ADFFDA0T0>0"6( (FF ? S (=%GA "T66G)( SS ("T0%NG6"" "T66G)( 12 (0G$=%N$=)) This commands is a fancy way of stic)ing a dis)ette in the EA/050.s drive to update the cut chart files. %t lets you send a whole cut chart file in one go (3 files in all). Normally( you won.t need to worry about the internal format of those files( but here it is anyway* same +B comma delimited fields as usual each cut chart must end with a C# G: pair. each cut chart file must end with* .9. Gower case 9 to indicate end of database. 2 byte revision( ie.;>0; >.0 .c. Gower case ;c; to indicate beginning of chec)sum 2 byte chec)sum( represented as a plain decimal number. "ee Aescription above. 1 ? success( >0ADC4==0NA ? failure C6TD%4D"T0T$" Cet the status of all 12 %14 ports of the /050. 6ach port will be transmitted as a he,adecimal number. 1 indicating the bit is 4N( 0 indicating the bit is 4::. 6ach port will be comma separated. The function of each signal is listed in the file "ignalGist.,ls (none) 12 ports * ::( 62( ::( :2(V G40AD=#$D!#4C6"" Goad the most recently used process (none) process description (see process description below) !$#C6 "tart the /0 second purge cycle. !rocess must be loaded (none) 1 ? success otherwise will return >$"Q "6TD0GGDC0"D:G47" "ame as ;cv"6TDC0"D:G47DFFF;( but for all B flows at the same time. "pace delimited integers. 4rder of gas flows is* !recut1 Cut1 !reshield1 "hield1 !recut2 Cut2 !reshield2 "hield2. 1 ? success otherwise will return >0ADC4==0NA. C6TD!"D%N:4 Tust a space delimited concatenation of (in that order) ;cvC6TD"T0T6;( ;cvC6TDG0"TD6##4#;( and the ;CCutChart**mDcutChartNumber; of the last process that was run (or N$GGDC$TDCE0#T if there is none). None "ee ;Aescription; above. C6TDA0T0>0"6DCE6CW"$= "pace delimited concatenation of the chec)sums of the 3 cut chart files (mild steel standard( stainless steel standard( aluminum standard( then same order but for the custom cut charts.) The chec)sums are from 0,00000 to 0,:::::( represented as he,adecimal in 0"C%% notation.

Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata =essage %A Aescription

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Command Aata None #esponse Aata "ee ;Aescription; above. Note* The "G66! and 70W6 commands are used to implement multiple EA/050 systems to communicate on the same serial line. "G66! disables all systems and 70W6 will enable the system with matching %A to communicate on the line. Command X 70W6 (7ill be implemented for EA/050 software #evision W and 0/131+ !C> #ev C) %A 0B2 Command Aata "ystem %A( which is set by dipswitches on !C board. Aescription This command is used to wa)e a system an enable is transmitter to tal) on a multi drop line. #esponse Aata X "ystem %A "ample* L0B21C:M L0B21C:M Command X "G66! (7ill be implemented for EA/050 software #evision W and 0/131+ !C> #ev C) %A 0B3 Command Aata None Aescription Tell all systems on the line to disconnect their transmitters #esponse Aata None "ample* L0B3@:M No response Command X #ead Ais) 2 %A 203 Command Aata None Aescription X $sed in the process of upgrading the main system firmware( see section &"oftware $pgrade $sing "erial Commands' #esponse Aata None "ample* L203@>M L203@>M

Ceneric !ower "upply #esponses

=essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata =essage %A >0ADCE6CW"$= chec)sum received doesn.t match computed chec)sum (none) (none) >0ADC4==0NA un)nown or illegal command (none) (none) C$TT%NC !" is cutting and will ignore the command from #$% (none) (none) G4C0GD=4A6 !" is in local mode( will not process commands from #$% (none) (none) G4C0GDCE0NC6"

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Aescription Command Aata #esponse Aata =essage %A Aescription Command Aata #esponse Aata

!" may have changed parameters or database locally since last #$% -uery (none) (none) !"D6##4# !" has an internal software or configuration error (none) (error code) error code is from the list in CNCdatadefs.h

Software Up!rade Usin! Serial Commands To upgrade the main system firmware of the EA/050* 1. $ser inserts dis) S1 into the EA/050Is floppy dis) drive and powers up the system. 2. Goader programs e,ecutes from the floppy dis) drive. 0t this point the EA/050 can only respond to 2 serial commands. The E6GG4 command will generate a response of &upgrade' (string) and the C6TD"T0T6 command will generate a response of &upgradeDwaitDdis)D2' (see status enums). +. 6ither of these 2 responses indicates that the user should remove dis) S1 and insert dis) S2. /. 0fter the user has confirmed dis) S2 is in the dis) drive( the #60ADA%"WD2 command should be sent to the power supply. This will trigger the system to copy the source code from the floppy dis) to the hard drive. 0t this point the system will not be able to respond to serial commands( until the source code has been transferred. 2. 7hen the upgrade is complete( the C6TD"T0T6 command will generate the response &upgradeDdone' (see status enums). 3. The user should be instructed to remove all dis)s from the EA/050 and to repower the system.

Structure of

essa!e +ata

"ome of the !" responses transmit multiple parameters. The formats of the response.s data are described here. CounterDTimerDTe,t is 3 fields of decimal integers. The fields are delimited by spaces. The fields represent* 0rcDstarts8 11 0 0rcDseconds8 11 1 0rcDerrors8 11 2 TotalDstarts8 11 + TotalDseconds8 11 / TotalDerrors8 11 2 !lasmaD!rocessDTe,t is +B fields of decimal integers. 6ach field has a fi,ed length. The fields are delimited by commas. The part numbers are unsigned longs. The fields represent*

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!rocessDNum8 =aterialDType8 Thic)ness8 6lectrodeD!N8 No99leD!N8 "hieldCapD!N8 "wirl#ingD!N8 Cas1DType8 Cas2DType8 Cas+DType8 Cut1D"et8 Cut2D"et8 !recut1D"et8 !recut2D"et8 "hield1D"et8 "hield2D"et8 !reshld1D"et8 !reshld2D"et 8 0mperage8 0rcDKoltage8 Color18 #eserved( must ? 08 !ierceDEt8 CutDEt8 !ierceDAelay8 !ilotDCurrent8 6ndDCurrent8 #ampdownDCurve8 6,ponentialDramp8 CutD"peed8 #ampupD"tep8 #ampupDTime8 #ampdownD"tep8 #ampdownDTime8 TransferD#ef8 CasD#ampDdelay8 Aescription8 Custom8 1+

length ? + bytes ie. 0@@ 11 0 length ? 1 see CNCdatadefs.h enum 11 1 length ? 2 see CNCdatadefs.h enum 11 2 length ? 3 11 + length ? 3 11 / length ? 3 11 2 length ? 3 11 3 length ? 1 see CNCdatadefs.h enum 11 5 length ? 1 see CNCdatadefs.h enum 11 B length ? 1 see CNCdatadefs.h enum 11 @ length ? + 010 100U 11 10 length ? + 010 100U 11 11 length ? + 010 100U 11 12 length ? + 010 100U 11 1+ length ? + 010 100U 11 1/ length ? + 010 100U 11 12 length ? + 010 100U 11 13 length ? + 010 100U 11 15 length ? + 002 200 amps11 1B length ? / 0200 +000 tenths of volts11 1@ length ? 2 see CNCdatadefs.h enum 11 20 length ? 1 11 21 length ? + 020 +00U11 22 length ? / 0020 1000 thousandths of inches11 2+ length ? / 0000 @000 milliseconds11 2/ length ? 2 00 @@ amps11 22 length ? + 000 200 amps11 23 length ? 1 Ginear ? 0( 6,ponential ? 1 11 25 length ? 2 00 @@U drop in amps per time interval 112B length ? + 001 @@@ inches per minute11 2@ length ? 2 00 @@ amps11 +0 length ? 2 00 @@ milliseconds11 +1 length ? 2 00 @@ amps11 +2 length ? 2 00 @@ milliseconds11 ++ length ? 1 0 5 0 ? lowest 5 ? highest 11 +/ length ? + 000 @@@ milliseconds 11 +2 length ? 1 see CNCdatadefs.h enum 11 +3 length ? 1 see CNCdatadefs.h enum 11 +5

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