Hypertherm ArcGlide Torch Height Control Instruction Manual

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ArcGlide THC

Instruction Manual

806450 – Revision 3 – November 2010

ArcGlide

Torch Height Control

Instruction Manual

(P/N 806450)

Revision 3 – November, 2010

ArcGlide, EDGE Pro, Hypertherm, HPR and Sensor THC are trademarks of Hypertherm, Inc.

and may be registered in the United States and/or other countries

Hypertherm, Inc.

Hanover, NH USA

www.hypertherm.com

Hypertherm, Inc.

Etna Road, P.O. Box 5010 Hanover, NH 03755 USA 603-643-3441 Tel (Main Office) 603-643-5352 Fax (All Departments) info@hypertherm.com (Main Office Email)

800-643-9878 Tel (Technical Service)

technical.service@hypertherm.com (Technical Service Email) 800-737-2978 Tel (Customer Service) customer.service@hypertherm.com (Customer Service Email)

Hypertherm Automation

5 Technology Drive, Suite 300 West Lebanon, NH 03784 USA 603-298-7970 Tel 603-298-7977 Fax

Hypertherm Europe B.V.

Vaartveld 9 4704 SE Roosendaal, Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel (Marketing)

31 165 596900 Tel (Technical Service) 00 800 4973 7843 Tel (Technical Service)

Hypertherm Japan Ltd.

Level 9, Edobori Center Building 2-1-1 Edobori, Nishi-ku Osaka 550-0002 Japan 81 6 6225 1183 Tel 81 6 6225 1184 Fax

Hypertherm Plasmatechnik GmbH

Technologiepark Hanau Rodenbacher Chaussee 6 D-63457 Hanau-Wolfgang, Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax

49 6181 58 2123 (Technical Service)

Hypertherm (S) Pte Ltd.

82 Genting Lane Media Centre Annexe Block #A01-01 Singapore 349567, Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax

65 6841 2489 (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

Unit A, 5th Floor, Careri Building 432 West Huai Hai Road Shanghai, 200052 PR China 86-21 5258 3330/1 Tel 86-21 5258 3332 Fax

Hypertherm Brasil Ltda.

Avenida Doutor Renato de Andrade Maia 350 Parque Renato Maia CEP 07114-000 Guarulhos, SP Brasil 55 11 2409 2636 Tel 55 11 2408 0462 Fax

Hypertherm México, S.A. de C.V.

Avenida Toluca No. 444, Anexo 1, Colonia Olivar de los Padres Delegación Álvaro Obregón México, D.F. C.P. 01780 52 55 5681 8109 Tel 52 55 5683 2127 Fax

12/17/09

CONTENTS

Safety and Compliance ........................................................................................................................................................S-1

Product Stewardship ............................................................................................................................................................................ PS-1

Environmental Stewardship ..................................................................................................................................................................ES-1

Speciﬁcations ..........................................................................................................................................................................1-1

Introduction .................................................................................................................................................................................................1-3

Control module ................................................................................................................................................................................1-3

Lifter assembly .................................................................................................................................................................................1-3

Human machine interface (HMI) ..................................................................................................................................................1-3

Plasma interface ..............................................................................................................................................................................1-4

Industrial Ethernet switch ..............................................................................................................................................................1-4

Speciﬁcations .............................................................................................................................................................................................1-5

System ...............................................................................................................................................................................................1-5

Control module (090054) .............................................................................................................................................................1-5

Lifter assembly (090053) ..............................................................................................................................................................1-6

Optional HMI (090055) .................................................................................................................................................................1-7

Discrete plasma interface (090052) ...........................................................................................................................................1-8

Ethernet switch ................................................................................................................................................................................1-9

ArcGlide communication ......................................................................................................................................................................1-11

Hypernet communication conﬁgurations ................................................................................................................................ 1-12

Discrete communication conﬁgurations .................................................................................................................................. 1-13

Mixed communication conﬁgurations ..................................................................................................................................... 1-13

INSTALLATION .........................................................................................................................................................................2-1

Hardware setup ..........................................................................................................................................................................................2-3

Upon receipt .....................................................................................................................................................................................2-3

Claims ................................................................................................................................................................................................2-3

Installation requirements ................................................................................................................................................................2-3

Placement of system components ..............................................................................................................................................2-3

Recommended grounding and shielding practices ...........................................................................................................................2-4

Types of grounding .........................................................................................................................................................................2-4

Steps to take ....................................................................................................................................................................................2-5

RFI and EMI Grounding .................................................................................................................................................................2-9

System description for a Hypernet conﬁguration ............................................................................................................................ 2-10

System description for a discrete conﬁguration ..............................................................................................................................2-11

ArcGlide THC Instruction Manual v

TABLE OF CONTENTS

Conﬁguration examples ......................................................................................................................................................................... 2-13

Multiple ArcGlide THCs with Hypernet connection to an EDGE Pro CNC and HPR or HPRXD plasma

system .............................................................................................................................................................................................2-13

ArcGlide THC with Hypernet connection to an EDGE Pro CNC and discrete connection to an HPR

or HPRXD plasma system .........................................................................................................................................................2-14

ArcGlide THC with discrete connection to a Picopath CNC and HPR or HPRXD plasma system ....................... 2-15

ArcGlide THC with discrete connection to a generic CNC and HPR or HPRXD plasma system ..........................2-16

ArcGlide THC with discrete connection to a generic CNC and HPR400XD .............................................................. 2-17

ArcGlide plasma interface with discrete connection to an HPR or HPRXD plasma system .................................... 2-18

ArcGlide THC with discrete communication to Picopath CNC and HSD130 plasma system .................................2-19

ArcGlide THC with discrete connections to Picopath CNC and MAX200, HT2000, or HT2000LHF

plasma system ...............................................................................................................................................................................2-20

ArcGlide plasma interface with discrete connection to MAX200, HT2000, or HT2000LHF

plasma system ...............................................................................................................................................................................2-21

ArcGlide plasma interface connection to Powermax G3 series plasma system ........................................................... 2-22

ArcGlide CNC interface with discrete connection to a Picopath CNC .......................................................................... 2-23

ArcGlide plasma interface discrete connection to any plasma system ...........................................................................2-24

Install the lifter ..........................................................................................................................................................................................2-25

Connect the Ohmic wire to HPR XD plasma systems ........................................................................................................2-27

Connect the Ohmic wire to other plasma systems .............................................................................................................. 2-28

Ground the lifter ............................................................................................................................................................................2-29

Install the control module ......................................................................................................................................................................2-30

Ground the control module .......................................................................................................................................................2-31

Install the optional HMI ..........................................................................................................................................................................2-32

Ground the HMI ............................................................................................................................................................................ 2-33

Connect Hypernet cables ..................................................................................................................................................................... 2-34

Connect discrete cables ....................................................................................................................................................................... 2-36

Cables ....................................................................................................................................................................................................... 2-38

Lifter interface cable ...................................................................................................................................................................2-38

Hypernet and HMI interface cable ............................................................................................................................................2-39

Operator console I/O cable .......................................................................................................................................................2-40

ArcGlide motor control CNC interlock kit (228594) ........................................................................................................... 2-41

CNC I/O cable .............................................................................................................................................................................. 2-42

Plasma interface I/O cable ......................................................................................................................................................... 2-44

Non-serial plasma interface cable ............................................................................................................................................2-46

Serial plasma interface cable .....................................................................................................................................................2-48

vi ArcGlide THC Instruction Manual

TABLE OF CONTENTS

ArcGlide discrete interface signal examples .................................................................................................................................... 2-49

Inputs ...............................................................................................................................................................................................2-49

Outputs ........................................................................................................................................................................................... 2-50

CNC discrete I/O .........................................................................................................................................................................2-51

Plasma discrete I/O ..................................................................................................................................................................... 2-53

Optional operator console discrete I/O .................................................................................................................................. 2-55

ArcGlide software setup ....................................................................................................................................................................... 2-56

ArcGlide axes ................................................................................................................................................................................2-57

ArcGlide THC ports .....................................................................................................................................................................2-58

ArcGlide setup parameters ........................................................................................................................................................ 2-59

Operation ..................................................................................................................................................................................3-1

Operator controls .......................................................................................................................................................................................3-2

Control module ................................................................................................................................................................................3-2

Lifter ....................................................................................................................................................................................................3-3

HMI .....................................................................................................................................................................................................3-4

Daily operations ..........................................................................................................................................................................................3-5

Startup procedure ...........................................................................................................................................................................3-5

Shutdown procedure ......................................................................................................................................................................3-5

ArcGlide THC operating modes ............................................................................................................................................................3-6

Manual mode...............................................................................................................................................................................................3-6

Automatic modes .......................................................................................................................................................................................3-6

Arc voltage control (AVC) disabled ............................................................................................................................................3-7

Set arc voltage mode .....................................................................................................................................................................3-7

Sampled arc voltage mode ...........................................................................................................................................................3-7

Operating the HMI .....................................................................................................................................................................................3-9

HMI screen hierarchy ...................................................................................................................................................................3-10

Main parameters ...........................................................................................................................................................................3-11

Setup parameters ......................................................................................................................................................................... 3-12

Diagnostics screen ......................................................................................................................................................................3-14

Installation screen .........................................................................................................................................................................3-20

Manual Mode ................................................................................................................................................................................3-22

Lifter Disabled Mode .................................................................................................................................................................. 3-23

ArcGlide operating parameters ........................................................................................................................................................... 3-24

ArcGlide THC Instruction Manual vii

TABLE OF CONTENTS

Maintenance .............................................................................................................................................................................4-1

Lifter routine maintenance ........................................................................................................................................................................4-3

Carriage .............................................................................................................................................................................................4-3

Sealing strip ......................................................................................................................................................................................4-4

Cable connections ..........................................................................................................................................................................4-5

System grounding ...........................................................................................................................................................................4-5

Flow of ArcGlide operations ...................................................................................................................................................................4-6

Common cutting faults ..........................................................................................................................................................................4-10

How to optimize cut quality .................................................................................................................................................................. 4-11

Plasma set-up tips ...................................................................................................................................................................... 4-11

Maximize the life of consumable parts ..................................................................................................................................... 4-11

Additional factors of cut quality .................................................................................................................................................4-12

Additional improvements ........................................................................................................................................................... 4-13

Update ArcGlide software ....................................................................................................................................................................4-14

Download through Phoenix software ....................................................................................................................................... 4-14

Download from a laptop ..............................................................................................................................................................4-14

Operator tests..........................................................................................................................................................................................4-15

Problems and solutions .........................................................................................................................................................................4-16

Troubleshooting routines ......................................................................................................................................................................4-19

Edge Pro will not communicate with HPR power supply ...................................................................................................4-19

Error message troubleshooting ...........................................................................................................................................................4-20

Printed circuit board (PCB) block diagrams ....................................................................................................................................4-41

ArcGlide PCBs ........................................................................................................................................................................................4-43

HMI processor (228581) ........................................................................................................................................................... 4-43

HMI 7-segment display interface (228582) ..........................................................................................................................4-45

THC controller interface (228577) ..........................................................................................................................................4-46

THC processor (228578) ..........................................................................................................................................................4-51

Discrete plasma interface (228576) ........................................................................................................................................4-55

Hypernet plasma interface (141161) ...................................................................................................................................... 4-59

Lifter interface (228580) ............................................................................................................................................................ 4-61

PARTS LIST...............................................................................................................................................................................5-1

Lifter parts ....................................................................................................................................................................................................5-2

THC controller parts..................................................................................................................................................................................5-4

HMI parts .....................................................................................................................................................................................................5-5

Plasma interface PCB ...............................................................................................................................................................................5-6

Wiring Diagrams .....................................................................................................................................................................6-1

Wiring diagram symbols ...........................................................................................................................................................................6-1

viii ArcGlide THC Instruction Manual

SAFETY

RECOGNIZE SAFETY INFORMATION

The symbols shown in this section are used to identify potential hazards. When you see a safety symbol in this manual or on your machine, understand the potential for personal injury, and follow the related instructions to avoid the hazard.

FOLLOW SAFETY INSTRUCTIONS

Read carefully all safety messages in this manual and safety labels on your machine.

• Keep the safety labels on your machine in good condition. Replace

missing or damaged labels immediately.

• Learn how to operate the machine and how to use thecontrols

properly. Do not let anyone operate it without instruction.

• Keep your machine in proper working condition. Unauthorized

modifications to the machine may affect safety and machine service life.

A PLASMA ARC CAN DAMAGE FROZEN PIPES

Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch.

DANGER WARNING CAUTION

Hypertherm uses American National Standards Institute guidelines

for safety signal words and symbols. A signal word DANGER or WARNING is used with a safety symbol. DANGER identifies the most serious hazards.

• DANGER and WARNING safety labels are located on your machine

near specific hazards.

• DANGER safety messages precede related instructions in the

manual that will result in serious injury or death if not followed correctly.

• WARNING safety messages precede related instructions in this

manual that may result in injury ordeath if not followed correctly.

• CAUTION safety messages precede related instructions in this

manual that may result in minorinjury or damage to equipment if not followedcorrectly.

STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS

Use proper precautions when handling printed circuit boards:

• Store PC boards in anti-static containers.

• Wear a grounded wrist strap when handling PCboards.

GROUNDING SAFETY

Work cable Attach the work cable securely to the workpiece or the

work table with good metal-to-metal contact. Do not connect it to the piece that will fall away when the cut is complete.

Work table Connect the work table to an earth ground, in accordance with appropriate national and local electrical codes.

Input power

• Be sure to connect the power cord ground wire to the ground in the

disconnect box.

• If installation of the plasma system involves connecting the power

cord to the power supply, be sure to connect the power cord ground wire properly.

• Place the power cord’s ground wire on the stud first, then place any

other ground wires on top of the power cord ground. Fasten the retaining nut tightly.

• Tighten all electrical connections to avoid excessive heating.

S-1 Hypertherm Safety and Compliance

English

ELECTRICAL HAZARDS

• Only trained and authorized personnel may open this equipment.

• If the equipment is permanently connected, turn it off, and lock out/

tag out power before the enclosure is opened.

• If power is supplied to the equipment with a cord, unplug the unit

before the enclosure is opened.

• Lockable disconnects or lockable plug covers must be provided by

others.

• Wait 5 minutes after removal of power before entering the enclosure

to allow stored energy to discharge.

ELECTRIC SHOCK CAN KILL

SAFETY

• If the equipment must have power when the enclosure is open

for servicing, arc flash explosion hazards may exist. Follow ALL local requirements (NFPA 70E in the USA) for safe work practices and for Personal Protective Equipment when servicing energized equipment.

• The enclosure shall be closed and the proper earth ground

continuity to the enclosure verified prior to operating the equipment after moving, opening, or servicing.

• Always follow these instructions for disconnecting power before

inspecting or changing torch consumable parts.

Touching live electrical parts can cause a fatal shock or severe burn.

• Operating the plasma system completes an electrical circuit

between the torch and the workpiece. The workpiece and anything touching the workpiece are part of the electrical circuit.

• Never touch the torch body, workpiece or the waterin awater table

when the plasma system isoperating.

Electric shock prevention

All Hypertherm plasma systems use high voltage in the cutting process (200 to 400 VDC are common). Take the following precautions when operating this system:

• Wear insulated gloves and boots, and keep your body and clothing

dry.

• Do not stand, sit or lie on – or touch – any wet surface when using

the plasma system.

• Insulate yourself from work and ground using dry insulating mats or

covers big enough to prevent any physical contact with the work or ground. If you must work in or near a damp area, use extreme caution.

• Provide a disconnect switch close to the power supply with properly

sized fuses. This switch allows the operator to turn off the power supply quickly in anemergency situation.

• When using a water table, be sure that it is correctly connected to

earth ground.

• Install and ground this equipment according to the instruction

manual and in accordance with national and local codes.

• Inspect the input power cord frequently for damage or cracking

of the cover. Replace a damaged power cord immediately. Bare wiring can kill.

• Inspect and replace any worn or damaged torch leads.

• Do not pick up the workpiece, including the waste cutoff, while you

cut. Leave the workpiece in place or on the workbench with the work cable attached during the cutting process.

• Before checking, cleaning or changing torch parts, disconnect the

main power or unplug the power supply.

• Never bypass or shortcut the safety interlocks.

• Before removing any power supply or system enclosure

cover, disconnect electrical input power. Wait 5 minutes after disconnecting the main power toallow capacitors to discharge.

• Never operate the plasma system unless the power supply covers

are in place. Exposed power supply connections present a severe electrical hazard.

• When making input connections, attach proper grounding conductor

first.

• Each Hypertherm plasma system is designed to be used only with

specific Hypertherm torches. Do not substitute other torches which could overheat and present a safety hazard.

Hypertherm Safety and Compliance S-2

English

SAFETY

CUTTING CAN CAUSE FIRE OR EXPLOSION

Fire prevention

• Be sure the area is safe before doing any cutting. Keep a fire

extinguisher nearby.

• Remove all flammables within 35 feet (10 m) of the cutting area.

• Quench hot metal or allow it to cool before handling or before letting

it touch combustible materials.

• Never cut containers with potentially flammable materials inside –

they must be emptied and properlycleaned first.

• Ventilate potentially flammable atmospheres beforecutting.

• When cutting with oxygen as the plasma gas, an exhaust ventilation

system is required.

Explosion prevention

• Do not use the plasma system if explosive dust or vapors may be

present.

• Do not cut pressurized cylinders, pipes, or any closedcontainer.

• Do not cut containers that have held combustible materials.

WARNING

Explosion Hazard

Argon-Hydrogen and Methane

Hydrogen and methane are flammable gases that present an explosion

hazard. Keep flames away from cylinders and hoses that contain methane or hydrogen mixtures. Keep flames and sparks away from the

torch when using methane or argon-hydrogen plasma.

WARNING

Explosion Hazard

Underwater Cutting with Fuel Gases

• Do not cut under water with fuel gases containing hydrogen.

• Cutting under water with fuel gases containing hydrogen can result

in an explosive condition that can detonate during plasma cutting operations.

WARNING

Hydrogen Detonation with

Aluminum Cutting

• Do not cut aluminum underwater or with water touching the

underside of the aluminum.

• Cutting aluminum underwater or with the water touching the

underside of the aluminum can result in an explosive condition that can detonate during plasma cutting operations.

COMPRESSED GAS EQUIPMENT SAFETY

• Never lubricate cylinder valves or regulators with oil orgrease.

• Use only correct gas cylinders, regulators, hoses and fittings

designed for the specific application.

• Maintain all compressed gas equipment and associated parts in

good condition.

• Label and color-code all gas hoses to identify the type of gas in

each hose. Consult applicable national and local codes.

Gas cylinders contain gas under high pressure. Ifdamaged, a cylinder can explode.

• Handle and use compressed gas cylinders in accordance with

applicable national and local codes.

• Never use a cylinder that is not upright and secured inplace.

• Keep the protective cap in place over valve except when the cylinder

is in use or connected for use.

• Never allow electrical contact between the plasma arc and a

cylinder.

• Never expose cylinders to excessive heat, sparks, slag or open

flame.

• Never use a hammer, wrench or other tool to open a stuck cylinder

valve.

GAS CYLINDERS CAN EXPLODE IF DAMAGED

S-3 Hypertherm Safety and Compliance

English

TOXIC FUMES CAN CAUSE INJURY OR DEATH

SAFETY

The plasma arc by itself is the heat source used for cutting. Accordingly, although the plasma arc has not been identified as a source of toxic fumes, the material being cut can be a source of toxic fumes or gases that deplete oxygen.

Fumes produced vary depending on the metal that is cut. Metals that may release toxic fumes include, but arenot limited to, stainless steel, carbon steel, zinc (galvanized), and copper.

In some cases, the metal may be coated with a substance that could release toxic fumes. Toxic coatingsinclude, but are not limited to, lead (in some paints), cadmium (insome paints and fillers), and beryllium.

Gases produced by plasma cutting vary based on the material to be cut and the method of cutting, but may include ozone, oxides of nitrogen, hexavalent chromium, hydrogen, and other substances if such are contained inor released by the material being cut.

Caution should be taken to minimize exposure to fumes produced by any industrial process. Depending upon the chemical composition and concentration of the fumes (as well as other factors, such as ventilation), there may be a risk of physical illness, such as birth defects or cancer.

It is the responsibility of the equipment and site owner totest the air quality in the area where the equipment is used and to ensure that the air quality in the workplace meets all local and national standards andregulations.

The air quality level in any relevant workplace depends on site-specific variables such as:

• Table design (wet, dry, underwater).

• Material composition, surface finish, and composition of coatings.

• Volume of material removed.

• Duration of cutting or gouging.

• Size, air volume, ventilation and filtration of the workarea.

• Personal protective equipment.

• Number of welding and cutting systems in operation.

• Other site processes that may produce fumes.

If the workplace must conform to national or local regulations, only monitoring or testing done at the site can determine whether the site is above or below allowable levels.

To reduce the risk of exposure to fumes:

• Remove all coatings and solvents from the metal before cutting.

• Use local exhaust ventilation to remove fumes from theair.

• Do not inhale fumes. Wear an air-supplied respirator when cutting

any metal coated with, containing, or suspected to contain toxic elements.

• Assure that those using welding or cutting equipment, as well as air-

supplied respiration devices, are qualified and trained in the proper use of such equipment.

• Never cut containers with potentially toxic materials inside. Empty

and properly clean the container first.

• Monitor or test the air quality at the site as needed.

• Consult with a local expert to implement a site plan toensure safe

air quality.

A PLASMA ARC CAN CAUSE INJURY AND BURNS

Instant-on torches

Plasma arc comes on immediately when the torch switch is activated.

The plasma arc will cut quickly through gloves andskin.

• Keep away from the torch tip.

Hypertherm Safety and Compliance S-4

• Do not hold metal near the cutting path.

• Never point the torch toward yourself or others.

English

SAFETY

ARC RAYS CAN BURN EYES AND SKIN

Eye protection Plasma arc rays produce intense visible and invisible (ultraviolet and infrared) rays that can burneyes and skin.

• Use eye protection in accordance with applicable national and local codes.

• Wear eye protection (safety glasses or goggles with side shields, and a welding helmet) with appropriate lensshading to protect your eyes from the arc’s ultraviolet and infrared rays.

Skin protection Wear protective clothing to protect against burns caused by ultraviolet light, sparks, and hotmetal.

• Gauntlet gloves, safety shoes and hat.

• Flame-retardant clothing to cover all exposed areas.

• Cuff less trousers to prevent entry of sparks and slag.

• Remove any combustibles, such as a butane lighter or matches, from your pockets before cutting.

Cutting area Prepare the cutting area to reduce reflection and transmission of ultraviolet light:

• Paint walls and other surfaces with dark colors to reduce reflection.

• Use protective screens or barriers to protect others from flash and glare.

• Warn others not to watch the arc. Use placards orsigns.

Minimum protective

Arc current

(amps)

Less than 40 A 5 5 8 9

41 to 60 A 6 6 8 9 61 to 80 A 8 8 8 9

81 to 125 A 8 9 8 9 126 to 150 A 8 9 8 10 151 to 175 A 8 9 8 11 176 to 250 A 8 9 8 12 251 to 300 A 8 9 8 13 301 to 400 A 9 12 9 13 401 to 800 A 10 14 10 N/A

shade number

(ANSIZ49.1:2005)

Suggested shade

number for comfort

(ANSI Z49.1:2005)

OSHA 29CFR

1910.133(a)(5)

PACEMAKER AND HEARINGAID OPERATION

Pacemaker and hearing aid operation can be affected by magnetic fields from high currents.

Pacemaker and hearing aid wearers should consult a doctor before going near any plasma arc cutting and gouging operations.

To reduce magnetic field hazards:

• Keep both the work cable and the torch lead to one side, away from

your body.

• Route the torch leads as close as possible to the workcable.

• Do not wrap or drape the torch lead or work cable around your

body.

• Keep as far away from the power supply as possible.

Europe

EN 169:2002

S-5 Hypertherm Safety and Compliance

English

NOISE CAN DAMAGE HEARING

SAFETY

Cutting with a plasma arc can exceed acceptable noise levels as defined by local codes in many applications. Prolonged exposure to excessive noise can damage hearing. Always wear proper ear protection when cutting or gouging, unless sound pressure level measurements taken at the installed site have verified personal hearing protection is not necessary per relevant international, regional, and local codes.

Significant noise reduction can be obtained by adding simple engineering controls to cutting tables such as barriers or curtains positioned between the plasma arc and the workstation; and/or locating the workstation away from the plasma arc. Implement

DRY DUST COLLECTION INFORMATION

At some sites, dry dust can represent a potential explosion hazard.

The U.S. National Fire Protection Association’s 2007 edition of NFPA

standard 68, “Explosion Protection by Deflagration Venting,” provides requirements for the design, location, installation, maintenance, and use of devices and systems to vent combustion gases and pressures after any deflagration event. Consult with the manufacturer or installer of any dry dust collection system for applicable requirements before you install a new dry dust collection system or make significant changes in the process or materials used with an existing dry dust collection system.

Consult your local “Authority Having Jurisdiction” (AHJ) to determine whether any edition of NFPA 68 has been “adopted by reference” in your local building codes.

Refer to NFPA68 for definitions and explanations of regulatory terms

such as deflagration, AHJ, adopted by reference, the Kst value,

deflagration index, and other terms.

administrative controls in the workplace to restrict access, limit operator exposure time, screen off noisy working areas and/or take measures to reduce reverberation in working areas by putting up noise absorbers.

Use ear protectors if the noise is disruptive or if there is a risk of hearing damage after all other engineering and administrative controls have been implemented. If hearing protection is required, wear only approved personal protective devices such as ear muffs or ear plugs with a noise reduction rating appropriate for the situation. Warn others in the area of possible noise hazards. In addition, ear protection can prevent hot splatter from entering the ear.

Note 1 – Hypertherm’s interpretation of these new requirements is

that unless a site-specific evaluation has been completed to determine that all dust generated is not combustible, the 2007 edition of NFPA 68 requires the use of explosion vents designed to the worst-case

Kst value (see annex F) that could be generated from dust so that

the explosion vent size and type can be designed. NFPA 68 does not specifically identify plasma cutting or other thermal cutting processes as requiring deflagration venting systems, but it does apply these new requirements to all dry dust collection systems.

Note 2 – Users of Hypertherm manuals should consult and comply

with all applicable federal, state, and local laws and regulations. Hypertherm does not, by the publication of any Hypertherm manual, intend to urge action that is not in compliance with all applicable regulations and standards, and this manual may never be construed as doing so.

Hypertherm Safety and Compliance S-6

English

SAFETY

LASER RADIATION

Exposure to the laser output can result in serious eye injury. Avoid direct eye exposure.

For your convenience and safety, on Hypertherm products that use a laser, one of the following laser radiation labels has been applied on the product near where the laser beam exits the enclosure. The maximum output (mV), wavelength emitted (nM) and, if appropriate, the pulse duration is also provided.

Additional laser safety instructions:

• Consult with an expert on local laser regulations. Laser safety

training may be required.

• Do not allow untrained persons to operate the laser. Lasers can be

dangerous in the hands of untrained users.

• Do not look into the laser aperture or beam at any time.

• Position the laser as instructed to avoid unintentional eye contact.

• Do not use the laser on reflective workpieces.

• Do not use optical tools to view or reflect the laser beam.

• Do not disassemble or remove the laser or aperture cover.

• Modifying the laser or product in any way can increase the risk of

laser radiation.

• Use of adjustments or performance of procedures other than those

specified in this manual may result in hazardous laser radiation exposure.

• Do not operate in explosive atmospheres, such as in the presence of

flammable liquids, gases, or dust.

• Use only laser parts and accessories that are recommended or

provided by the manufacturer for your model.

• Repairs and servicing MUST be performed by qualified personnel.

• Do not remove or deface the laser safety label.

ADDITIONAL SAFETY INFORMATION

1. ANSI Standard Z49.1, Safety in Welding and Cutting, American

Welding Society, 550 LeJeune Road P.O. Box 351020, Miami, FL 33135

2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and Welding Processes, American National Standards Institute 1430 Broadway, New York, NY 10018

3. ANSI Standard Z87.1, Safe Practices for Occupation and Educational Eye and Face Protection, American National Standards Institute, 1430 Broadway, New York, NY 10018

4. AWS F4.1, Recommended Safe Practices for the Preparation for

Welding and Cutting of Containers and Piping That Have Held Hazardous Substances, American Welding Society

550 LeJeune Road, P.O. Box 351040, Miami, FL 33135

5. AWS F5.2, Recommended Safe Practices for Plasma Arc Cutting, American Welding Society 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135

6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in Cylinders, Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202

7. CSA Standard W117.2, Code for Safety in Welding and Cutting, Canadian Standards Association Standard Sales 178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada

8. NFPA Standard 51B, Cutting and Welding Processes, National Fire Protection Association 470 Atlantic Avenue, Boston, MA 02210

9. NFPA Standard 70–1978, National Electrical Code, National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210

10. OSHA, Safety and Health Standards, 29FR 1910

U.S. Government Printing Office, Washington, D.C. 20402

11. AWS Safety and Health Fact Sheets, American Welding Society 550

LeJeune Road, P.O. Box 351040, Miami, FL 33135 www.aws.org/technical/facts/

12. ASTM, D 4185-96(2001) E1, Practice for Measurement of

Metals in Workplace Atmosphere by Flame Atomic Absorption Spectrophotometry, ASTM International, 100 Barr Harbor Drive, West

Conshohocken, Pennsylvania 19428 http://www.astm.org/

13. AS/NZS 3760:2003, In-service safety inspection and testing of electrical equipment. Standards Australia, Level 10, The Exchange Centre, 20 Bridge Street, Sydney, GPO Box 476, Sydney NSW 2001 http://www.standards.org.au

14. NFPA 68, Standard on Explosion Protection by Deflagration Venting, National Fire Protection Association (NFPA), 1 Batterymarch Park Quincy, Massachusetts 02169-7471 http://www.nfpa.org

15. CEN publication, EN 169:2002 Personal eye-protection - Filters for

welding and related techniques - Transmittance requirements and recommended use. The European Committee for Standardization

(CEN), CEN-CENELEC Management Centre, Avenue Marnix 17, B-1000 Brussels http://www.cen.eu

S-7 Hypertherm Safety and Compliance

English

Hypertherm Safety and Compliance S-8

English

PRODUCT STEWARDSHIP

Introduction

Hypertherm maintains a global Regulatory Management System to ensure that products comply with regulatory and environmental requirements.

National and local safety regulations

National and Local safety regulations shall take precedence over any instructions provided with the product. The product shall be imported, installed, operated and disposed of in accordance with national and local regulations applicable to the installed site.

Certification test marks

Certified products are identified by one or more certification test marks from accredited testing laboratories. The certification test marks are located on or near the data plate.

Each certification test mark means that the product and its safetycritical components conform to the relevant national safety standards as reviewed and determined by that testing laboratory. Hypertherm places a certification test mark on its products only after that product is manufactured with safety-critical components that have been authorized by the accredited testing laboratory.

Once the product has left the Hypertherm factory, the certification test marks are invalidated if any of the following occurs:

• The product is modified in a manner that creates a hazard or non-

conformance with the applicable standards.

• Safety-critical components are replaced with unauthorized spare

parts.

• Any unauthorized assembly, or accessory that uses or generates a

hazardous voltage is added.

• There is any tampering with a safety circuit or other feature that is

designed into the product as part of the certification, or otherwise.

CE marking constitutes a manufacturer’s declaration of conformity to

applicable European directives and standards. Only those versions of Hypertherm products with a CE Marking located on or near the data plate have been tested for compliance with the European Low Voltage Directive and the European EMC Directive. EMC filters needed to comply with the European EMC Directive are incorporated within versions of the power supply with a CE Marking.

Certificates of compliance for Hypertherm products are available from the Downloads Library on the Hypertherm web site at https://www.hypertherm.com.

Differences in national standards

Nations may apply different performance, safety or other standards. National differences in standards include, but are not limited to:

• Voltages

• Plug and cord ratings

• Language requirements

• Electromagnetic compatibility requirements

These differences in national or other standards may make it impossible or impractical for all certification test marks to be placed on the same version of a product. For example, the CSA versions

of Hypertherm’s products do not comply with European EMC

requirements, and therefore do not have a CE marking on the data plate.

Countries that require CE marking or have compulsory EMC regulations must use CE versions of Hypertherm products with the CE marking on the data plate. These include, but are not limited to:

• Australia

• New Zealand

• Countries in the European Union

• Russia

It is important that the product and its certification test mark be suitable for the end-use installation site. When Hypertherm products are shipped to one country for export to another country; the product must be configured and certified properly for the end-use site.

Safe installation and use of shape cutting equipment

IEC 60974-9, titled Arc Welding Equipment – Installation and

use, provides guidance in the safe installation and use of shape cutting equipment and the safe performance of cutting operations. The requirements of national and local regulations shall be taken into consideration during installation, including, but not limited to, grounding or protective earth connections, fuses, supply disconnecting device, and type of supply circuit. Read these instructions before installing the equipment. The first and most important step is the safety assessment of the installation.

The safety assessment must be performed by an expert, and determines what steps are necessary to create a safe environment, and what precautions should be adopted during the actual installation and operation.

Procedures for periodic inspection and testing

Where required by local national regulations, IEC60974-4 specifies test procedures for periodic inspection and after repair or maintenance, to ensure electrical safety for plasma cutting power sources built in conformity with IEC 60974-1. Hypertherm performs the continuity of the protective circuit and insulation resistance tests in the factory as non-operating tests. The tests are performed with the power and ground connections removed.

Hypertherm also removes some protective devices that would cause false test results. Where required by local national regulations, a label shall be attached to the equipment to indicate that it has passed the tests prescribed by IEC60974-4. The repair report shall indicate the results of all tests unless an indication is made that a particular test has not been performed.

Hypertherm Safety and Compliance PS-1

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Product StewardShiP

Qualification of test personnel

Electrical safety tests for shape cutting equipment can be hazardous and shall be carried out by an expert in the field of electrical repair, preferably someone also familiar with welding, cutting, and allied processes. The safety risks to personnel and equipment, when unqualified personnel are performing these tests, may be much greater than the benefit of periodic inspection and testing.

Hypertherm recommends that only visual inspection be performed unless the electrical safety tests are specifically required by local national regulations in the country where the equipment is installed.

Residual current devices (RCDs)

In Australia and some other countries, local codes may require the use of a Residual Current Devices (RCD) when portable electrical equipment is used in the workplace or at construction sites to protect operators from electrical faults in the equipment. RCDs are designed to safely disconnect the mains electrical supply when an imbalance is detected between the supply and return current (there is a leakage current to earth). RCDs are available with both fixed and adjustable trip currents between 6to 40 milliamperes and a range of trip times up to 300milliseconds selected for the equipment installation, application and intended use. Where RCDs are used, the trip current and trip time on RCDs should be selected or adjusted high enough to avoid nuisance tripping during normal operation of the plasma cutting equipment and low enough in the extremely unlikely event of an electrical fault in the equipment to disconnect the supply before the leakage current under a fault condition can pose a life threatening electrical hazard to operators.

To verify that the RCDs continue to function properly over time, both the trip current and the trip time should be tested periodically. Portable electrical equipment and RCDs used in commercial and industrial areas in Australia and New Zealand are tested to the Australian standard AS/NZS3760. When you test the insulation of plasma cutting equipment to AS/NZS 3760, measure the insulation resistance according to Appendix B of the standard, at 250VDC with the power switch in the ON position to verify proper testing and to avoid the false failure of the leakage current test. False failures are possible because the metal oxide varistors (MOVs) and electromagnetic compatibility (EMC) filters, used to reduce emissions and protect the equipment from power surges, may conduct up to 10milliamperes leakage current to earth under normal conditions.

If you have any questions regarding the application or interpretation of any IEC standards described here, you are required to consult with an appropriate legal or other advisor familiar with the International Electrotechnical standards, and shall not rely on Hypertherm in any respect regarding the interpretation or application of such standards.

protection against hazardous moving parts. Unless the higherlevel system is certified when the OEM incorporates Hypertherm products into it, the installation also may be subject to approval by local authorities. Seek advice from legal counsel and local regulatory experts if you are uncertain about compliance.

External interconnecting cables between component parts of the higher level system must be suitable for contaminants and movement as required by the final end use installation site. When the external interconnecting cables are subject to oil, dust, water, or other contaminants, hard usage ratings may be required.

When external interconnecting cables are subject to continuous movement, constant flexing ratings may be required. It is the responsibility of the end-use customer or the OEM to ensure the cables are suitable for the application. Since there are differences in the ratings and costs that can be required by local regulations for higher level systems, it is necessary to verify that any external interconnecting cables are suitable for the end-use installation site.

Higher-level systems

When a system integrator adds additional equipment; such as cutting tables, motor drives, motion controllers or robots; to a Hypertherm plasma cutting system, the combined system may be considered a higher-level system. A higher-level system with hazardous moving parts may constitute industrial machinery or robotic equipment, in which case the OEM or end-use customer may be subject to additional regulations and standards than those relevant to the plasma cutting system as manufactured by Hypertherm.

It is the responsibility of the end-use customer and the OEM to perform a risk assessment for the higher-level system, and to provide

PS-2 Hypertherm Safety and Compliance

English

Introduction

The Hypertherm Environmental Specification requires RoHS, WEEE

and REACH substance information to be provided by Hypertherm’s

suppliers.

Product environmental compliance does not address the indoor air quality or environmental release of fumes by the end user. Any materials that are cut by the end user are not provided by Hypertherm with the product. The end user is responsible for the materials being cut as well as for safety and air quality in the workplace. The end user must be aware of the potential health risks of the fumes released from the materials being cut and comply with all local regulations.

National and local environmental regulations

National and local environmental regulations shall take precedence over any instructions contained in this manual.

The product shall be imported, installed, operated and disposed of in accordance with all national and local environmental regulations applicable to the installed site.

The European Environmental regulations are discussed later in The WEEE Directive.

The RoHS directive

Hypertherm is committed to complying with all applicable laws and regulations, including the European Union Restriction of Hazardous Substances (RoHS) Directive that restricts the use of hazardous materials in electronics products. Hypertherm exceeds RoHS Directive compliance obligations on a global basis.

Hypertherm continues to work toward the reduction of RoHS materials in our products, which are subject to the RoHS Directive, except where it is widely recognized that there is no feasible alternative.

Declarations of RoHS Conformity have been prepared for the current CE versions of Powermax plasma cutting systems manufactured by Hypertherm. There is also a “RoHS mark” on the Powermax CE versions below the “CE Marking” on the data plate of CE versions of Powermax series units shipped since 2006. Parts used in CSA versions of Powermax and other products manufactured by Hypertherm that are either out of scope or exempt from RoHS are continuously being converted to RoHS compliance in anticipation of future requirements.

Proper disposal of Hypertherm products

Hypertherm plasma cutting systems, like all electronic products, may contain materials or components, such as printed circuit boards, that cannot be discarded with ordinary waste. It is your responsibility to dispose of any Hypertherm product or component part in an environmentally acceptable manner according to national and local codes.

• In the United States, check all federal, state, and local laws.

ENVIRONMENTAL STEWARDSHIP

• In the European Union, check the EU directives, national, and local

laws. For more information, visit www.hypertherm.com/weee.

• In other countries, check national and local laws.

• Consult with legal or other compliance experts when appropriate.

The WEEE directive

On January 27, 2003, the European Parliament and the Council of the European Union authorized Directive 2002/96/EC or WEEE (Waste Electrical and Electronic Equipment).

As required by the legislation, any Hypertherm product covered by the directive and sold in the EU after August 13, 2005 is marked with the WEEE symbol. This directive encourages and sets specific criteria for the collection, handling, and recycling of EEE waste. Consumer and business-to-business wastes are treated differently (all Hypertherm products are considered business-to-business). Disposal instructions for the CE versions of Powermax plasma systems can be found at www.hypertherm.com/weee.

The URL is printed on the symbol-only warning label for each of these CE version Powermax series units shipped since 2006. The CSA versions of Powermax and other products manufactured by Hypertherm are either out of scope or exempt from WEEE.

The REACH regulation

The REACH regulation (1907/2006), in force since June1, 2007, has an impact on chemicals available to the European market. The REACH regulation requirements for component manufacturers states that the component shall not contain more than 0.1% by weight of the Substances of Very High Concern (SVHC).

Component manufacturers and other downstream users, such as Hypertherm, are obligated to obtain assurances from its suppliers that all chemicals used in or on Hypertherm products will have a European Chemical Agency (ECHA) registration number. To provide chemical information as required by the REACH regulation, Hypertherm requires suppliers to provide REACH declarations and identify any known use of REACH SVHC. Any use of SVHC in amounts exceeding 0.1% w/w of the parts has been eliminated. The MSDS contains a full disclosure of all substances in the chemical and can be used to verify REACH SVHC compliance.

The lubricants, sealants, coolants, adhesives, solvents, coatings and other preparations or mixtures used by Hypertherm in, on, for, or with its shape cutting equipment are used in very small quantities (except the coolant) and are commercially available with multiple sources that can and will be replaced in the event of a supplier problem associated with REACH Registration or REACH Authorization (SVHCs).

Proper handling and safe use of chemicals

Chemical Regulations in the USA, Europe, and other locations require that Material Safety Data Sheets (MSDS) be made available for all chemicals. The list of chemicals is provided by Hypertherm.

Hypertherm Safety and Compliance eS-1

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environmental StewardShiP

The MSDS are for chemicals provided with the product and other chemicals used in or on the product. MSDS can be downloaded from the Downloads Library on the Hypertherm web site at https://www. hypertherm.com. On the Search screen, insert MSDS in the document title and click on Search.

In the USA, OSHA does not require Material Safety Data Sheets for articles such as electrodes, swirl rings, retaining caps, nozzles, shields, deflectors and other solid parts of the torch.

Hypertherm does not manufacture or provide the materials that are cut and has no knowledge whether the fumes released from materials that are cut will pose a physical hazard or health risk. Please consult with your supplier or other technical advisor if you need guidance concerning the properties of the material you will cut using a

Hypertherm product.

Fumes emission and air quality

Note: The following information on air quality is intended for general information only and should not be used as a substitute for reviewing and implementing applicable government regulations or legal standards in the country where the cutting equipment will be installed and operated.

In the USA, the National Institute for Occupational Safety and Health (NIOSH) Manual of Analytical Methods (NMAM) is a collection of methods for sampling and analyzing contaminants in workplace air. Methods published by others, such as OSHA, MSHA, EPA, ASTM, ISO or commercial suppliers of sampling and analytical equipment, may have advantages over NIOSH methods.

For example, ASTM Practice D 4185 is a standard practice for the collection, dissolution, and determination of trace metals in workplace atmospheres. The sensitivity, detection limit, and optimum working concentrations for 23 metals are listed in ASTMD4185. An industrial hygienist should be used to determine the optimum sampling protocol, considering analytical accuracy, cost, and optimum sample number. Hypertherm uses a third party industrial hygienist to perform and interpret air quality testing results taken by air sampling equipment positioned at operator stations in Hypertherm buildings where plasma cutting tables are installed and operated.

Where applicable, Hypertherm also uses a third party industrial hygienist to obtain air and water permits.

If you are not fully aware and up to date on all applicable government regulations and legal standards for the installation site, you should consult a local expert prior to purchasing, installing, and operating the equipment.

eS-2 Hypertherm Safety and Compliance

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Section 1

SPECIFICATIONS

In this section

Control module ................................................................................................................................................................................1-3

Lifter assembly .................................................................................................................................................................................1-3

Human machine interface (HMI) ..................................................................................................................................................1-3

Plasma interface ..............................................................................................................................................................................1-4

Industrial Ethernet switch ..............................................................................................................................................................1-4

Specifications .............................................................................................................................................................................................1-5

Control module (090054) .............................................................................................................................................................1-5

Lifter assembly (090053) ..............................................................................................................................................................1-6

Optional HMI (090055) .................................................................................................................................................................1-7

Discrete plasma interface (090052) ...........................................................................................................................................1-8

Ethernet switch ................................................................................................................................................................................1-9

ArcGlide communication ......................................................................................................................................................................1-11

Hypernet communication configurations ................................................................................................................................ 1-12

Discrete communication configurations .................................................................................................................................. 1-13

Mixed communication configurations ..................................................................................................................................... 1-13

ArcGlide THC Instruction Manual 1-1

SPECIFICATIONS

Cutting table GantryWorkpiece

ArcGlide lifter

ArcGlide control

module

Plasma system

Example of an ArcGlide THC installed on a cutting table with a plasma system and CNC

Note:

The ArcGlide control module and Ethernet switch should be located in an electrical cabinet that is electrically grounded and environmentally clean.

ArcGlide HMI

(optional)

CNC

Star ground

Rails

1-2 ArcGlide THC Instruction Manual

SPECIFICATIONS

Introduction

The Hypertherm ArcGlide THC is a voltage sensing, torch height control (THC) system that is designed for plasma cutting applications on an X-Y cutting table. The system uses the plasma arc voltage to control the physical distance between the torch and the workpiece during cutting. Up to 4 ArcGlide systems can be installed on a cutting table. The system includes the following components, as shown in the illustration on the facing page:

Control module

The control module houses a microcontroller, I/O interface, and a motor drive. This unit provides arc voltage control, and interfaces with the torch lifter, the CNC machine, and the plasma system through standard discrete I/O interfaces through the Hypernet® interface.

Lifter assembly

The torch lifter station, under control of the control module, positions a torch head vertically above the workpiece.

The lifter has the following features:

• Ability to detect the workpiece using Ohmic contact sense circuitry or stall force

• Magnetic torch breakaway with circuitry to indicate a collision

• Lifter station enable and disable switch with an indicator light

• Manual up and down switch

• Laser pointer for work piece alignment

• Single interface cable

Human machine interface (HMI)

The HMI includes a liquid crystal display (LCD), operating switches, and a rotary/push knob selector for THC setup and control. This module is optional when used with Hypertherm CNCs that can run Phoenix version 9.5 software (or later).

The main functions are:

• THC system and operational setup

• Entry for operating parameters

• Manual and automatic operation

• Initial height sense (IHS) test

• THC status and arc voltage display

• THC error display

• Multiple language support

• English or metric unit support

• Station enable and disable

ArcGlide THC Instruction Manual 1-3

SPECIFICATIONS

Plasma interface

The plasma interface performs two main functions. It provides precise, scaled feedback of the plasma arc voltage to the control module. It also provides a convenient control signal interface to the ArcGlide THC. Hypertherm offers two types of plasma interface:

• HPR: Hypernet communication, factory installed

• All other plasma systems: discrete communication, field installed

Industrial Ethernet switch

An industrial grade Ethernet switch is required in configurations that have more than one span of Hypernet. For more detailed requirements, refer to Ethernet switch in this section.

1-4 ArcGlide THC Instruction Manual

SPECIFICATIONS

Specifications

System

Input power 115 VAC or 230 VAC, 1 Phase, 50/60 Hz

Operating temperature -10º C to 40º C (14º F to 104º F)

Operating humidity 95% relative humidity

Warranty 2 years for electronics and lifter

Control module (090054)

Regulatory approvals CE, CSA

Fused input power (selectable)*

100 to 120 VAC/200 to 240 VAC, 2.6 A/1.5A, 50/60Hz, 1Phase,

Slow blow fuse 250 VAC, 5 A

Parallel digital input range +12 VDC to +24 VDC

Serial digital I/O +5 VDC (Plasma interface serial)

Maximum motor drive output 70 VDC, 6 A

Hypernet communication Shielded RJ-45 Cat-5e

* To prevent damage to equipment, use the input module switch on the front of the control module to select the input voltage (115 V or 240 V) that will be used.

157.23 mm (6.19”)

206.25 mm (8.12”)

358.65 mm (14.12”)

ArcGlide THC Instruction Manual 1-5

381.00 mm (15.37”)

127.00 mm (5.00”)

7.26 kg

(16.00 lb)

Control module

SPECIFICATIONS

Lifter assembly (090053)

Regulatory approvals CE

Motor 70 VDC, 3 A

Limit switches +24 VDC

Motor Permanent magnet

Motor drive PWM Servo amplifier

Lifter feedback Incremental encoder

Lifter limit switches Home switch and lower limit switch

Lifter control switches Manual up/down and station disable switches

Maximum Z axis speed 1520 cm/minute (600 in/minute)

Maximum Z axis stroke 239 mm (9.4 in)

Breakaway switch +24 VDC

Motor brake +24 VDC

Laser pointer (Class 3B) +5 VDC, Maximum power: 500 mW, Wavelength: 400 - 695 nm

Lifter capacity 11.3 kg (25.0 lb)

Part

Torch mounting and breakaway options

number

090082 51 mm (2 in) mounting, 11 kg (25 lb) magnetic

breakaway

090083 51 mm (2 in) mounting, pneumatic breakaway

090084 44 mm (1 3/4 in) mounting, pneumatic

breakaway

090085 35 mm (1 3/8 in) mounting, pneumatic

breakaway

090086 44 mm (1 3/4 in) mounting, 11 kg (25 lb)

magnetic breakaway

090087 35 mm (1 3/8 in) mounting, 11 kg (25 lb)

magnetic breakaway

090088 51 mm (2 in) mounting, 4.5 kg (10 lb) magnetic

breakaway

090089 44 mm (1 3/4 in) mounting, 4.5 kg (10 lb)

magnetic breakaway

090090 35 mm (1 3/8 in) mounting, 4.5 kg (10 lb)

magnetic breakaway

151.0 mm

268.1 mm (10.6”)

743.2 mm (29.3”)

50.8 mm

(5.9”)

(2.0”)

78.7 mm (3.1”)

11.11 kg

(24.50 lb)

238.8 mm (9.4”)

85.5 mm (3.4”)

090091 Pneumatic breakaway

090092 4.5 kg (10 lb) magnetic breakaway

090093 11 kg (25 lb) magnetic breakaway

1-6 ArcGlide THC Instruction Manual

127.0 mm (5.0”)

Lifter assembly

Optional HMI (090055)

Regulatory approvals CE, CSA

SPECIFICATIONS

Input power

100 VAC to 240 VAC, 50/60 Hz, 40 mA to 20mA, 1Phase,

Hypernet communication Shielded RJ-45 Cat-5e

Operating temperature -10º C to 40º C (14º F to 104º F)

Operating humidity 95% relative humidity

130.50 mm (5.14”)

117.60 mm

(4.63”)

65.00 mm (2.50”)

298.00 mm (11.73”)

1.91 kg

(4.20 lb)

HMI

ArcGlide THC Instruction Manual 1-7

SPECIFICATIONS

Discrete plasma interface (090052)

This plasma interface is required for configurations that use discrete communication.

Electrical

Input power 24 V (AC or DC)

Parallel digital I/O +12 VDC to +24 VDC

Serial digital I/O 5 VDC

Voltage divider ratio 50:1 Arc voltage

50.80 mm (2.00”)

27.69 mm (1.09”)

145.29 mm (5.72”)

127.00 mm

5.00”

0.68 kg (1.5 lb)

Discrete plasma interface

1-8 ArcGlide THC Instruction Manual

SPECIFICATIONS

Ethernet switch

If your ArcGlide THC uses more than one span of Hypernet to communicate with either the CNC or the plasma system, you must include an Ethernet switch in the system configuration for communication between these components.

Notes: This switch must be an industrial grade switch that supports shielded Cat-5e Ethernet cable. The Ethernet switch should be located in an electrical cabinet that is electrically grounded and

environmentally clean.

Hypertherm recommends three Advantech™ unmanaged industrial Ethernet switches, which are also available from Hypertherm. The following page provides part numbers and details about each model.

A plasma arc cutting system can be configured with 1 CNC, up to 4 plasma systems, 4 THC controllers, 4 lifters, and 4 optional HMIs. The total number of ports your system requires depends on the number of power supplies and ArcGlide THCs that are configured. Use the following table to help determine the number of Ethernet ports your system needs.

For each of these components: You need this many Ethernet ports:

CNC 1

Plasma system (1 to 4) + lifter (1 to 4) 2 to 8

Plasma system (1 to 4) + lifter (1 to 4) + HMI (1 to 4) 3 to 12

Total 4 to 13

For example, a cutting system with 2 power supplies + 2 THCs + 2 HMIs + 1 CNC = 7 ports.

Note: Hypernet connections and Ethernet connection to a LAN cannot be made through the same switch. If your

cutting system is connected to a LAN over Ethernet, you must use a separate Ethernet switch for these connections.

ArcGlide THC Instruction Manual 1-9

SPECIFICATIONS

5 Ports 8 Ports 16 Ports

Hypertherm part number 005657 005655 005656

Advantech part number EKI-2525I-AE EKI-7629C-AE EKI-7626C-AE

Width x height x depth

Maximum power consumption

Power input (not included)

The following table lists the operating specifications for the recommended Advantech Ethernet switches. Refer to the respective Advantech user manuals for detailed and current information about installing and operating these switches.

37 mm x 140 mm x 95mm (1.46 in x 5.51 in x 3.74in)

5 W 6.5 W 6.5 W

12 - 48 VDC redundant dual inputs with twisted pair cable.

79 mm x 152 mm x 105mm

(3.11 in x 5.98 in x 4.13in)

79 mm x 152 mm x 105mm

(3.11 in x 5.98 in x 4.13in)

If your cutting system does not include one of these Advantech Ethernet switches, use the specifications in the following table to select an industrial-grade Ethernet switch that will support your plasma cutting system.

Ethernet connectors Shielded RJ-45e ports

Electrical protection

I/O transmission distance

I/O transmission speed 10/100 Mbps auto-negotiation

Operating temperature -10º C to 60º C (14º F to 140º F)

4000 VDC Ethernet ESD protection, 3000 VDC surge (EFT) protection for the power line

Up to 100 m (109 yd) (4-wire Cat-5e)

1-10 ArcGlide THC Instruction Manual

SPECIFICATIONS

ArcGlide communication

The diagrams on the next two pages illustrate discrete and Hypernet communication that the ArcGlide THC uses to exchange signals with the CNC and the plasma system. Use the following table to distinguish between discrete and Hypernet communication.

Communication style Data architecture Cabling configuration

Discrete

Hypernet Ethernet data packets

Note that both communication styles transmit the same signals. The difference is in the way the signals are “packaged” for transmission over the two cabling configurations.

Notes Do not use redundant (both discrete and Hypernet) communication between the same two components in

the same ArcGlide configuration.

Discrete I/O and serial data

A dedicated cable to each component from the ArcGlide control module; within each cable, there is a dedicated wire for each signal

A standard, Cat-5e, shielded Ethernet cable from the Ethernet switch to each component of the cutting system

ArcGlide THC Instruction Manual 1-11

SPECIFICATIONS

Hypernet communication configurations

ArcGlide THCs in Hypernet configurations connect to the CNC and plasma system using the Hypernet protocol over shielded, Ethernet Cat-5e cables. Both the CNC and plasma systems in this configuration must have a dedicated, Hypernetconfigured, Ethernet port for these connections.

In addition, a Hypernet configuration must include an industrial-grade Ethernet switch to route communication from the CNC to the other units in the system.

Note: Each ArcGlide THC component (HMI, control module, and plasma interface) that is connected to the Hypernet

must have the same Hypernet unit address. This address must correspond to the station number for the THC that is selected in Phoenix, on the Station setup screen. For more information, see Assign ArcGlide THC ports in Section 3 Installation.

EDGE Pro HyPath

CNC

Key

Hypernet connection

Discrete connection

Hypernet address: 1

HMI

Hypernet address: 2

Lifter

ArcGlide control

module

Hypernet address: 1

Ethernet switch

Hypernet address: 2

ArcGlide control

module

Lifter

Station 1

HPR plasma system

with Hypernet

Plasma interface PCB

Hypernet address: 1

Hypernet address: 2

Plasma interface PCB

HPR plasma system

with Hypernet

Station 2

Basic configuration with Hypernet connections

There is no serial port on the ArcGlide THC. In a Hypernet configuration, serial signals are carried on the Hypernet cable between the CNC and the ArcGlide THC and the ArcGlide plasma interface. Serial communication is carried between the ArcGlide plasma interface and the plasma control board by a serial cable (123760).

CNC

Hypernet

Cat-5e

1-12 ArcGlide THC Instruction Manual

ArcGlide

THC

Hypernet

Cat-5e

ArcGlide plasma

interface

Plasma control

board

RS-422

SPECIFICATIONS

Discrete communication configurations

In a discrete configuration, signals are routed through the ArcGlide control module. Each unit in the configuration, except the HMI, is connected to the control module with discrete cables. The HMI communicates with the control module using the Hypernet protocol over a shielded Ethernet Cat-5e cable. In a discrete configuration, the HMI must be included.

Lifter

Plasma system

MicroEDGE Picopath

CNC

Key

Hypernet connection

Discrete connection

ArcGlide control

module

Plasma interface PCB

HMI

Basic configuration with discrete connections

Mixed communication configurations

In a mixed configuration, Hypernet communication is used between the ArcGlide THC and CNC or plasma system and discrete communication is used for the alternate link from the ArcGlide THC. Whenever the HMI is used, it must be connected to the control module with a Hypernet connection. See the following illustrations for details.

Hypernet-capable CNC

Hypernet connection

Discrete connection

CNC

Key

Lifter

ArcGlide control module

HMI

Lifter

ArcGlide control module

Plasma system

Plasma interface PCB

ArcGlide THC Instruction Manual 1-13

HMI

Basic configuration with mixed connections

Plasma system

SPECIFICATIONS

1-14 ArcGlide THC Instruction Manual

Section 2

INSTALLATION

In this section: