Esab Ultrarex UXD-P2000 Upgrade Project

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02 Jun 2020 13:21 #169801 by Esaber
This is all good. We keep the existing z axis.
So I need help with the shopping list please:
- PC and monitor => Ready.
- Mesa 7i77 => I see two versions on eusurplus site:
- MESA 7i77 Analog servo interface plus I/O daughtercard - sourcing output version
- MESA 7i77D Analog servo interface plus I/O daughtercard - Sinking output version
- THCAD => I see 3 models on eusurplus.com => THCAD-5, THCAD-10,THCAD-300.
Which one is ok for me?
From eusurplus site:
The THCAD is available in two voltage ranges, 0-10V and 0-300V. When used for plasma voltage monitoring, the 10V version requires an external high voltage resistor. The advantage of the 10V THCAD and external resistor is that the resistor can be selected to work with high-frequency start torches. The 300V version of the THCAD has all input divider resistor on board and can connect directly to the plasma voltage of touch start type torches only
- 2X small 24V relays => I will look them up but if you have a link would be great if that's not too much asking :-)
- Sensor => Any additional info? Link please
- 1 Encoder => Any additional info? Link please
- 1 Drive => Link please. I see what that is now. What are you using on your machines.
- CAT6 cable
- DVM => available

My friend will keep the max200 because he is not sure his small plasma will handle the esab machine once he starts using it. He will start with his small cutter and see if that work out well.
My friend would also like to upgrade the plasma 'head' as esab told him there are no spare parts available for this part. What do you think? Did you keep that part?

List without text:

- PC and monitor
- Mesa 7i77
- THCAD
- 2X small 24V relays
- Sensor
- Encoder
- Drive
- CAT6 cable
- DVM

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02 Jun 2020 13:50 - 02 Jun 2020 13:57 #169804 by Esaber
This is the small plasma cutter he has wired to the esab but not yet used.
Attachments:
Last edit: 02 Jun 2020 13:57 by Esaber.

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02 Jun 2020 14:32 #169807 by tommylight
7i77 without the D, and THCAD 300 for the small plasma, most probably THCAD10 for the big one, although both can be made to work with any THCAD and with only one of THCAD. Yes that does men you can have 2 plasma cutters on the same machine and switch to the one you need at any given time just by replacing the torch on the holder and starting a different config from the desktop.

www.ebay.fr/itm/OMRON-MY2NJ-5-AMP-8-PIN-...4c5db659b00a2e248e83
www.ebay.fr/itm/24v-DC-Coil-General-purp...1:g:oXkAAOSwu7hbSxS0

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02 Jun 2020 14:40 #169809 by tommylight
Encoders
www.ebay.fr/itm/Rotary-Encoder-400P-R-6m...b:g:lOQAAOSwFEhd~A5o
www.ebay.fr/itm/1x-OMRON-1000P-Increment...c:g:vc4AAOSwjIVaYutq
www.ebay.fr/itm/360-600P-R-Photoelectric...uW1F2qXINSH51TqAjhTg
Do not forget to remove the tacho from above the Z axis motor and check how the encoder can be mounted to it, so probably you would need a coupler between the motor and encoder and a mount for the encoder.

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02 Jun 2020 15:52 - 02 Jun 2020 15:56 #169814 by Esaber
Great. We are getting there. Let me update the list and see if I have all the components.

- PC and monitor => OK
- Mesa 7i77 => OK
MESA 7i77 Analog servo interface plus I/O daughtercard - sourcing output version
eusurplus.com/index.php?route=product/pr...ct_id=51&search=7i77
- THCAD => OK
THCAD+300
eusurplus.com/index.php?route=product/pr...=53&search=THCAD+300
- 2X small 24V relays
24v-DC-Coil-General-purpose-Relays-8-Pin-with-DIN-Sockets-DPDT-5A-MY2NJ
www.ebay.co.uk/itm/24v-DC-Coil-General-p...A-MY2NJ/163150100577
- Sensor: Missing
- Encoder => OK
Rotary-Encoder-400P-R-6mm-Incremental-Optical-Shaft-Working-Measurement-5-24V-S2
www.ebay.co.uk/itm/Rotary-Encoder-400P-R...-24V-S2/233439617211
- Drive: missing
- CAT6 cable => OK
- DVM = > OK

I'm still missing two items from the list, the sensor you mentioned in your initial list and the drive part.
I picked a random encoder from your list. Items are not expensive so once we get the machine running I can upgrade or replace if needed. Am I ok or do I have to mach the encoder specs with the epcs of the esab machine?
I also picked a random relay.
I understood I need a single encoder, right?
Last edit: 02 Jun 2020 15:56 by Esaber.

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02 Jun 2020 16:02 - 02 Jun 2020 16:04 #169815 by Esaber
So I'm keeping the original drive and putting the encoder on top of it. I'm still doing some reading :-)
And I don't need the sensor.
Last edit: 02 Jun 2020 16:04 by Esaber.

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02 Jun 2020 16:13 - 02 Jun 2020 16:13 #169818 by Esaber
I see in your UXD-P2500 retrofit thread that you used this config:

I used the old servo motors and drives, limit switches, E-stop loop, most of the wiring

added
a 6i25 and 7i77, new PC with monitor, power supplies, added a stepper motor and drive to one of the Z axis ( has 2 Z axis ), a Proma THC150.


Do I need one or two Mesa cards for the P-2000.
I'm adding the schematics so you see what I'm sealing with.
Last edit: 02 Jun 2020 16:13 by Esaber.

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02 Jun 2020 16:16 #169819 by Esaber
Files were sent by my friend over whatsapp so quality is not that good. I'll do a proper scan later.
There are the schematics he has of the UXD-P2000.
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02 Jun 2020 16:16 #169820 by Esaber
And this one is for the HyperTherm Max200.
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02 Jun 2020 17:12 #169825 by tommylight

Esaber wrote: So I'm keeping the original drive and putting the encoder on top of it. I'm still doing some reading :-)
And I don't need the sensor.

The drive for the Z axis will most probably have to go, that is why i said that you do need a new drive, the motor remains. Maybe it can be used but the time it takes to figure that out and to do the new wiring to and from it is much more expensive than a new drive. The one i did, i did not bother with it, way to much work, so just added a new one.
Just checked the pictures again, no need for a sensor, it already has them.
And there is no machine schematics in the attached pictures. That is the important part as without it it will be quite a challenge to help you set everything properly.
You need only one 7i77, hopefully ! :)

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