Hypertherm Automation Family Instruction Manual (IM)

EDGE® Pro SERCOS III

Shape Cutting Control

Instruction Manual

807650 | Revision 4 | English

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EDGE Pro SERCOS III CNC

Instruction Manual

807650

Revision 4

English

June 2015

Hypertherm Inc.

Hanover, NH 03755 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)
[e-mail] (Main Office Email)

800-643-9878 Tel (Technical Service)

[e-mail] (Technical Service Email)

800-737-2978 Tel (Customer Service)

[e-mail] (Customer Service Email)

866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization)

[e-mail] (RMA email)

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 301, South Building
495 ShangZhong Road
Shanghai, 200231
PR China
86-21-60740003 Tel
86-21-60740393 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 Brasil Ltda.

Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP - Brasil
CEP 07115-030
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

Hypertherm Korea Branch

#3904 Centum Leaders Mark B/D,
1514 Woo-dong, Haeundae-gu, Busan
Korea, 612-889
82 51 747 0358 Tel
82 51 701 0358 Fax

Contents

Safety ....................................................................................................................................... SC-11

Recognize safety information ...............................................................................................................................................SC-11

Inspect equipment before using ..........................................................................................................................................SC-11

Follow safety instructions ......................................................................................................................................................SC-11

Responsibility for safety ........................................................................................................................................................SC-11

A plasma arc can damage frozen pipes ............................................................................................................................SC-11

Static electricity can damage printed circuit boards ......................................................................................................SC-11

Grounding safety ....................................................................................................................................................................SC-12

Electrical hazards ....................................................................................................................................................................SC-12

Electric shock can kill ............................................................................................................................................................SC-12

Cutting can cause fire or explosion ....................................................................................................................................SC-13

Fire prevention .................................................................................................................................................................SC-13

Explosion prevention ......................................................................................................................................................SC-13

Machine motion can cause injury ........................................................................................................................................SC-13

Compressed gas equipment safety ...................................................................................................................................SC-14

Gas cylinders can explode if damaged .............................................................................................................................SC-14

Toxic fumes can cause injury or death ...............................................................................................................................SC-14

A plasma arc can cause injury and burns .........................................................................................................................SC-15

Arc rays can burn eyes and skin .........................................................................................................................................SC-15

Pacemaker and hearing aid operation ...............................................................................................................................SC-15

Noise can damage hearing ...................................................................................................................................................SC-16

Dry dust collection information ............................................................................................................................................SC-16

Laser radiation .........................................................................................................................................................................SC-17

Additional safety information ................................................................................................................................................SC-17

EDGE Pro SERCOS III CNC Instruction Manual 807650 5

Contents

Product Stewardship ...........................................................................................................SC-19

Introduction ..............................................................................................................................................................................SC-19

National and local safety regulations .................................................................................................................................SC-19

Certification test marks .........................................................................................................................................................SC-19

Differences in national standards .......................................................................................................................................SC-19

Safe installation and use of shape cutting equipment ...................................................................................................SC-19

Procedures for periodic inspection and testing ..............................................................................................................SC-19

Qualification of test personnel .............................................................................................................................................SC-20

Residual current devices (RCDs) .......................................................................................................................................SC-20

Higher-level systems ..............................................................................................................................................................SC-20

Environmental Stewardship .............................................................................................. SC-21

Introduction ..............................................................................................................................................................................SC-21

National and local environmental regulations ...................................................................................................................SC-21

The RoHS directive ................................................................................................................................................................SC-21

Proper disposal of Hypertherm products ..........................................................................................................................SC-21

The WEEE Directive ..............................................................................................................................................................SC-21

The REACH regulation ..........................................................................................................................................................SC-21

Proper handling and safe use of chemicals .....................................................................................................................SC-22

Fumes emission and air quality ...........................................................................................................................................SC-22

Electromagnetic Compatibility (EMC) ............................................................................ SC-23

Introduction ..............................................................................................................................................................................SC-23

Installation and use .................................................................................................................................................................SC-23

Assessment of area ................................................................................................................................................................SC-23

Methods of reducing emissions ..........................................................................................................................................SC-23

Mains supply ....................................................................................................................................................................SC-23

Maintenance of cutting equipment .....................................................................................................................................SC-23

Cutting cables .........................................................................................................................................................................SC-23

Equipotential bonding ....................................................................................................................................................SC-23

Earthing of the workpiece .............................................................................................................................................SC-23

Screening and shielding .......................................................................................................................................................SC-24

6 EDGE Pro SERCOS III CNC Instruction Manual 807650

Contents

Warranty ..................................................................................................................................SC-25

Attention ....................................................................................................................................................................................SC-25

General .....................................................................................................................................................................................SC-25

Patent indemnity .....................................................................................................................................................................SC-25

Limitation of liability ................................................................................................................................................................SC-25

National and local codes .......................................................................................................................................................SC-25

Liability cap ..............................................................................................................................................................................SC-25

Insurance ..................................................................................................................................................................................SC-26

Transfer of rights .....................................................................................................................................................................SC-26

1 Specifications .............................................................................................................................. 27

Main features of an automated cutting system ...................................................................................................................... 27

CNC ......................................................................................................................................................................................... 29

Cutting table .......................................................................................................................................................................... 29

Cutting system ...................................................................................................................................................................... 29

Control box ............................................................................................................................................................................. 29

Drive system ........................................................................................................................................................................... 29

Torch height control ............................................................................................................................................................. 30

Operator console .................................................................................................................................................................. 30

Oxyfuel torch .......................................................................................................................................................................... 30

Marker ...................................................................................................................................................................................... 30

Overview ......................................................................................................................................................................................... 31

Features of the EDGE Pro SERCOS III CNC ....................................................................................................................... 32

Touchscreen .......................................................................................................................................................................... 32

Operator console .................................................................................................................................................................. 32

Rear panel .............................................................................................................................................................................. 33

System specifications .................................................................................................................................................................. 34

SERCOS III models ............................................................................................................................................................. 36

Symbols and Marks ...................................................................................................................................................................... 37

2 Installation .................................................................................................................................... 39

Upon receipt .................................................................................................................................................................................. 39

Claims ...................................................................................................................................................................................... 39

Installation requirements ............................................................................................................................................................. 39

Placement of system components .................................................................................................................................... 40

Mounting the CNC ....................................................................................................................................................................... 40

Enclosure dimensions .......................................................................................................................................................... 41

Mounting hole patterns on the bottom of the CNC ...................................................................................................... 42

Recommended grounding and shielding practices .............................................................................................................. 43

Introduction ............................................................................................................................................................................ 43

Types of grounding ............................................................................................................................................................... 43

EDGE Pro SERCOS III CNC Instruction Manual 807650 7

Contents

Grounding practices ............................................................................................................................................................ 43

X and Y axis configuration .......................................................................................................................................................... 47

The operator console ................................................................................................................................................................... 48

Operator console and dedicated I/O ............................................................................................................................... 48

AC power ....................................................................................................................................................................................... 49

Power input ............................................................................................................................................................................ 49

Chassis grounding ............................................................................................................................................................... 50

Communication interfaces .......................................................................................................................................................... 51

Hypernet interface ................................................................................................................................................................ 51

LAN interface ......................................................................................................................................................................... 51

USB interface ........................................................................................................................................................................ 51

Serial ports ............................................................................................................................................................................. 51

Wireless antennas ................................................................................................................................................................ 51

SERCOS III I/O configuration ................................................................................................................................................... 52

SERCOS III Cable ....................................................................................................................................................................... 53

3 Operation ...................................................................................................................................... 55

Operating the CNC ..................................................................................................................................................................... 55

Touchscreen LCD ................................................................................................................................................................ 56

Touchscreens, drops of water, and unintended motion .............................................................................................. 56

Screen navigation ................................................................................................................................................................. 56

Help ......................................................................................................................................................................................... 57

View additional manuals ...................................................................................................................................................... 57

Show bookmarks .................................................................................................................................................................. 58

Automated operations ................................................................................................................................................................. 58

Align Wizard ........................................................................................................................................................................... 58

CutPro Wizard ....................................................................................................................................................................... 59

Updating Phoenix software ........................................................................................................................................................ 59

Updating the software ......................................................................................................................................................... 59

Updating the Help ................................................................................................................................................................ 59

Updating the cut charts ....................................................................................................................................................... 59

4 Maintenance and Diagnostics ................................................................................................ 61

Introduction .................................................................................................................................................................................... 61

Care and handling of the touchscreen .................................................................................................................................... 61

Diagnostic tests ............................................................................................................................................................................ 62

Machine interface tests ....................................................................................................................................................... 62

LAN and Hypernet tests ...................................................................................................................................................... 62

Serial test ................................................................................................................................................................................ 63

USB test ................................................................................................................................................................................. 63

Operator console test .......................................................................................................................................................... 64

8 EDGE Pro SERCOS III CNC Instruction Manual 807650

Contents

Troubleshooting ............................................................................................................................................................................ 65

Power ....................................................................................................................................................................................... 66

Operator console .................................................................................................................................................................. 66

Input failure ............................................................................................................................................................................. 67

Output failure ......................................................................................................................................................................... 67

Hypernet connection ............................................................................................................................................................ 67

LAN connection ..................................................................................................................................................................... 67

Serial communication issues .............................................................................................................................................. 67

USB port ................................................................................................................................................................................. 68

Cut quality or plasma performance issues ...................................................................................................................... 69

The CNC feels excessively warm ...................................................................................................................................... 69

Loading files ........................................................................................................................................................................... 69

Wireless troubleshooting .................................................................................................................................................... 70

Component locations and information ..................................................................................................................................... 71

Operator console board (141058) .......................................................................................................................................... 72

Motherboard (141110) ............................................................................................................................................................... 74

Surge board (141134) ................................................................................................................................................................ 75

Power distribution board (141153) ......................................................................................................................................... 76

Utility and serial isolation board (141307) ............................................................................................................................. 78

SERCOS III master board (141310) ....................................................................................................................................... 80

5 Parts List ....................................................................................................................................... 81

Diagnostic kits ............................................................................................................................................................................... 81

Cables ............................................................................................................................................................................................. 81

SERCOS III PCB kits .................................................................................................................................................................. 82

Additional kits ................................................................................................................................................................................ 83

6 Wiring Diagrams ......................................................................................................................... 85

Wiring diagram symbols ............................................................................................................................................................. 86

Sheet 4 – EDGE Pro CNC with SERCOS III interface ...................................................................................................... 89

Sheet 5 – Power distribution board (141153) and surge board (141134) ................................................................... 90

Sheet 6 – Power distribution board, field and clean power out (J4 – J6) (141153) ................................................... 91

Sheet 7 – Operator console board (141058) ....................................................................................................................... 92

Sheet 8 – Operator console components (141058) ........................................................................................................... 93

Sheet 9 – Motherboard (141110) ........................................................................................................................................... 94

Sheet 10 – ATX power supply (229403) ............................................................................................................................... 95

Sheet 12 – Utility and serial isolation board (141307) ....................................................................................................... 96

EDGE Pro SERCOS III CNC Instruction Manual 807650 9

Contents

10 EDGE Pro SERCOS III CNC Instruction Manual 807650

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

Carefully read 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.

RESPONSIBILITY FOR SAFETY

The person or entity responsible for the safety of the workplace must:

• Make sure that operators and their supervisors are trained in the safe
use of their equipment, the safe use of the process, and emergency
procedures.

• Make sure that all hazards and safety precautions identified herein
are communicated to and understood by workers before the start of
work.

• Designate approved cutting areas and establish procedures for safe
cutting.

• Be responsible for authorizing cutting operations in areas not
specifically designed or approved for such processes.

• Make sure that only approved equipment, such as torches and
personal protective equipment, are used.

DANGER WARNING CAUTION

American National Standards Institute (ANSI) guidelines are used for
safety signal words and symbols. The 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.

INSPECT EQUIPMENT BEFORE USING

All cutting equipment must be inspected as required to make sure it is in
safe operating condition. When found to be incapable of reliable and
safe operation, the equipment must be repaired by qualified personnel
prior to its next use or withdrawn from service.

• Select contractors who provide trained and qualified personnel, and
who have awareness of the risks involved, to do cutting.

• Tell contractors about flammable materials or hazardous conditions
that are specific to the site, or hazardous conditions that they may not
be aware of.

• Make sure that the quality and quantity of air for ventilation is such
that personnel exposures to hazardous contaminants are below the
allowable limits.

• Make sure that ventilation in confined spaces is sufficient to allow
adequate oxygen for life support, to prevent accumulation of
asphixiants or flammable explosive mixtures, to prevent
oxygen-enriched atmospheres, and to keep airborne contaminants in
breathing atmospheres below allowable limits.

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.

STATIC ELECTRICITY CAN DAMAGE PRINTED CIRCUIT BOARDS

Use proper precautions when handling printed circuit boards:

• Store printed circuit boards in anti-static containers.

• Wear a grounded wrist strap when handling printed circuit boards.

Safety and Compliance SC-11

Safety

GROUNDING SAFETY

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

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

Cutting table Connect the cutting table to an earth ground, in
accordance with appropriate national and local electrical regulations.

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

Input power

• Make 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, make 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. Tighten the
retaining nut.

• Tighten all electrical connections to avoid excessive heating.

• 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.

• Prior to operating the equipment after moving, opening, or servicing,
make sure to close the enclosure and make sure that there is proper
earth ground continuity to the enclosure.

• 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.

• In machine torch applications, never touch the torch body,
workpiece, or water in a water table when the plasma system is
operating.

Electric shock prevention

All 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 the work and ground using dry insulating
mats or covers big enough to prevent any physical contact with the
work or ground. If you must cut 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, make sure that it is correctly connected
to an earth ground.

• Install and ground this equipment according to the instruction
manual and in accordance with national and local regulations.

• 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 lead 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 a proper grounding
conductor first.

• Each plasma system is designed to be used only with specific
torches. Do not substitute other torches, which could overheat and
present a safety hazard.

SC-12 Safety and Compliance

CUTTING CAN CAUSE FIRE OR EXPLOSION

Safety

Fire prevention

• Make sure the cutting 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 containers.

• Do not cut containers that have held combustible materials.

Explosion Hazard

Hydrogen Detonation with Aluminum Cutting

When you use a plasma torch to cut aluminum alloys under water or
on a water table, a chemical reaction between the water and the
workpiece, parts, fine particles, or molten aluminum droplets
generates significantly more hydrogen gas than occurs with other
metals. This hydrogen gas may get trapped under the workpiece. If
exposed to oxygen or air, the plasma arc or a spark from any source
can ignite this trapped hydrogen gas, causing an explosion that may
result in death, personal injury, loss of property, or equipment damage.

Consult with the table manufacturer and other experts prior to cutting
aluminum to implement a risk assessment and mitigation plan that
eliminates the risk of detonation by preventing hydrogen
accumulation.

WARNI NG

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.

WARNI NG

Explosion Hazard

Underwater Cutting with Fuel Gases

Containing Hydrogen

• Do not cut underwater with fuel gases containing hydrogen.

• Cutting underwater with fuel gases containing hydrogen can result
in an explosive condition that can detonate during plasma cutting
operations.

WARNI NG

Also, make sure that the water table, fume extraction (ventilation), and
other parts of the cutting system have been designed with aluminum
cutting in mind.

Do not cut aluminum alloys underwater or on a water table
unless you can prevent the accumulation of hydrogen gas.

Note: With proper mitigation, most aluminum alloys can be plasma
cut on a water table. An exception is aluminum-lithium alloys. Never
cut aluminum-lithium alloys in the presence of water. Contact

your aluminum supplier for additional safety information regarding
hazards associated with aluminum-lithium alloys.

MACHINE MOTION CAN CAUSE INJURY

When an original equipment manufacturer (OEM) makes a cutting system by combining Hypertherm equipment with other equipment, the end-use
customer and the OEM are responsible for providing protection against the hazardous moving parts of this cutting system. However, we advise the
following to prevent operator injury and equipment damage:

• Read and follow the instruction manual provided by the OEM.

• Maintain a restricted-access area larger than the maximum
movement range of the cutting system’s moving parts.

• Where there is a risk of collision, do not allow personnel or
equipment near the cutting system’s moving parts.

• Avoid accidental contact with the CNC touchscreen or joystick.
Accidental contact can activate commands and result in
unintended motion.

Safety and Compliance SC-13

• Do not service or clean the machinery during operation.

• If servicing is required, enable the safety interlock or disconnect
and lock out/tag out power to disable the motors and prevent
motion.

• Allow only qualified personnel to operate, maintain, and service
the machinery.

Safety

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 regulations.

TOXIC FUMES CAN CAUSE INJURY OR DEATH

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.

The 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.

The 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 on 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 cutting area and to make sure that the air quality in the
workplace meets all local and national standards and regulations.

GAS CYLINDERS CAN EXPLODE IF DAMAGED

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 regulations.

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

• Keep the protective cap in place over the 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.

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 workplace.

• Personal protective equipment.

• Number of welding and cutting systems in operation.

• Other workplace 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
workplace 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.

• Make sure 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 make sure air
quality is safe.

SC-14 Safety and Compliance

A PLASMA ARC CAN CAUSE INJURY AND BURNS

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
regulations.

• 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.

• Wear gauntlet gloves, safety shoes, and hat.

• Wear flame-retardant clothing to cover all exposed areas.

• Wear cuffless trousers to prevent entry of sparks and slag.

Also, 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.

Safety

Instant-on torches

A plasma arc ignites immediately when the torch switch is activated.

The plasma arc will cut quickly through gloves and skin.

• Keep away from the torch tip.

• Do not hold metal near the cutting path.

• Never point the torch toward yourself or others.

ARC RAYS CAN BURN EYES AND SKIN

Minimum protective

Arc current

Less than 40 A 5 5 8 9
41 A to 60 A 6 6 8 9
61 A to 80 A 8 8 8 9
81 A to 125 A 8 9 8 9
126 A to 150 A 8 9 8 10
151 A to 175 A 8 9 8 11
176 A to 250 A 8 9 8 12
251 A to 300 A 8 9 8 13
301 A to 400 A 9 12 9 13
401 A to 800 A101410N/A

shade number

(ANSIZ49.1:2012)

Suggested shade

number for comfort

(ANSI Z49.1:2012)

OSHA 29CFR

1910.133(a)(5)

Europe

EN168:2002

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.

Safety and Compliance SC-15

To reduce magnetic field hazards:

• Keep both the work lead and the torch lead to one side, away from
your body.

• Route the torch leads as close as possible to the work lead.

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

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

Safety

NOISE CAN DAMAGE HEARING

Cutting with a plasma arc can exceed acceptable noise levels as
defined by local regulations 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 site have verified personal hearing
protection is not necessary per relevant international, regional, and
local regulations.

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

DRY DUST COLLECTION INFORMATION

In some workplaces, dry dust can represent a potential explosion
hazard.

The U.S. National Fire Protection Association’s 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 standard 68 has been “adopted by
reference” in your local building codes.

Refer to NFPA standard 68 for definitions and explanations of
regulatory terms such as deflagration, AHJ, adopted by reference, the
Kst value, deflagration index, and other terms.

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 equipment such as ear muffs
or ear plugs with a noise reduction rating appropriate for the
situation. Warn others near the cutting area of possible noise
hazards. In addition, ear protection can prevent hot splatter from
entering the ear.

Note 1 – Unless a site-specific evaluation has been completed that
determines that none of the dust generated is combustible, then
NFPA standard 68 requires the use of explosion vents. Design the
explosion vent size and type to conform to the worst-case Kst value
as described in Annex F of NFPA standard 68. NFPA standard 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 should consult and comply with all applicable
national, state, and local regulations. Publications do not 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.

SC-16 Safety and Compliance

Safety

LASER RADIATION

Exposure to the laser beam from a laser pointer can result in serious eye injury. Avoid direct eye exposure.

On products that use a laser pointer for alignment, 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, pulse duration are 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.

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

• 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.

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, 1 Batterymarch Park, Quincy, MA
02169-7471

9. NFPA Standard 70, National Electrical Code, National Fire
Protection Association, 1 Batterymarch Park, Quincy, MA
02169-7471

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/

Safety and Compliance SC-17

Safety

SC-18 Safety and Compliance

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 safety-critical
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.

Safety and Compliance SC-19

Product Stewardship

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 IEC 60974-4. The repair report shall indicate the
results of all tests unless an indication is made that a particular test has
not been performed.

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.

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 protection
against hazardous moving parts. Unless the higher-level 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.

SC-20 Safety and Compliance

Environmental Stewardship

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.

• 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).

Safety and Compliance SC-21

Environmental Stewardship

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. 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.

SC-22 Safety and Compliance

Electromagnetic Compatibility (EMC)

Introduction

Hypertherm’s CE-marked equipment is built in compliance with standard
EN60974-10. The equipment should be installed and used in
accordance with the information below to achieve electromagnetic
compatibility.

The limits required by EN60974-10 may not be adequate to completely
eliminate interference when the affected equipment is in close proximity
or has a high degree of sensitivity. In such cases it may be necessary to
use other measures to further reduce interference.

This cutting equipment is designed for use only in an industrial
environment.

Installation and use

The user is responsible for installing and using the plasma equipment
according to the manufacturer’s instructions.

If electromagnetic disturbances are detected then it shall be the
responsibility of the user to resolve the situation with the technical
assistance of the manufacturer. In some cases this remedial action may
be as simple as earthing the cutting circuit, see Earthing of the
workpiece. In other cases, it could involve constructing an
electromagnetic screen enclosing the power source and the work
complete with associated input filters. In all cases, electromagnetic
disturbances must be reduced to the point where they are no longer
troublesome.

Methods of reducing emissions

Mains supply

Cutting equipment must be connected to the mains supply according to
the manufacturer’s recommendations. If interference occurs, it may be
necessary to take additional precautions such as filtering of the mains
supply.

Consideration should be given to shielding the supply cable of
permanently installed cutting equipment, in metallic conduit or
equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the cutting mains supply so
that good electrical contact is maintained between the conduit and the
cutting power source enclosure.

Maintenance of cutting equipment

The cutting equipment must be routinely maintained according to the
manufacturer’s recommendations. All access and service doors and
covers should be closed and properly fastened when the cutting
equipment is in operation. The cutting equipment should not be modified
in any way, except as set forth in and in accordance with the
manufacturer’s written instructions. For example, the spark gaps of arc
striking and stabilizing devices should be adjusted and maintained
according to the manufacturer’s recommendations.

Cutting cables

Assessment of area

Before installing the equipment, the user shall make an assessment of
potential electromagnetic problems in the surrounding area. The
following shall be taken into account:

a. Other supply cables, control cables, signaling and telephone

cables; above, below and adjacent to the cutting equipment.

b. Radio and television transmitters and receivers.
c. Computer and other control equipment.
d. Safety critical equipment, for example guarding of industrial

equipment.

e. Health of the people around, for example the use of pacemakers

and hearing aids.

f. Equipment used for calibration or measurement.

g. Immunity of other equipment in the environment. User shall

ensure that other equipment being used in the environment is
compatible. This may require additional protection measures.

h. Time of day that cutting or other activities are to be carried out.

The size of the surrounding area to be considered will depend on the
structure of the building and other activities that are taking place. The
surrounding area may extend beyond the boundaries of the premises.

The cutting cables should be kept as short as possible and should be
positioned close together, running at or close to the floor level.

Equipotential bonding

Bonding of all metallic components in the cutting installation and
adjacent to it should be considered.

However, metallic components bonded to the workpiece will increase
the risk that the operator could receive a shock by touching these
metallic components and the electrode (nozzle for laser heads) at the
same time.

The operator should be insulated from all such bonded metallic
components.

Earthing of the workpiece

Where the workpiece is not bonded to earth for electrical safety, nor
connected to earth because of its size and position, for example, ship’s
hull or building steel work, a connection bonding the workpiece to earth
may reduce emissions in some, but not all instances. Care should be
taken to prevent the earthing of the workpiece increasing the risk of injury
to users, or damage to other electrical equipment. Where necessary, the
connection of the workpiece to earth should be made by a direct
connection to the workpiece, but in some countries where direct
connection is not permitted, the bonding should be achieved by suitable
capacitances selected according to national regulations.

Safety and Compliance SC-23

Electromagnetic Compatibility (EMC)

Note: The cutting circuit may or may not be earthed for safety reasons.
Changing the earthing arrangements should only be authorized by a
person who is competent to assess whether the changes will in crease
the risk of injury, for example, by allowing parallel cutting current return
paths which may damage the earth circuits of other equipment. Further
guidance is provided in IEC 60974-9, Arc Welding Equipment, Part 9:
Installation and Use.

Screening and shielding

Selective screening and shielding of other cables and equipment in the
surrounding area may alleviate problems of interference. Screening of the
entire plasma cutting installation may be considered for special
applications.

SC-24 Safety and Compliance

Warranty

Attention

Genuine Hypertherm parts are the factory-recommended replacement
parts for your Hypertherm system. Any damage or injury caused by the
use of other than genuine Hypertherm parts may not be covered by the
Hypertherm warranty, and will constitute misuse of the Hypertherm
Product.

You are solely responsible for the safe use of the Product. Hypertherm
does not and cannot make any guarantee or warranty regarding the safe
use of the product in your environment.

General

Hypertherm Inc. warrants that its Products shall be free from defects in
materials and workmanship for the specific periods of time set forth
herein and as follows: if Hypertherm is notified of a defect (i) with respect
to the plasma power supply within a period of two (2) years from the date
of its delivery to you, with the exception of Powermax brand power
supplies, which shall be within a period of three (3) years from the date of
delivery to you, and (ii) with respect to the torch and leads within a period
of one (1) year from its date of delivery to you, with the exception of the
HPRXD short torch with integrated lead, which shall be within a period of
six (6) months from the date of delivery to you, and with respect to torch
lifter assemblies within a period of one (1) year from its date of delivery to
you, and with respect to Automation products one (1) year from its date
of delivery to you, with the exception of the EDGE Pro CNC,
EDGE Pro Ti CNC, MicroEDGE Pro CNC, and ArcGlide THC, which
shall be within a period of two (2) years from the date of delivery to you,
and (iii) with respect to HyIntensity fiber laser components within a
period of two (2) years from the date of its delivery to you, with the
exception of laser heads and beam delivery cables, which shall be within
a period of one (1) year from its date of delivery to you.

This warranty shall not apply to any Powermax brand power supplies that
have been used with phase converters. In addition, Hypertherm does not
warranty systems that have been damaged as a result of poor power
quality, whether from phase converters or incoming line power. This
warranty shall not apply to any product which has been incorrectly
installed, modified, or otherwise damaged.

Hypertherm provides repair, replacement or adjustment of the Product as
the sole and exclusive remedy, if and only if the warranty set forth herein
properly is invoked and applies. Hypertherm, at its sole option, shall
repair, replace, or adjust, free of charge, any defective Products covered
by this warranty which shall be returned with Hypertherm’s prior
authorization (which shall not be unreasonably withheld), properly
packed, to Hypertherm’s place of business in Hanover, New Hampshire,
or to an authorized Hypertherm repair facility, all costs, insurance and
freight pre paid by the customer. Hypertherm shall not be liable for any
repairs, replacement, or adjustments of Products covered by this
warranty, except those made pursuant to this paragraph and with
Hypertherm’s prior written consent.

The warranty set forth above is exclusive and is in lieu of all other
warranties, express, implied, statutory, or otherwise with respect to the
Products or as to the results which may be obtained therefrom, and all
implied warranties or conditions of quality or of merchantability or fitness
for a particular purpose or against infringement. The foregoing shall
constitute the sole and exclusive remedy for any breach by Hypertherm
of its warranty.

Distributors/OEMs may offer different or additional warranties, but
Distributors/OEMs are not authorized to give any additional warranty
protection to you or make any representation to you purporting to be
binding upon Hypertherm.

Patent indemnity

Except only in cases of products not manufactured by Hypertherm or
manufactured by a person other than Hypertherm not in strict conformity
with Hypertherm’s specifications and in cases of designs, processes,
formulae, or combinations not developed or purported to be developed
by Hypertherm, Hypertherm will have the right to defend or settle, at its
own expense, any suit or proceeding brought against you alleging that
the use of the Hypertherm product, alone and not in combination with
any other product not supplied by Hypertherm, infringes any patent of
any third party. You shall notify Hypertherm promptly upon learning of any
action or threatened action in connection with any such alleged
infringement (and in any event no longer than fourteen (14) days after
learning of any action or threat of action), and Hypertherm’s obligation to
defend shall be conditioned upon Hypertherm’s sole control of, and the
indemnified party’s cooperation and assistance in, the defense of the
claim.

Limitation of liability

In no event shall Hypertherm be liable to any person or entity for
any incidental, consequential direct, indirect, punitive or
exemplary damages (including but not limited to lost profits)
regardless of whether such liability is based on breach of
contract, tort, strict liability, breach of warranty, failure of
essential purpose, or otherwise, and even if advised of the
possibility of such damages.

National and local codes

National and local codes governing plumbing and electrical installation
shall take precedence over any instructions contained in this manual.
In no event shall Hypertherm be liable for injury to persons or property
damage by reason of any code violation or poor work practices.

Liability cap

In no event shall Hypertherm’s liability, if any, whether such
liability is based on breach of contract, tort, strict liability,
breach of warranties, failure of essential purpose or otherwise,
for any claim, action, suit or proceeding (whether in court,
arbitration, regulatory proceeding or otherwise) arising out of or
relating to the use of the Products exceed in the aggregate the
amount paid for the Products that gave rise to such claim.

Safety and Compliance SC-25

Warranty

Insurance

At all times you will have and maintain insurance in such quantities and
types, and with coverage sufficient and appropriate to defend and to hold
Hypertherm harmless in the event of any cause of action arising from the
use of the products.

Transfer of rights

You may transfer any remaining rights you may have hereunder only in
connection with the sale of all or substantially all of your assets or capital
stock to a successor in interest who agrees to be bound by all of the
terms and conditions of this Warranty. Within thirty (30) days before any
such transfer occurs, you agree to notify in writing Hypertherm, which
reserves the right of approval. Should you fail timely to notify Hypertherm
and seek its approval as set forth herein, the Warranty set forth herein
shall be null and void and you will have no further recourse against
Hypertherm under the Warranty or otherwise.

SC-26 Safety and Compliance

Section 1

Optional operator

console

Cutting table

Control box

Drive amplifier

Oxyfuel cutting

system

EDGE Pro

SERCOS III

CNC

THC

Cutting system

(plasma, laser,

waterjet, marking)

Products available from Hypertherm

Specifications

Main features of an automated cutting system

Figure 1 illustrates the relationship between the components of an automated cutting system. The following topics
describe these components and their relationships.

Figure 1 Components of an automated cutting system

EDGE Pro SERCOS III CNC Instruction Manual 807650 27

1 – Specifications

987

6

5

4

3

2

1

Plasma system

2

Cutting table

3

Workpiece

4

Lifter

5

Gantry

6

Star ground

7

Rails

8

Operator console

9

EDGE Pro SERCOS III CNC

Main features of an automated cutting system

Figure 2 illustrates a typical cutting table with an EDGE Pro CNC and other components that are described in the
following topics.

Figure 2 Illustration of a plasma cutting table

1

28 EDGE Pro SERCOS III CNC Instruction Manual 807650

1 – Specifications

Main features of an automated cutting system

CNC

The computerized numerical control (CNC) reads part programs and communicates with the other components of the
shape cutting system. It controls which parts (shapes) are cut from the workpiece.

Refer to the sections in this manual for more detailed information about the hardware features of the EDGE Pro
SERCOS III CNC. Refer to the following Phoenix™ software manuals for detailed information on the software that
operates on the EDGE Pro SERCOS III CNC:

• Phoenix Software V9 Series Installation and Setup Manual (806410)

• Phoenix Software Operator Manual (806400)

• Phoenix Software V9 Series Programmer’s Reference (806420)

Cutting table

The cutting table is the frame that supports the workpiece from which parts are cut. A typical cutting table has two rails
that run the length of the table on either side and form the track for the gantry. The gantry rides along these rails and
spans the width of the table. A torch height control (THC) is attached to the gantry and provides the vertical movement of
the cutting torch. The horizontal motion of the gantry and torch station, and the vertical motion of the torch on the THC
provide the three axes that are necessary for controlling the torch’s position on the workpiece. Additional equipment can
be included on the cutting table to permit bevel and other types of cutting.

Hypertherm does not manufacture cutting tables. For more information on the cutting table in your system, refer to the
manual that the table manufacturer supplied.

Cutting system

The cutting tool is the heart of any cutting system and may be a plasma, oxyfuel, laser, or waterjet system. The cutting
system controls key parameters, such as the plasma gas and assist gases, and controls how they are mixed. It also
provides process parameters, such as standoff and speed for optimal cut quality.

Your cutting system may include a Hypertherm cutting system. Refer to the appropriate manual for additional information.
Electronic (PDF) versions of Hypertherm manuals are available at https://www.hypertherm.com or on the CNC. If your
cutting system is manufactured by another company, refer to the appropriate manual.

Control box

The control box (supplied by the table manufacturer) contains terminal blocks that route power and control signals to the
subsystems of the cutting system. The control box may also contain the drive amplifiers that amplify control signals from
the CNC to the motors for motion.

Drive system

The speed, smoothness, and accuracy of the cuts are determined by the combination of the CNC, encoders, servo drive
amplifiers, THC, gears, rails, servo motors, and how well they are integrated (tuned) by the table manufacturer. The table
manufacturer must select and install the drives and motors that will be used with the EDGE Pro SERCOS III CNC. For
more information on the drive system for your cutting system, refer to the manual that the table manufacturer supplied.

EDGE Pro SERCOS III CNC Instruction Manual 807650 29

1 – Specifications

Main features of an automated cutting system

Torch height control

The THC controls the distance between the torch and the workpiece, also known as the standoff. This standoff is usually
defined by height or voltage.

If a Hypertherm THC is part of your system, consult one of the following manuals for more information about installing and
using it:

®

•ArcGlide

•Sensor

THC (806450)

™

THC (806400, 806410, and 806420)

• Sensor PHC (806150)

If your THC is manufactured by another company, refer to the manual that the table manufacturer supplied.

Operator console

The EDGE Pro SERCOS III operator console controls two cutting stations. Additional operator consoles, not
manufactured by Hypertherm, may be installed by the table manufacturer to control oxyfuel, markers, ventilation systems,
and other devices. For more information about an optional operator console, refer to the manual that the table
manufacturer supplied.

Oxyfuel torch

Automated cutting systems can also be configured with oxyfuel torches with or without an oxygen height control (OHC).

If the Hypertherm Sensor™ OHC is configured in your system, refer to the Sensor OHC manual (MANU–0044) for
information about installation and operation.

For more information about any other oxyfuel torch, refer to the manual that the table manufacturer supplied.

Marker

A marker can be any device or process that marks a workpiece rather than piercing or cutting it. If the Hypertherm
ArcWriter
operation. Any HPR
HPR manual.

For other devices or processes, refer to the manual that the table manufacturer supplied.

®

is configured in your system, refer to the ArcWriter manual (802520) for information about installation and

®

plasma system can also be used for marking. For more information, refer to the appropriate

30 EDGE Pro SERCOS III CNC Instruction Manual 807650

1 – Specifications

2-Station operator console

Touchscreen

Overview

Overview

The EDGE Pro SERCOS III is a PC-based CNC and uses Hypertherm’s Phoenix software to control one or more cutting
or marking stations.

®

The EDGE Pro SERCOS III CNC has a two-station operator console, a 15-inch touchscreen, and Hypernet
and wireless LAN communication.

EDGE Pro SERCOS III CNC features can be configured with multiple drive axes, integrated Sensor THC interface,
bevel head control, and networking to download part programs or to support remote diagnostic utilities.

, Ethernet,

Figure 3 Front view of the EDGE

Pro SERCOS III CNC

EDGE Pro SERCOS III CNC Instruction Manual 807650 31

1 – Specifications

5

4

3

2

1

1

Data transfer

2

Power switch

3

Program execution controls

4

Station controls

5

Manual motion controls

Features of the EDGE Pro SERCOS III CNC

Features of the EDGE Pro SERCOS III CNC

Touchscreen

The touchscreen is a 15-inch LCD monitor combined with software that allows direct user input from the screen. A user
makes selections on the screen using check boxes, radio buttons, drop-down menus, and data input. Data input boxes
automatically display a numeric or alphanumeric keypad for entries in the fields.

The touchscreen has a resolution of 1024 x 768, or higher.

See Care and handling of the touchscreen on page 61 for more information about how to care for the touchscreen.

Operator console

The operator console provides the physical controls that allow you to regulate part program execution, as well as station
and manual motion.

Figure 4 EDGE Pro SERCOS III operator console

32 EDGE Pro SERCOS III CNC Instruction Manual 807650

1 – Specifications

1

Wireless antennas

2

Serial ports

3

USB port

4

LAN port

5

Hypernet port

6

SERCOS III Port 1 and Port 2

7

AC power input

745

6

3

2

Features of the EDGE Pro SERCOS III CNC

Rear panel

The rear panel of the EDGE Pro SERCOS III CNC has cable connectors for power, motion control, I/O, and
communication ports. These connectors are clearly labeled with their function. In addition, there are two antennas for
wireless LAN communication.

Figure 5 Rear panel of an EDGE Pro SERCOS III CNC

1

EDGE Pro SERCOS III CNC Instruction Manual 807650 33

1 – Specifications

System specifications

System specifications

The following table contains technical specifications for the EDGE Pro CNC.

Table 1 System specifications for the EDGE Pro CNC

System features

Processor

Operating system Windows XPe

RAM

LAN port 1 RJ-45 Ethernet port

Hypernet port 1 Hypernet port for use with the ArcGlide THC and Hypertherm Fiber Laser systems

USB ports 2 USB 2.0 ports

Serial ports 2 RS-422/RS-232 configurable ports with D-sub 9-pin connectors

Wireless communication Complies with 802.11G and 802.11N standards.

Onboard monitoring devices Hardware monitoring, CPU fan, CPU temperature, voltages, POST display

Hard drive SATA drive

Operator console 2-station standard (can be expanded by table manufacturer)

Display 381 mm (15 in.) touchscreen, surface acoustic wave glass

Regulatory compliance CE, CSA, GOST-TR, C-Tick, UkrSEPRO

Configuration

Number of I/O 512/512

I/O Type Table manufacturers provide I/O modules

Axes available 2 –12

Intel® Processor

 1GB

Power

AC input Voltage: 100 VAC to 240 VAC

Current: 1.85 A at 100 VAC/0.65 A at 240 VAC
Frequency: 50/60 Hz

Slow blow fuse 250 V, 2 A, 5 mm x 20 mm (2) or 0.25 in. x 1.25 in. (1)

34 EDGE Pro SERCOS III CNC Instruction Manual 807650

System features

Environmental

Temperature -10º C to 40º C (14º F to 104º F)

Humidity 95% maximum relative humidity

Ingress Protection IP21S

Protect the equipment from exposure to excessive moisture.

Altitude Operational up to 2000 m (6561 ft)

Environment Pollution degree Level II

Mechanical

Height 490.9 mm (19.33 in.)

Width 435 mm (17.13 in.)

Depth 316 mm (12.43 in.)

Weight 23.64 kg (52 lb)

1 – Specifications

System specifications

EDGE Pro SERCOS III CNC Instruction Manual 807650 35

1 – Specifications

System specifications

SERCOS III models

SERCOS stands for SErial Real time COmmunication System servo drive interface. This approach to communication
with the drives uses an Ethernet ring and replaces the traditional +/- 10 VDC analog output motion control card (MCC)
with a driver card that manages SERCOS III, real-time transmissions and allows you to expand your system to
accommodate up to 12 axes and 512 I/O.

Note:

• Multiple THC connections are available as a function of SERCOS III.

• SERCOS III-compatible (digital) drives must be used with this configuration.

Table 2 EDGE Pro SERCOS III part numbers

Part numbers Number of axes

090150 2
090151 3
090152 4
090153 5
090154 6
090155 7
090156 8
090157 9
090158 10
090159 11
090160 12

Figure 6 Rear panel for EDGE Pro SERCOS III models

36 EDGE Pro SERCOS III CNC Instruction Manual 807650

1 – Specifications

s

Symbols and Marks

Symbols and Marks

Your product may have one or more of the following markings on or near the data plate. Due to differences and conflicts
in national regulations, not all marks are applied to every version of a product.

S mark

The S mark indicates that the power supply and torch are suitable for operations carried out in environments
with increased hazard of electrical shock according to IEC 60974-1.

CSA mark

Products with a CSA mark meet the United States and Canadian regulations for product safety. The products
were evaluated, tested, and certified by CSA-International. Alternatively, the product may have a mark by one
of the other Nationally Recognized Testing Laboratories (NRTL) accredited in both the United States and
Canada, such as UL or TÜV.

CE mark

The CE marking signifies the manufacturer’s declaration of conformity to applicable European directives and
standards. Only those versions of 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 Electromagnetic
Compatibility (EMC) Directive. EMC filters needed to comply with the European EMC Directive are
incorporated within versions of the product with a CE marking.

Eurasian Customs Union (CU) mark

CE versions of products that include an EAC mark of conformity meet the product safety and EMC
requirements for export to Russia, Belarus, and Kazakhstan.

GOST-TR mark

CE versions of products that include a GOST-TR mark of conformity meet the product safety and EMC
requirements for export to the Russian Federation.

C-Tick mark

CE versions of products with a C-Tick mark comply with the EMC regulations required for sale in Australia
and New Zealand.

CCC mark

The China Compulsory Certification (CCC) mark indicates that the product has been tested and found
compliant with product safety regulations required for sale in China.

UkrSEPRO mark

The CE versions of products that include a UkrSEPRO mark of conformity meet the product safety and EMC
requirements for export to the Ukraine.

Serbian AAA mark

CE versions of products that include a AAA Serbian mark meet the product safety and EMC requirements for
export to Serbia.

EDGE Pro SERCOS III CNC Instruction Manual 807650 37

1 – Specifications

Symbols and Marks

38 EDGE Pro SERCOS III CNC Instruction Manual 807650

Section 2

Installation

Upon receipt

• Verify that all the system components on your order have been received. Contact your supplier if any items are
missing.

• EDGE Pro SERCOS III CNC

• Power cable (North America) (108884)

• Power connector (all other regions) (108842)

• EDGE Pro SERCOS III CNC instruction manual (807650)

• Phoenix software instruction manuals (806400, 806410, 806420)

• Any other optional components that appear on your order form

• Inspect the system components for any physical damage that may have occurred during shipping. If there is evidence
of damage, refer to the following topic, Claims on page 39. All communications regarding claims must include the
model number and serial number located on the back of the CNC.

• Record your product information on the inside front cover of this manual, then use the instructions there to register
your product’s serial number at www.hypertherm.com.

Claims

Claims for damage during shipment – If your unit was damaged during shipment, you must file a claim with the carrier.
Hypertherm will furnish you with a copy of the bill of lading upon request. If you need additional assistance, call Customer
Service listed in the front of this manual, or your authorized Hypertherm distributor.

Claims for defective or missing merchandise – If any of the merchandise is defective or missing, contact your supplier.
If you need additional assistance, call Customer Service listed in the front of this manual, or your authorized Hypertherm
distributor.

Installation requirements

All installation and service of electrical systems must conform to national and local electrical codes. This work should be
performed only by qualified personnel.

EDGE Pro SERCOS III CNC Instruction Manual 807650 39

2 – Installation

Mounting the CNC

Placement of system components

• Place all system components in position prior to making electrical, gas and interface connections. See Mounting the
CNC on page 40 for details.

• Ground all system components to earth. See Recommended grounding and shielding practices on page 43 for
grounding details.

WARNING!

Use a 2-man lift to position the EDGE Pro SERCOS III CNC and avoid bodily injury.

Mounting the CNC

Before you connect the EDGE Pro SERCOS III CNC to other system components, mount all the components using the
appropriate instructions.

Do not allow the system components to lie unsecured on top of cabinets or on the floor.

40 EDGE Pro SERCOS III CNC Instruction Manual 807650

Enclosure dimensions

36 mm
(1.42 in)

435 mm

(17.13 in)

316 mm

(12.43 in)

21 mm

(0.82 in)

228.5 mm
(9.00 in)

90 mm

(3.50 in)

58 mm

(2.29 in)

Use M6 x 1 hardware for side mounting.

Maximum length inside enclosure must not exceed 7.8 mm (0.31 in.)

491 mm

(19.33 in)

Figure 7 Front and side views of the SERCOS III CNC

2–Installation

Mounting the CNC

EDGE Pro SERCOS III CNC Instruction Manual 807650 41

2 – Installation

Use M6 x 1 hardware.

(10 places)

Maximum length inside

enclosure must not

exceed 7.8 mm (0.31 in.)

305 mm

(12 in)

356 mm

(14 in)

58 mm
(2.29 in)

94 mm
(3.7 in)

203 mm

(8 in)

127 mm

(5 in)

109.2 mm
(4.3 in)

148 mm

(5.8 in)
89 mm
(3.5 in)

Mounting the CNC

Mounting hole patterns on the bottom of the CNC

The EDGE Pro SERCOS III CNC has 10 mounting holes on the bottom of the enclosure for mounting the CNC to the
cutting table. Fasten the mounting screws through the holes that will provide the most stability for your CNC during the
operation of your table.

Figure 8 EDGE Pro SERCOS III CNC mounting hole pattern

42 EDGE Pro SERCOS III CNC Instruction Manual 807650

2–Installation

Recommended grounding and shielding practices

Recommended grounding and shielding practices

WARNING!

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before performing any maintenance.

All work requiring the removal of the plasma system cover must be performed
by a qualified technician.

See the Safety section of your manual for more safety precautions.

Introduction

This section describes practices for grounding and shielding to protect a plasma cutting system against radio frequency
interference (RFI) and electromagnetic interference (EMI) (also called noise). It also describes the DC power ground and
the service ground. The diagram at the end of this section shows these types of grounds in a plasma cutting system.

The grounding practices in this section have been used on many installations with excellent results, and Hypertherm



recommends that these practices be a routine part of the installation process. The actual methods used to implement
these practices may vary from system to system, but should remain as consistent as possible. However, due to the
variation in equipment and installations, these grounding practices may not succeed in every case to eliminate RFI/EMI
noise issues.

Types of grounding

Service ground (also called safety ground or potential earth (PE) ground) is the grounding system that applies to the

incoming line voltage. It prevents a shock hazard to any personnel from any of the equipment or the cutting table. It
includes the service ground coming into the plasma system and other systems such as the CNC and the motor drives, as
well as the supplemental ground rod connected to the cutting table. In the plasma circuits, the ground is carried from the
plasma system chassis to the chassis of each separate console through the interconnecting cables.

DC power ground (also called cutting current ground) is the grounding system that completes the path of the cutting
current from the torch back to the plasma system. It requires that the positive lead from the plasma system be firmly
connected to the cutting table ground bus with a properly sized cable. It also requires that the slats, on which the
workpiece rests, make firm contact with the table and the workpiece.

RFI and EMI grounding and shielding is the grounding system that limits the amount of electrical noise emitted by
the plasma and motor drive systems. It also limits the amount of noise that is received by the CNC and other control and
measurement circuits. The grounding practices described in this section mainly target RFI and EMI grounding and
shielding.

Grounding practices

1. Unless noted, use only 16 mm2 (6 AWG) welding cables (047040) for the EMI ground cables shown on the diagram
at the end of this section.

2. The cutting table is used for the common, or star, EMI ground point and should have threaded studs welded to the
table with a copper bus bar mounted on them. A separate bus bar should be mounted on the gantry as close to

EDGE Pro SERCOS III CNC Instruction Manual 807650 43

2 – Installation

Recommended grounding and shielding practices

each motor as possible. If there are motors at each end of the gantry, run a separate EMI ground cable from the

2

far motor to the gantry bus bar. The gantry bus bar should have a separate, heavy EMI ground cable 21.2 mm
(4 AWG; 047031) to the table bus bar. The EMI ground cables for the torch lifter and the RHF console must each
run separately to the table ground bus.

3. A ground rod that meets all applicable local and national electrical codes must be installed within 6 m (20 ft) of the

2

cutting table. This is a PE ground and should be connected to the cutting table ground bus bar using 16 mm
(6 AWG) green and yellow grounding cable (047121) or equivalent.

4. For the most effective shielding, use the Hypertherm CNC interface cables for I/O signals, serial communication
signals, between plasma systems in multi-drop connections, and for interconnections between all parts of the
Hypertherm system.

5. All hardware used in the ground system must be brass or copper. While you can use steel studs welded to the
cutting table for mounting the ground bus, no other aluminum or steel hardware can be used in the ground system.

6. AC power, PE, and service grounds must be connected to all equipment according to local and national codes.

7. For a system with a remote high frequency console (RHF), the positive, negative, and pilot arc leads should be

bundled together for as long a distance as possible. The torch lead, work lead, and the pilot arc (nozzle) leads may be
run parallel to other wires or cables only if they are separated by at least 150 mm (6 inches). If possible, run power
and signal cables in separate cable tracks.

8. For a system with an RHF console, the ignition console should be mounted as closely as possible to the torch, and
must have a separate ground cable that connects directly to the cutting table ground bus bar.

9. Each Hypertherm component, as well as any other CNC or motor drive cabinet or enclosure, must have a separate
ground cable to the common (star) ground on the table. This includes the ignition console, whether it is bolted to the
plasma system or to the cutting table.

10. The metal braided shield on the torch lead must be connected firmly to the ignition console and to the torch. It must
be electrically insulated from any metal and from any contact with the floor or building. The torch lead can be run in a
plastic cable tray or track, or covered with a plastic or leather sheath.

11 . The torch holder and the torch breakaway mechanism – the part mounted to the lifter, not the part mounted to the

torch – must be connected to the stationary part of the lifter with copper braid at least 12.7 mm (0.5 inches) wide. A
separate cable must run from the lifter to the gantry ground bus bar. The valve assembly should also have a separate
ground connection to the gantry ground bus bar.

12. If the gantry runs on rails that are not welded to the table, then each rail must be connected with a ground cable from
the end of the rail to the table. The rail ground cables connect directly to the table and do not need to connect to the
table ground bus bar.

13. If you are installing a voltage divider board, mount it as closely as possible to where the arc voltage is sampled.
One recommended location is inside the plasma system enclosure. If a Hypertherm voltage divider board is used, the
output signal is isolated from all other circuits. The processed signal should be run in twisted shielded cable
(Belden 1800F or equivalent). Use a cable with a braided shield, not a foil shield. Connect the shield to the chassis
of the plasma system and leave it unconnected at the other end.

14. All other signals (analog, digital, serial, and encoder) should run in twisted pairs inside a shielded cable. Connectors
on these cables should have a metal housing. The shield, not the drain, should be connected to the metal housing of
the connector at each end of the cable. Never run the shield or the drain through the connector on any of the pins.

44 EDGE Pro SERCOS III CNC Instruction Manual 807650

2–Installation

1 Gantry ground bus

2 Ground rod

3 Plasma system lead (+)

4 Remote high frequency (RHF) console

5 CNC enclosure

6 Torch holder

7 Plasma system chassis

1 2 3 4 5 6

7

1 Cable to the cutting table ground bus

2 Ground cables from components on the gantry

1 2

Recommended grounding and shielding practices

The following picture shows an example of a cutting table ground bus. The components shown here may differ from your
system.

The following picture shows an example of a gantry ground bus. It is bolted to the gantry, close to the motor. All of the
individual ground cables from the components mounted on the gantry connect to the bus. A single heavy cable then
connects the gantry ground bus to the table ground bus.

EDGE Pro SERCOS III CNC Instruction Manual 807650 45

2 – Installation

Chassis and RFI ground

AC earth ground

1

2

3

4

5

6

7

8 9

10

11

12

13

1 Cutting table
2 Gantry
3 Plasma system
4 Table ground bus bar
5 Gantry ground bus bar
6 Torch height control lifter (ArcGlide, Sensor THC,

Sensor PHC, or other)

7 RHF console (not on all systems). Connect to table

ground bus bar.

8, 9 System-specific component such as metering

console, gas console, or selection console

10 CNC chassis
11 Torch height control module

(ArcGlide, Command THC)

12 System-specific component such as a cooler or

chiller

13 DC power ground

Recommended grounding and shielding practices

The following diagram shows an example of grounding the components in a plasma cutting system.

46 EDGE Pro SERCOS III CNC Instruction Manual 807650

2–Installation

X-

Y-

Y+

X+

1

EDGE Pro SERCOS III CNC

2

CNC operator console

3

Table origin and Home position (0,0)

3

2

X and Y axis configuration

X and Y axis configuration

To configure the X and Y axes, first decide which axis on the table will be the X axis and where the home position will be.

Next, define the X and Y orientation and home position in Phoenix software (Setups > Password > Machine Setups) to
match the configuration you want on the table. The definition of the axes orientation and home position in software and on
the table must agree so the system can execute the part programs as expected.

Figure 9 Example of a shape cutting system configured with an EDGE Pro SERCOS III CNC

1

EDGE Pro SERCOS III CNC Instruction Manual 807650 47

2 – Installation

The operator console

The operator console

The EDGE Pro SERCOS III CNC comes with a 2-station operator console that allows you to operate two cutting
torches or stations.

The operator console allows you to:

• Start and stop the cutting program

• Switch to manual mode

• Manually jog the torch with the joystick

• Jog forward or backward on path

• Adjust the jog and cutting feed rates

• Activate or deactivate the 2 cutting stations

The device I/O for the operator console are assigned to Input and Output 129 and higher, as listed in Table 3.

Operator console and dedicated I/O

The I/O for the devices on the operator console of the CNC are all pre-assigned as factory defaults. These I/O
assignments begin at 129.

Table 3 Operator console and dedicated I/O assignments

Function Input No. Output No.

Front Panel Start 129
Front Panel Stop 130
Front Panel Manual 131
Front Panel Forward On Path 132
Front Panel Backward On Path 133
Jog Up 134
Jog Down 135
Jog Left 136
Jog Right 137
Auto Select 1 138
Manual Select 1 139
Raise Torch 1 140
Lower Torch 1 141
Auto Select 2 142
Manual Select 2 143
Raise Torch 2 144
Lower Torch 2 145
Station Enable LED 1 129
Station Enable LED 2 130
Speed Pot 1 (Program Speed) Analog Input 1
Speed Pot 2 (Jog Speed) Analog Input 2
Scaled interior temperature Analog Input 4

Note: If you load a setup file from a different Hypertherm CNC, these I/O assignments will not change.
Phoenix software restores these assignments the next time it starts up.

48 EDGE Pro SERCOS III CNC Instruction Manual 807650

2–Installation

AC Power connector
Voltage range: 115 to 240 V, single phase
Fuse size: 250 V, 2 Amp, slow-blow,
5 mm x 20 mm (2) or 0.25 in. x 1.25 in. (1)

Ground nut and lock washer 1/4 in. – 20 UNC

EDGE Pro SERCOS III CNC (as shipped)

Power entry module:
2 Fuses: 250 V, 2A, slow blow, 5 mm x 20 mm

EDGE Pro SERCOS III CNC (as shipped)

Power entry module:
2 Fuses: 250 V, 2 A, slow blow, 5 mm x 20 mm

Customer-supplied power

L1 – line
L2 – line

PE ground

L1 – line

L2 – neutral

PE ground

Customer-supplied power

AC power

AC power

Power input

Figure 10 AC power input connector illustrates the power input connector on the rear of the EDGE Pro SERCOS III
CNC.

Figure 10 AC power input connector

An AC power cable is standard equipment for North America, and is shipped with the CNC. For other regions, use a
power cable that has an IEC-60320-C13 end which meets the requirements of local code and power connections.

To create a power cable, use the power connector (108842) that ships with the CNC and connect a 3-wire cable for line,
neutral, and ground signals according to local electrical codes. For more electrical specifications, see System
specifications on page 34. Figure 11 shows examples of how power cables can be created.

Figure 11 Input VAC wiring examples

EDGE Pro SERCOS III CNC Instruction Manual 807650 49

2 – Installation

EDGE Pro SERCOS III CNC
(field selectable option)

Power entry module:
1 Fuse: 250 V, 2 A, slow blow, 0.25 in. x 1.25 in.

L1 – line
L2 – line

PE ground

Customer-supplied power

To the star ground on the cutting table.
The ground stud has a 1/4-20 thread.

AC power

Chassis grounding

The CNC must be properly grounded according to national and local electrical codes for safe operation. Use a number

2

16 mm

(6 AWG) wire between the ground stud on the rear of the CNC and the star ground on the cutting table, as

shown in Figure 12.

WAR NING!

ELECTRIC SHOCK CAN KILL

This ground connection must be wired for safe and reliable operation.

Figure 12 Ground cable on the SERCOS III CNC

50 EDGE Pro SERCOS III CNC Instruction Manual 807650

2–Installation

Communication interfaces

Communication interfaces

Figure 13 illustrates the interface ports and their location on the rear of the EDGE Pro SERCOS III CNC.

Figure 13 Interface ports

Hypernet interface

The Hypernet interface allows the EDGE Pro SERCOS III CNC to connect to an ArcGlide THC and plasma system
using the Hypernet protocol over shielded, Ethernet Cat-5e cables. This configuration must include an industrial-grade
Ethernet switch to route communication from the EDGE Pro SERCOS III
Parts List for Hypernet cable lengths and part numbers.

LAN interface

CNC to the other units in the system. See

The RJ-45 LAN interface allows the EDGE Pro SERCOS III CNC to connect to a local area network (LAN) for
downloading parts and using Remote Help. See Parts List for LAN cable lengths and part numbers.

For more information on setting up the CNC to communicate over a LAN, see the Phoenix Software V9 Series
Installation and Setup Manual (806410).

USB interface

The USB 2.0 port on the back of the EDGE Pro SERCOS III CNC, like the one on the operator console, can be used to
load programs or to connect a USB keyboard or mouse.

Serial ports

The two serial RS-232/RS-422 ports on the back of the EDGE Pro SERCOS III CNC are configurable ports and
accept D-sub 9-pin connectors. Transmission rate is up to 115K Baud. Both ports are preset for RS-422 as the default.
For more information, see Utility and serial isolation board on page 78.

Wireless antennas

The wireless antennas on the back of the EDGE Pro SERCOS III CNC are connected to the wireless network board
(141223). The wireless board conforms to 802.11N and 802.11G standards and connects to either a wireless G or N
LAN. It provides wireless G or better performance for part program downloads, Remote Help, or other network tasks.
For information about connecting your CNC to a wireless network, see Networking in the Phoenix Software V9 Series
Installation and Setup Manual (806410).

EDGE Pro SERCOS III CNC Instruction Manual 807650 51

2 – Installation

SERCOS III board
(141310) is installed in
PCI slot 4

SERCOS III I/O configuration

SERCOS III I/O configuration

The EDGE Pro SERCOS III I/O configuration conforms to the SERCOS III standard. The full details of this specification
cannot be addressed in this manual. For a complete description of SERCOS III technology and specifications, refer to
http://www.sercos.com.

Figure 14 Rear panel for EDGE Pro SERCOS III CNC

Figure 15 Location of the SERCOS III master board

52 EDGE Pro SERCOS III CNC Instruction Manual 807650

2–Installation

2

1

1

P1A

2

P2A

SERCOS III Cable

SERCOS III Cable

A Cat-5e Ethernet cable connects the SERCOS III I/O interface on the rear of the CNC enclosure to the drive amplifier
cabinet. A minimum of one cable is required for this connection to create a single SERCOS III line that connects Port 1
(P1) on the CNC and all the SERCOS III drives in the drive amplifier cabinet.

To create a SERCOS III ring that will provide communication redundancy and security, connect a second cable between
Port 2 (P2) on the CNC and the drive amplifier cabinet.

Within the drive amplifier cabinet, the amplifiers are connected, in a series, by short jumper cables. Purchase these
cables, in the appropriate lengths, from your drive supplier.

See Figure 17 for the location of P1 and P2.

Figure 16 SERCOS III cable

Figure 17 SERCOS III ports

To create a SERCOS III line or ring topology, order one or two of the following Hypertherm cables. If you use Ethernet
cables from another supplier, verify that the cable is a standard, shielded RJ-45 Cat-5e cable or better.

Part number Length

223212 3.0 m (10 ft)
223222 6.0 m (20 ft)
223119 7.5 m (25 ft)
223223 10.5 m (35 ft)
223008 15.0 m (50 ft)
223099 23.0 m (75 ft)
223100 30.5 m (100 ft)
223101 45.5 m (150 ft)
223102 61.0 m (200 ft)

EDGE Pro SERCOS III CNC Instruction Manual 807650 53

2 – Installation

SERCOS III Cable

54 EDGE Pro SERCOS III CNC Instruction Manual 807650

Section 3

1

Data transfer

2

Power switch

3

Program execution controls

4

Station controls

5

Manual motion controls

4

5

3

2

Operation

Operating the CNC

The EDGE Pro CNC supports a touchscreen with an optional USB-connected keyboard and mouse for entering
information and navigating the software. For more information, see the Phoenix Software Operator Manual (806400).

For more information about the components of your cutting system that are supplied by your table manufacturer, refer to
the manuals supplied by the manufacturer.

An operator console powers up the CNC and controls machine motion such as station selection, raising or lowering the
cutting tool, and positioning the cutting tool before starting a part program.

Figure 18 The EDGE Pro operator console is shown below.

1

EDGE Pro SERCOS III CNC Instruction Manual 807650 55

3 – Operation

Operating the CNC

Touchscreen LCD

The Phoenix software is designed for touchscreens with 1024 x 768 resolution. You can enter data into the software by
touching the window controls and fields. Any field that requires data input automatically displays an on-screen keypad
when you double-tap it.

Touchscreens, drops of water, and unintended motion

Drops of water can be a safety concern if the CNC is installed on an X-Y water table and the Watch Window displays jog
keys. If water splashes from the table onto the touchscreen, the drops can activate a jog key and create unintended
motion on the table. Unintended motion can result in danger to the operator and other people, damage to machinery,
or faults in cutting. To prevent motion caused by drops of water on the touchscreen:

• Insure that your hands are dry when you use the touchscreen.

• Install the CNC so that the touchscreen is shielded from water splashes.

• If water could accidently hit the touchscreen, do not display the jog keys in the Watch Window.

For additional information, contact your local Hypertherm Technical Service team.

Screen navigation

The keys located at the bottom of the screen in the software are called soft keys. The soft keys correspond to function
keys on a PC keyboard. OK and Cancel soft keys let you save or cancel changes that you make in a screen.

For more information, refer to the Phoenix Software Operator Manual (806400).

Note: The features shown on each screen vary depending on the user level (Beginner, Intermediate, or Advanced)
and the features enabled on the Special Setups and Station Configuration screens. This manual assumes the
CNC is in Advanced Mode and shows all features.

56 EDGE Pro SERCOS III CNC Instruction Manual 807650

Help

Choose the Help soft key to display information about each screen

Choose the OK soft key to exit the Help screen and return to the control screen.

3–Operation

Operating the CNC

The Show Bookmarks soft key opens the navigation pane.

View additional manuals

The Help screen may also display soft keys for other types of information, for example:

• Manuals for the Hypertherm equipment installed with your CNC, such as plasma systems or torch

height controls.

• Manuals for equipment provided by your table manufacturer.

Choose any of these keys to view this additional information.

EDGE Pro SERCOS III CNC Instruction Manual 807650 57

3 – Operation

Automated operations

Show bookmarks

Note: Choose the Show Bookmarks soft key on the Help screen to view the list of Help topics. Click on a topic

in the list to view it.

Automated operations

The Phoenix software includes two wizards that automate workpiece alignment and part cutting operations.

Align Wizard

The Align Wizard automates several tasks including aligning a nest on a workpiece, adjusting for a skewed workpiece,
and positioning the torch at the program start location.

To start the Align Wizard, choose Current Part Options on the Main screen, then choose Align. The Align Wizard may
launch automatically. If not, choose the Align Wizard soft key.

For more information, see Align Wizard in the Phoenix Software V9 Series Operator Manual (806400).

58 EDGE Pro SERCOS III CNC Instruction Manual 807650

3–Operation

Updating Phoenix software

CutPro Wizard

The CutPro Wizard automates common cutting tasks including loading a part or nest, selecting the cutting process,
aligning the part or nest on the workpiece, and starting the program.

The CutPro Wizard may launch automatically when you start the CNC. If not, choose the CutPro Wizard soft key on the
Main screen to start the wizard. For more information on the CutPro Wizard see Cutting Parts in the Phoenix Software V9
Series Operator Manual (806400).

Updating Phoenix software

Hypertherm provides regular updates to the Phoenix software. You can download the most current software from the
website www.hypertherm.com. Choose Products > Automated cutting > Controls > Phoenix software updates to open
the Phoenix Software Update downloads page. On this page you can download:

• Phoenix software update (update.exe)

• Phoenix Help file (Help.exe)

• Cut charts (CutChart.exe)

To download the updates in your language, follow the instructions in the Release Notes document on the Phoenix
Software Update downloads page.

Before you update the Phoenix software, follow these guidelines:

• Back up your system files: On the Main screen, choose Files > Save to Disk > Save System Files to

Disk. See Saving System Files in Diagnostics and Troubleshooting in the Phoenix Software Operator
Manual (806400) for more information.

• Copy the files that you download from Hypertherm.com to the root folder of a USB memory stick.

The CNC cannot read files inside folders.

• Be prepared to restart the CNC after you have updated the software.

Updating the software

1. At the CNC, plug the memory stick that contains the file update.exe into a USB port.

Note: Verify that update.exe resides in the root folder of the memory stick.

2. On the Main screen, choose Setups > Password. Double-tap the screen to display an on-screen keyboard.

3. Enter UPDATESOFTWARE (all upper case, one word) and choose Enter. The Phoenix software automatically reads

the memory stick and installs the new software.

Updating the Help

1. At the CNC, plug the memory stick that contains the file Help.exe into a USB port.

Note: Verify that Help.exe resides in the root folder of the memory stick.

2. On the Main screen, choose Setups >Password. Double-tap the screen to display an on-screen keyboard.

3. Enter UPDATEHELP (all upper case, one word) and choose Enter. The Phoenix software automatically reads the

memory stick and installs the new help file.

Updating the cut charts

Hypertherm provides cut charts in two different file types: .fac and .usr. The .fac files are the factory-default cut charts.
These cut charts cannot be changed. The .usr cut charts contain any changes you have made to a cut chart and saved
with the Save Process soft key.

The cut chart update file (CutChart.exe) contains both .fac and .usr cut chart files. The update automatically overwrites all
.usr cut charts. Before installing the update, back up your modified cut charts.

EDGE Pro SERCOS III CNC Instruction Manual 807650 59

3 – Operation

Updating Phoenix software

Hypertherm recommends saving modified cut charts as custom cut charts. When you create a custom cut chart, Phoenix
creates a .usr file with a unique name. This prevents the custom cut charts from being overwritten by the .usr files in
CutChart.exe. See the Phoenix Software Operator Manual (806400) for instructions.

To back up modified cut charts:

1. At the CNC, insert a memory stick into a USB port.

2. On the Main screen, choose one of the cut chart soft keys, such as Plasma 1 Cut Chart.

3. Choose the Save Cut Charts soft key. Phoenix copies all the cut charts associated with the Plasma 1 Power Supply
Type onto the memory stick.

To update the cut charts:

1. At the CNC, plug the memory stick that contains the file CutChart.exe into a USB port.
Note: Verify that CutChart.exe resides in the root of the memory stick. The CNC cannot read files inside folders.

2. On the Main screen, choose Process, and choose one of the cut chart soft keys such as Plasma 1 Cut Chart.

3. Choose the Load Cut Charts soft key, then choose Yes when prompted to load cut charts from the memory stick.
Phoenix extracts the cut charts and copies them to the hard drive.

®

4. If you have modified cut charts to copy back onto the hard drive, you will need to exit Phoenix and use Windows
Explorer to copy your .usr files back onto the hard drive. The cut chart folder is c:\Phoenix\CutCharts.

60 EDGE Pro SERCOS III CNC Instruction Manual 807650

Section 4

Maintenance and Diagnostics

WARNING!

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before performing any maintenance.

Only qualified personnel can work inside the CNC cabinet with AC power connected.

See Safety on page 11 for more safety precautions.

Introduction

Hypertherm assumes that the service personnel who perform troubleshooting testing are high-level electronic service
technicians who have worked with high-voltage electro-mechanical systems. Knowledge of final isolation troubleshooting
techniques is also assumed.

In addition to being technically qualified, maintenance personnel must perform all testing with safety in mind. For more
information, see Safety on page 11 for operating precautions and warnings.

Care and handling of the touchscreen

The following tips will help keep the touchscreen functioning at the optimal level:

• To clean the touchscreen, use window or glass cleaner. Put the cleaner on a soft clean rag and wipe
the touchscreen. Never apply the cleaner directly to the touchscreen.

• Avoid getting liquids inside your touchscreen. If liquid does get inside, have a qualified service
technician check it before you power it on again.

• Do not wipe the screen with a cloth or sponge that could scratch the surface.

• Do not use alcohol (methyl, ethyl or isopropyl) or any strong solvent. Do not use thinner or benzene,
abrasive cleaners or compressed air.

EDGE Pro SERCOS III CNC Instruction Manual 807650 61

4 – Maintenance and Diagnostics

Diagnostic tests

Diagnostic tests

Machine interface tests

You can perform diagnostic tests with the following connectors (in kit 228512) and Phoenix software to test the interface
ports on the EDGE Pro SERCOS III CNC:

• LAN and Hypernet (228503)

• Serial interface (228504)

• USB (228505)

To begin an interface test:

1. From the Main screen, choose Setups > Diagnostics > Machine Interface.

2. Enter the Machine password.

3. On the Machine Interface screen, choose the connector you want to test on the image of the CNC.

4. Follow the instructions in the following topics and on the individual test screens.

LAN and Hypernet tests

The LAN and Hypernet tests both use the same tester, shown in Figure 19.

Figure 19 LAN and Hypernet tester

Conduct this test if:

• The CNC is not communicating with the ArcGlide or plasma system.

• The CNC is not communicating with the local area network.

To test a LAN or Hypernet port:

1. On the Machine Interface screen, choose the LAN or Hypernet port.

2. Follow the instructions on the screen to plug in the tester.

3. Choose Test on the Hypernet or LAN test screen. A message informs you if the test is successful.

4. If either test fails, run the test on the motherboard. If the test fails again, replace the internal cable (223010, 223011,
or both).

5. Repeat the test. If the test fails again, replace the motherboard (141110).

62 EDGE Pro SERCOS III CNC Instruction Manual 807650

4 – Maintenance and Diagnostics

Diagnostic tests

Serial test

The EDGE Pro is equipped with two serial ports. Serial 1 and 2 support RS-422 or RS-232 communications, depending
on the jumper position. For more information, see Utility and serial isolation board (141307) on page 78.

Figure 20 Serial tester

Conduct this test if:

• Processes or information communicated through the serial port are not operating properly.

• The CNC is unable to download files through the serial port.

• The serial link to the plasma supply fails.

To test serial communications with the test hardware:

1. On the Machine Interface screen, choose the serial port you want to test.

2. On the CNC, plug the serial test hardware into the port you selected.

3. Choose Test on the serial test screen. A message informs you if the test is successful.

4. If the test fails, plug the tester into one of the serial ports on the motherboard and choose Test again.

5. If the test passes, contact your table manufacturer to replace the utility and serial isolation board (141307).

If you do not have the hardware tester, use the online serial diagnostic test. Choose Setups > Diagnostics > Ports and
follow the instructions on the screen.

USB test

Use this test to check the USB ports on the front and back of the CNC. The diagnostic software will test the first USB
memory stick that it finds, so it is important to remove all USB memory sticks before conducting this test.

Figure 21 USB tester

Conduct this test if the memory stick is not shown as an option when you try to load or save part programs or update cut
charts, software, or Help.

To test the USB port on the back of the CNC:

1. Verify that no USB memory stick is installed.

2. On the Machine Interface screen, choose the USB port on the back of the CNC.

3. Follow the instructions on the screen to insert the memory stick in the USB port on the back of the CNC.

4. Press Test. A message informs you if the test is successful.

EDGE Pro SERCOS III CNC Instruction Manual 807650 63

4 – Maintenance and Diagnostics

Diagnostic tests

To repeat this test for the USB port on the front of the CNC:

1. Verify that no USB memory stick is installed.

2. On the Operator Interface screen, choose the USB port on the front of the CNC.

3. Follow the instructions on the screen to insert the memory stick in the USB port on the front of the CNC.

4. Press Test. A message informs you if the test is successful.

If the test fails on a USB port, contact your table manufacturer to replace the motherboard (141110).

Operator console test

Perform these tests if any function on the integrated operator console is not working as expected.

Note: None of the components on the screen allow motion or any action to take place on the CNC or cutting table.

To test the controls on the operator console:

1. On the Machine Interface screen, press the Operator Interface soft key.

2. On the Operator Interface screen, follow the instructions on the screen and in the following steps.

3. To test the USB port, touch it on the picture on the Operator Interface screen then follow the instructions on the
screen.

4. To test the indicator lamps for Station 1 or 2, touch the corresponding light on the picture on the Operator Interface
screen.

5. You can also operate any component on the operator console of the CNC and watch the corresponding component
on the screen. Verify that the operation of the component on the screen matches what you do on the console.

6. If the test for a single component fails, replace that component.

If multiple components fail, contact your table manufacturer to replace one or all of the following parts:

• Ribbon cable to the operator console board

• Operator console board (141058)

• Utility and serial isolation board (141307)

(223013)

64 EDGE Pro SERCOS III CNC Instruction Manual 807650

4 – Maintenance and Diagnostics

Troubleshooting

Troubleshooting

Hypertherm assumes that the service personnel performing the troubleshooting are high-level electronic service
technicians who have worked with high-voltage electro-mechanical systems. Knowledge of final isolation troubleshooting
techniques is also assumed.

In addition to being technically qualified, service personnel must perform all tests with safety in mind. See Safety on
page 11 for operating precautions and warnings.

WARNING!

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before performing any maintenance.

Only qualified personnel can work inside the CNC cabinet with AC power connected.

See the Safety section in this manual for more safety precautions.

WARNING!

MOVING PARTS CAN CAUSE DAMAGE AND INJURY

To avoid unexpected machine motion and personal injury, disconnect the motor drive mechanics
responsible for table and component movement before using the Drive Diagnostics screen.

To avoid damage to the THC and motors, use extreme caution when you select the TEST THC soft key
or the TEST ALL soft key on the Drive Diagnostics screen.

CAUTION!

Turn OFF power to the CNC whenever you remove or reconnect a cable.

The procedures on the following pages provide information about solving problems that you could encounter during
operation of your CNC.

EDGE Pro SERCOS III CNC Instruction Manual 807650 65

4 – Maintenance and Diagnostics

Troubleshooting

Power

The CNC does not turn on when the ON/OFF button is pressed.

1. Verify that the power cord is plugged into the back of the CNC.

2. Verify that the wall circuit breaker is active.

3. Verify that the fuse in the power entry module is functional. Replace it, if necessary (008872).

4. Open the CNC enclosure and verify that the D6 AC lamp is illuminated on the power distribution board.
Seepage76.

5. If the lamp is not illuminated, replace the surge board or the power entry harness (kit 228464). See Surge board
(141134) on page 75 or Power distribution board (141153) on page 76.

6. Verify the connections for the ON/OFF switch on the operator console.

7. Verify that the green LED on the motherboard is illuminated. This LED indicates power is reaching the motherboard.
See page 74. If it is not illuminated, replace the ATX power supply (kit 228473), or contact your table manufacturer
for additional troubleshooting.

8. Check the 2-digit code in the POST display on the motherboard. The 00 code indicates that Windows can boot up;
all other codes indicate that Windows cannot boot up.

9. Verify that the green and white wires from the utility and serial isolation board (141307) are connected to the
motherboard.

10. Contact your table manufacturer.

The “Field power failure” error message is posted on the CNC.

1. Verify that the cable between the utility and serial isolation board (141307) and the power distribution board
(141153) is connected at both ends.

2. Verify that all other cables are properly connected.

3. Verify that the ATX power supply is operating.

4. Verify that the LEDs on the power distribution board are illuminated. See page 76.

5. If the LEDs on the power distribution board are not illuminated, replace the board.

The power switch is on and illuminated, but the touchscreen remains black.

1. Verify that the AC power connections are plugged into the touchscreen.

2. Verify that the VGA cable is connected to both the touchscreen and the motherboard.

3. Look at the motherboard to see if there is a BIOS fault (any code except 00).

4. Verify that the ambient temperature is within the operating range of the CNC. See System specifications on page 34.

Operator console

A button, function, or LED on the operator console is not responding when the corresponding switch is activated by the
operator.

1. Choose Setups > Diagnostics > Operator Interface.

2. Move or press any of the components on the physical operator console to verify the proper operation on the CNC
screen.

66 EDGE Pro SERCOS III CNC Instruction Manual 807650

4 – Maintenance and Diagnostics

Troubleshooting

3. If any of these tests fail:

• Verify that I/O for the operator console is set up correctly in Phoenix software. See Phoenix Software V9 Series
Installation and Setup Manual (806410) for details.

• Replace the individual component on the operator console (see Parts List for the appropriate part number).

Input failure

Contact your table manufacturer if you experience any of the following problems:

• An input is in an unexpected state or fails to change state.

• The table is not performing as set up when reaching limit switches.

• A continuous fault is occurring and will not clear.

Output failure

Contact your table manufacturer if you experience any of the following problems:

• An output is in an unexpected state or fails to change state.

• A continuous fault is occurring and will not clear.

Hypernet connection

Communications with components connected to the Hypernet are not working properly. See Diagnostic tests on
page 62.

LAN connection

• Downloading part programs over the LAN is not working properly.

• Previously mapped network drives are not shown when trying to load a part program.

If you have the test hardware, see Diagnostic tests on page 62.

If you do not have the test hardware, contact your local network administrator to test the device and local network
connections.

Serial communication issues

• Processes and information communicated through the serial ports are not operating properly.

• P-S link fail messages are occurring.

• You cannot download files over a configured serial port.

• HPR-link fail messages are occurring when the CNC uses serial communications with the HPR.

Note: This test only works with RS-422 configured ports. Refer to Utility and serial isolation board (141307) on
page 78 for information about how to determine whether the port is set up for RS-422.

With the serial port hardware tester

1. In Phoenix, choose Setups > Diagnostics > Machine Interface and enter the Machine password.

2. Test each of the serial port connectors on the back of the CNC by pressing one of the serial port connectors on the
touchscreen and following the on-screen instructions.

3. If the test passes, verify that the ports are set up for RS-422 or RS-232, as needed by the external components
connected to the serial port.

4. If the test fails, replace the following items one at a time and repeat the tests after each replacement:
a. Utility and serial isolation board (141307)
b. Ribbon cable (229245, 229249, or 229250)

EDGE Pro SERCOS III CNC Instruction Manual 807650 67

4 – Maintenance and Diagnostics

Troubleshooting

Without the serial port tester

1. Verify that the serial jumpers on the utility and serial isolation board (141307) are set properly, for RS-422 or
RS-232, for the device you are communicating with.

2. In Phoenix, choose Setups > Diagnostics > Ports and perform the on-screen loop-back test.

3. If the loop-back test fails, verify the connections between the following components:

• Serial isolation board or utility and serial isolation board (141307)

• Ribbon cable (for serial board only, 229245, 229249, or 229250)

• Motherboard (141110)

USB port

If the CNC is not recognizing a device in a USB port:

1. Verify that another computer can read the memory stick.

2. Verify that no other memory sticks are installed. The CNC can only read one memory stick at a time.

3. Verify that all files are on the root of the memory stick. The CNC cannot read files inside folders.

4. In Phoenix, choose one of the following paths:

• Setups > Diagnostics > Machine Interface and enter the Machine password

• Setups > Diagnostics > Operator Interface

5. Press the USB port on the operator console or rear panel on the touchscreen and follow the on-screen instructions.

6. If the test in Step 5 fails, repeat the test using the other USB port (operator console or rear panel).

7. If the test in Step 6 fails, install the memory stick directly into the motherboard and repeat the test.

8. If the test in Step 7 fails, contact Technical Service. The problem is with the motherboard, the USB ports on the
CNC, or the connection cables.

68 EDGE Pro SERCOS III CNC Instruction Manual 807650

4 – Maintenance and Diagnostics

Troubleshooting

Cut quality or plasma performance issues

Press the “Cutting Tips” soft key on the Main screen and follow the on-screen instructions to improve cut quality.

The CNC feels excessively warm

1. Verify that the external fan is running. If it is running slowly, clean the fan.

2. If the fan is not running and ambient temperature is above 20° C (70° F):

a. In Phoenix, choose Setups > Password and enter the FANON password to verify that the fan is enabled.
b. Verify that the internal harness between the fan and the utility board is connected.
c. Remove the fan shroud and verify that the connections to the fan are in place.
d. Replace the external fan (kit 228472).

3. If the external fan is running and the CNC is still excessively warm, open the front door of the CNC and verify that the

internal chassis fan is running. If the fan is not running, replace the internal fan (kit 228474).

Loading files

The CNC is loading files slower than when it was first installed or is taking a long time to perform operations that used to
happen faster.

1. In Phoenix, choose Setups > Password and enter the Special password, then choose System.

2. If all five numbers on the screen are blue, the CNC is performing as designed.

3. If any of the five numbers on the screen are red, the CNC is operating more slowly than is needed for peak

performance.
a. Restart the CNC. After 5 minutes, choose Setups > Password and enter the Special Password, then choose

System and recheck the numbers. If the five numbers are blue, the CNC is operating as expected.

b. If any of the five numbers are red, there may be other programs that are running on the CNC besides Phoenix

that are negatively affecting performance. Close these other programs. Call Technical Service for additional
troubleshooting.

4. If the CNC is having difficulty connecting to the network, files will load slowly. Verify network connections.

EDGE Pro SERCOS III CNC Instruction Manual 807650 69

4 – Maintenance and Diagnostics

Troubleshooting

Wireless troubleshooting

Refer to the Phoenix Software V9 Series Installation and Setup Manual (806410) for information about networking.

Follow these guidelines if you are experiencing problems using the wireless network on your CNC:

• The wireless network board (141223) requires a bus mastering slot on the motherboard. On the
motherboard (141110), PCI slot 1 is not a bus mastering slot. Verify that the wireless board is installed
in PCI slot 2.

• The wireless network board conforms to 802.11N and 802.11G standards and connects to either a
wireless G or N local area network (LAN). It provides wireless G or better performance for part
program downloads, remote help, or other network tasks.

• An 802.11G wireless network can operate at reasonable speeds up to 38 m (125 ft) from the wireless router or

access point, even if the path between the CNC and the access point is obstructed with a wall or door.

• An 802.11N wireless network can operate at reasonable speeds up to 70 m (230 ft) from the wireless router or

access point. However, 802.11N communication requires a clear line of sight between antennas.

• When in doubt, use the 802.11G wireless network connection.
Note: The network must be set to broadcast its SSID for it to be visible as a connection.

• Make sure the wireless network board appears in the Windows Device Manager under the
“Network Adapters” heading, and does not have a yellow ! or ? next to it.

• Use the Windows Network Connections Manager to locate your router or wireless network access
point. Choose Start > Settings > Network Connections.

• If the network connection wizard does not list any company wireless networks, check the network
availability using a Windows XP laptop or other wi-fi device to verify the router or access point
connection is available at that physical location.

• Signal strength diminishes with distance. A wireless network connection does not require 100% signal
strength to be effective (shown as four solid bars on the screen). If the Network Connections Manager
shows two or three signal strength bars, the network connection is reasonable.

• If the connection speed frequently dips below 24 Mbs or signal strength dips below two bars, move
the wireless router or access point closer to the CNC, or add another access point closer to the CNC.

• For best network performance, minimize the number of clients on the wireless network.

• Avoid connecting slower wireless devices to the network (for example, 802.11B devices) as the entire
network may degrade to that level of performance.

70 EDGE Pro SERCOS III CNC Instruction Manual 807650

4 – Maintenance and Diagnostics

Power distribution PCB

Motherboard

Operator console PCB

PCI slots (5)

Component locations and information

Component locations and information

The following pages provide details about the major components of the EDGE Pro SERCOS III CNC. Refer to Parts List
for the corresponding replacement kits and part numbers.

Note: Use the instructions in Replacement Parts for EDGE Pro CNC Field Service Bulletin (806440) to replace
parts in the EDGE Pro CNC. In addition:

• Use common safety precautions when replacing parts in the CNC.

• Turn off electrical power to the CNC before opening panels on the enclosure.

• Use common safety precautions when handling printed circuit boards.

• Store PC boards in anti-static containers.

• Wear a grounded wrist strap when handling PC boards.

Figure 22 Front internal view of the EDGE Pro SERCOS III CNC

EDGE Pro SERCOS III CNC Instruction Manual 807650 71

4 – Maintenance and Diagnostics

J1

J2

J3

J4

J5 J6

J7

J8

J10

J9

J11

J13

J12

J14 J15

J16

Operator console board (141058)

Operator console board (141058)

Figure 23 Operator console board

72 EDGE Pro SERCOS III CNC Instruction Manual 807650

4 – Maintenance and Diagnostics

Operator console board (141058)

Tabl e 4 Pin outs f or J1 – J16

Pin no. Signal Pin no. Signal Pin no. Signal

J1 Station 2 J7 To utility PCB J8 Joy stick

1 Auto select 2 1 Start 1 Up
2 Logic ground 2 Stop 2 Down
3 Manual select 2 3 Manual 3 Left
4 Not used 4 Forward on path 4 Right

J2 Jog potentiometer

1 Logic ground 6 Joystick +Y 6 Logic ground
2 Analog (jog speed) 7 Joystick -Y

3 4.096 V reference 8 Joystick -X 1 Logic ground

J3 Station 1

1 Auto select 1 10 Logic ground
2 Logic ground 11 Logic ground 1 Logic ground

3 Manual select 1 12 Not connected

4 Not used 13 Ground

J4 Cut potentiometer

1 Logic ground 15 Logic ground 2 Manual switch
2 Analog (cut speed) 16 Logic ground

3 4.096 V reference 17 Not connected

J5 Stop

1 Logic ground 19 Manual select 1
2 Stop switch 20 Raise torch 1 1 Logic ground

J6 Start

1 Logic ground 22 Auto select 2
2 Start switch 23 Manual select 2 1 Logic ground

5 Backward on path 5 Logic ground

J9 Raise 2

9 Joystick +X 2 Raise torch 2

J10 Raise 1

2 Raise torch 1

Front panel ID 1

Front panel ID 0

14 Not connected

Front panel ID 1

1 Logic ground

J11 Manual

J12 Lower 2

1 Logic ground

Front panel ID 2

18 Auto select 1 2 Lower torch 2

J13 Lower 1

21 Lower torch 1 2 Lower torch 1

J14 Forward

24 Raise torch 2 2 Forward on path
25 Lower torch 2
26 Station enable LED1 1 Logic ground

27 Station enable LED2 2 Backward on path
28 Motherboard On/Off 1

29 Motherboard On/Off 2 1 Logic +12 V
30 Cut speed 2 Motherboard On/Off 1
31 Jog speed 3 Motherboard On/Off 2
32 4.096 V Reference 4 Logic ground
33 Logic +5 V
34 Logic +12 V

J15 Back

J16 Power switch

EDGE Pro SERCOS III CNC Instruction Manual 807650 73

4 – Maintenance and Diagnostics

4

3

2

1

PCI slot 2 PCI slot 3 PCI slot 4 PCI slot 5

SERCOS III Wireless (141223) Utility (141307) SERCOS III master

(141310)

not used

PCI 3

PCI 4

PCI 5

PCI slots

Motherboard
ON/OFF
signals

POST display

(ready state is 00)

SATA connector

for the hard drive

Battery for
CMOS
memory

ATX 12 V power connector

Chassis fan connector

CPU

DIMM1 – 1 GB RAM

ATX power
connector

PS/2 Keyboard

PS/2 Mouse

Serial ports

VGA port

LAN port

Hypernet port

USB ports

PCI 2

PCI 1 (not used)

Power LED

1

COM 1

2

COM 2

3

COM 3

4

COM 4

Motherboard (141110)

Motherboard (141110)

Figure 24 Motherboard

74 EDGE Pro SERCOS III CNC Instruction Manual 807650

Surge board (141134)

J1 From AC power inlet J2 To power distribution board

Figure 25 Surge board

4 – Maintenance and Diagnostics

Surge board (141134)

Table 5 Pinouts for J1 and J2

Pin no. Signal

J1 – From AC power inlet

1 Neutral
2 Line

J2 – To power distribution board (J10)

1 Neutral
2 Line
3 Ground

EDGE Pro SERCOS III CNC Instruction Manual 807650 75

4 – Maintenance and Diagnostics

Note: LED D6 is illuminated at full

brightness when 220 VAC is supplied to
the CNC and at half brightness when
120 VAC is supplied.

LED Signal Color

D15 +5 V Field DC Green
D14 12 V Field DC Green
D13 -12 V Field DC Green
D12 24 V Field DC Green

D11 5 V ATX DC Green

D10 12 V ATX DC Green

D9 -12 V ATX DC Green
D8 External fan Green
D6 AC power Green

LEDs 6 – 15

See table, right, for signals

From the ATX power supply

Power distribution board (141153)

Power distribution board (141153)

Figure 26 Power distribution board

76 EDGE Pro SERCOS III CNC Instruction Manual 807650

4 – Maintenance and Diagnostics

Power distribution board (141153)

Table 6 Pinouts for J1 – J12

Pin no. Signal Pin no. Signal

J1 – Clean DC out J6 – Clean DC out

1 Logic +5 V fused 1 Logic +5 V fused
2 Logic -12 V fused 2 Logic -12 V fused
3 Logic +12 V fused 3 Logic +12 V fused
4 Logic ground 4 Logic ground

J2 – Clean DC in J7 – Utility

1 Logic +5 V 1 Fan disable
2 Logic +12 V 2 Field power good
3 Logic +12 V 3 Logic ground
4 Logic +12 V

5 Logic -12 V 1 Earth ground
6 Logic ground 2 Line 2
7 Logic ground 3 Line 1
8 Logic ground

J3 – External cooling

1 Fan +24 V 2 Line 2
2 Fan interlock 2 3 Earth ground
3 Fan interlock 1

4 Field ground 1 Line 2

J4 – Field DC out

1 Field ground
2 +24 V 1 Logic +12 V

3 +5 V 2 Logic ground
4 -12 V 3 Logic ground
5 +12 V 4 Logic +5 V
6 Field ground

1 Line 1

J10 – AC in (from surge board J2)

2 Line 1 switched

J5 – Field DC out

1 Field ground
2 +24 V
3 +5 V
4 -12 V
5 +12 V
6 Field ground

J8 – Display

J9 – ATX power supply

J11 and J12 HDD

EDGE Pro SERCOS III CNC Instruction Manual 807650 77

4 – Maintenance and Diagnostics

J6 – To motherboard on/off

and power distribution board

J8 – Port B Serial 2

J5 – Port A Serial 1

2x5 Jumpers =

2 connectors

RS-422

RS-232

J4

J7

J1 – To operator console

This board is installed on the motherboard in
PCI slot 3.

Utility and serial isolation board (141307)

Utility and serial isolation board (141307)

Figure 27 Utility and serial isolation board

78 EDGE Pro SERCOS III CNC Instruction Manual 807650

4 – Maintenance and Diagnostics

Utility and serial isolation board (141307)

Table 7 Pinouts for J1 – J8

Pin no. Signal Pin no. Signal

J1 – To and from the operator console J5 – Serial port A, Serial 1

1 Start 1 Not connected
2 Stop 2 Tr ansmit A -
3 Manual 3 Receive A-
4 Forward on path 4 Transm it A+
5 Backward on path 5 Signal ground 1
6 Joystick +Y 6 Not connected
7 Joystick -Y 7 Receive A+
8 Joystick -X 8 Not connected
9 Joystick +X 9 Not connected

10 Ground

11 Ground 1 Field power
12 Front panel ID1 2 Chiller
13 Front panel ID0 3 Logic ground
14 Front panel ID1 4 Motherboard ON/OFF 1
15 Ground 5 Motherboard ON/OFF 2

16 Ground
17 Front panel ID2 1 Not connected
18 Auto select 1 2 Transmit B-

19 Manual select 1 3 Receive B-
20 Raise torch 1 4 Transmit B+
21 Lower torch 1 5 Signal ground 2
22 Auto select 2 6 Not connected
23 Manual select2 7 Receive B+
24 Raise torch 2 8 Not connected
25 Lower torch 2 9 Not connected
26 Station enable LED 1
27 Station enable LED 2
28 Motherboard ON/OFF 1
29 Motherboard ON/OFF 2
30 Cut speed
31 Jog speed
32 4.096 V
33 5 V
34 12 V

J6 – To motherboard on/off and power distribution

J8 – Serial port B, Serial 2

EDGE Pro SERCOS III CNC Instruction Manual 807650 79

4 – Maintenance and Diagnostics

2

1

Port 1A

Port 2A

Port LEDs LED color and state

1

Port 1A Green = linked

2

Port 2A Yellow = transmitting

SERCOS III master board (141310)

SERCOS III master board (141310)

The SERCOS III master board is installed in PCI slot 4 on the motherboard.

Figure 28 SERCOS III master board ports and LEDs

80 EDGE Pro SERCOS III CNC Instruction Manual 807650

Diagnostic kits

Part Kit number Description

Communication testers 228512 Ethernet and Hypernet tester (228503)

Serial interface (RS-232 or RS-422) tester on the utility and serial
isolation board (228504)
USB tester (228505)

Cables

Part Part number Description

SERCOS III, Hypernet, and LAN cables 209195 Ferrite filter

223212 3.2 m (10 ft)
223222 6.08 m (20 ft)
223119 7.62 m (25 ft)
223223 10.66 m (35 ft)
223008 15.25 m (50 ft)
223099 22.86 m (75 ft)
223100 30.48 m (100 ft)
223101 45.72 m (150 ft)
223102 60.96 m (200 ft)

Section 5

Parts List

EDGE Pro SERCOS III CNC Instruction Manual 807650 81

5 – Parts List

765

4

3

2

1

SERCOS III PCB kits

SERCOS III PCB kits

Location Kit number Description
1
2 (PCI 2)
3 (PCI 3)
4 (PCI 4)
5
6
7

Figure 29 SERCOS III PCBs

228450 Operator control panel board (141058)
428063 Wireless board (141223), includes 2 cables and antennas
428001 Utility and serial isolation board (141307)
428071 SERCOS III master board (141310)
228454 Motherboard (141110), with CPU, heatsink/fan, and RAM
228460 Surge board (141134)
228448 Power distribution board (141153)

82 EDGE Pro SERCOS III CNC Instruction Manual 807650

5 – Parts List

Additional kits

Additional kits

Part Kit number Description

ATX power supply 228473 1 U, 400 W, with harness and bracket
Subchassis cooling fan 228474 Internal
CPU fan 428012 Internal
Battery for motherboard 428011 3 V lithium, coin cell, CR2032-type
Fuse (1) for power entry module 008872 250 V 2 A, slow-blow, 0.25 in. x 1.25 in.
Fuses (2) for power entry module 228464 250 V, 2 A, slow-blow, 5 mm x 20 mm
Power entry module 228464 Includes harness and 5 mm x 20 mm fuses
Wireless antenna (2) 428107
Ribbon cable for utility and serial board 229245
USB cable kit 428059
HASP hardware key 228446
Hard drive, SATA 228447 Includes Windows XPe operating system
15-inch LCD touchscreen 228462
Joy stick 228471
Speed potentiometer 228470
Stop switch assembly, red 228468
Start switch assembly, green 228467
Power switch 228465
Station select toggle switch 228469
White pushbutton switch assembly 228463
Hypernet/LAN RJ-45 connector 228445

EDGE Pro SERCOS III CNC Instruction Manual 807650 83

5 – Parts List

Additional kits

84 EDGE Pro SERCOS III CNC Instruction Manual 807650

Section 6

C

Sheet

4-D3

Reference block

Sheet number

Coordinates

Wiring Diagrams

This section contains the wiring diagrams for the system. When you trace a signal path, or reference the Parts List or
Troubleshooting sections, the following conventions will help you understand the organization of the wiring diagrams:

• Sheet numbers are located in the lower, right-hand corner of each page.

• References to other pages use the following connection symbol:

Use the sheet number to find the reference sheet. Line up the coordinates A–D on the Yaxis and numbers 1–4 on the
X axis of each sheet to find the reference blocks (similar to a road map).

EDGE Pro SERCOS III CNC Instruction Manual 807650 85

6 – Wiring Diagrams

Wiring diagram symbols

Wiring diagram symbols

Battery Ground clamp Receptacle

Cap, polarized Ground, chassis Relay, coil

Cap, not polarized Ground, earth Relay, normally closed

Cap, feed-through IGBT Relay, normally open

Circuit breaker Inductor Relay, solid state, AC

Coax shield LED Relay, solid state, DC

Current sensor Lamp Relay, solid state

Current sensor MOV Resistor

DC supply Pin SCR

Diode Socket Shield

Door interlock Plug Shunt

Fan PNP transistor Spark gap

Feed-through LC Potentiometer Switch, flow

Filter, AC

Fuse

Push button,
normally closed

Push button,
normally open

Switch, level,
normally closed

Switch, pressure,
normally closed

86 EDGE Pro SERCOS III CNC Instruction Manual 807650

6 – Wiring Diagrams

Wiring diagram symbols

Switch, pressure,
normally open

Switch, 1 pole, 1 throw

Switch, 1 pole, 2 throw

Switch, 1 pole, 2 throw,
center off

Switch, temperature,
normally closed

Switch, temperature,
normally open

Terminal block Triac

Time delay closed,
NC/off

Time delay open,
NO/off

Time delay open,
NC/on

Time delay closed,
NO/off

Transformer

Transformer, air core

Transfo rmer, c oil

VAC source

Valve, solenoid

Voltage source

Zener diode

Torch symbols

Electrode

Nozzle

Shield

To rc h

Torch, HyDefinition™

EDGE Pro SERCOS III CNC Instruction Manual 807650 87

6 – Wiring Diagrams

Wiring diagram symbols

88 EDGE Pro SERCOS III CNC Instruction Manual 807650

6 – Wiring Diagrams

AC

POWER

INPUT

SHEET 5

229248

PCB14

SURGE

SHEET 5

14113 4

USB

PORT

SHEET 9

HYP LAN

PORT

SHEET 9

LAN

PORT

SHEET 9

POWER

SWITCH

SHEET 8

FAN

INTERIOR

229307

USB

PORT

SHEET 9

PCB4

UTILITY/SERIAL

SHEET 12

1413 07

PCB15

SERCOS 3 MASTER

14131 0

PCB2

PWR DISTRIBUTION

SHEET 5 & 6

14115 3

TOUCHSCREEN

SHEET 5

007047

S ATA

HARD DRIVE

SHEET 5

12 72 4 0

ATX PWR SUPPLY

SHEET 10

229403

PCB3

OPR. PANEL

SHEET 7 & 8

141058

FAN

EXTERIOR

229287

PCB1

MOTHERBOARD

SHEET 9

1 4 111 0

SERIAL 1

SERIAL 2

P1
P2

PCB16

WIRELESS

1412 23

223250

223250

4

3

2

1

8

7

5

D

C

B

A

8

7

5

4

3

2

1

D

C

B

A

4

3

2

1

8

7

5

D

C

B

A

8

7

5

4

3

2

1

D

C

B

A

6

6

Sheet 4 – EDGE Pro CNC with SERCOS III interface

EDGE Pro SERCOS III CNC Instruction Manual 807650 89

6 – Wiring Diagrams

SATA POWER

SATA DATA

CUSTOMER SUPPLIED

1-PHASE 100-240V AC POWER

SEE OPTIONS

TOUCHSCREEN

007047

PCB2

POWER DISTRIBUTION PCB

(WITH INTEGRATED FIELD POWER SUPPLIES)

14115 3

1

2

3

4

5

6

7

8

1 +5V

2 +12V

3 +12V

4 +12V

5 -12V

6 GROUND

7 GROUND

8 GROUND

J3

4 GROUND

3 +12V

2 -12V

1 +5V

1 +5V

2 -12V

3 +12V

4 GROUND

6 GROUND FLD

5 +12V FLD

4 -12V FLD

3 +5V FLD

2 +24V FLD

1 GROUND FLD

1 GROUND FLD

2 +24V FLD

3 +5V FLD

4 -12V FLD

5 +12V FLD

6 GROUND FLD

1

2

3

4

1 +24V

2 FAN XLOCK 2

3 FAN XLOCK 1

4 GROUND

3 LINE/L1
2 NEUTRAL/L2
1 EARTH GROUND

3
2

1

J4 J5

J6 J1 J2

1

2

3

1 FAN DISABLE

2 /FLD PWR GD

3 GROUND

3 NEUTRAL/L2

4 LINE/L1

4
3
2

1 +12V

2 GROUND

3 GROUND

4 +5V

4

3

2

1

J12

J7

J8

J9

BLK

BLK

BLK

BLU

YEL

YEL

YEL

RED

RED

GRN

WHT

BLK

G/Y

WHT

BLK

WHT

BLK

YEL

BLK

BLK

RED

WHT

BLK

J10

1

2

1 NEUTRAL/L2

2 LINE/L1

229323

223025

D6 AC

D8 EXT. FAN

D9 -12V

D10 +12V

D11 +5V

D12 +24V FLD

D13 -12V FLD

D14 +12V FLD

D15 +5V FLD

100-240V AC

ATX PWR 100-240V AC

BLK

YEL

BLU

229273 UTILITY

SHEET

9-A7

AA

AJ

SHEET

9-D7

VGA
223028

USB

WHT

BLK

J2

3

2

1

3 EARTH GROUND

2 LINE

1 NEUTRAL

NEUTRAL 1

1
2

BLK

WHT

NC

LINE 2

PCB14

SURGE PCB

14113 4

J1

AC PWR

INLET

229248

SATA HARD

DRIVE

(PROGRAMMED)

229332

RED
BLK
BLK
YEL

223026

229256

SHEET

9-B7

SHEET

12 - C1

SHEET

10- C7

AB

AC

AD

AI

SHEET

10-B4

229334

229348

SEE PAGE 6 FOR HYPATH, PICOPATH

SERCOS HAS NO CONNECTIONS HERE

229403 ATX PWR SUPPLY

FIELD PWR

TO BACK DOOR INTERFACE

CLEAN PWR

TO BACK DOOR INTERFACE

ATX DC PWR

FIELD DC PWR

J11

4 +5V

3 GROUND

2 GROUND

1 +12V

PE Ground

L1 - Line

L2- Line

PE Ground

L1 - Line

Neutral

CUSTOMER SUPPLIED

POWER

VAC INPUT WIRING

OPTION 3

VAC INPUT WIRING

OPTION 2

CUSTOMER SUPPLIED

POWER

EDGE Pro CNC
Power Entry Module

EDGE Pro CNC
Power Entry Module

2A 250VAC
TD FUSES

2A 250VAC
TD FUSES

2A 250VAC
TD FUSE

EDGE Pro CNC
Power Entry Module

CUSTOMER SUPPLIED

POWER

VAC INPUT WIRING

OPTION 1

Neutral

L1 - Line

PE Ground

4

3

2

1

1

2

3

4

229287

EXTERIOR

FAN

RED

BLK

BLK

1

2
1 EARTH GROUND

G/Y

4

3

2

1

8

7

5

D

C

B

A

8

7

5

4

3

2

1

D

C

B

A

4

3

2

1

8

7

5

D

C

B

A

8

7

5

4

3

2

1

D

C

B

A

EDGE PRO REAR

6

6

Sheet 5 – Power distribution board (141153) and surge board (141134)

90 EDGE Pro SERCOS III CNC Instruction Manual 807650

6 – Wiring Diagrams

SEE SHEET 5

6 GROUND FLD

5 +12V FLD

4 -12V FLD

3 +5V FLD

2 +24V FLD

1 GROUND FLD

1 GROUND FLD

2 +24V FLD

3 +5V FLD

4 -12V FLD

5 +12V FLD

6 GROUND FLD

FROM ATX POWER SUPPLY

SEE SHT 5

SEE SHT 5

HYPATH 24 I/O OR 48 I/O

INTERFACE

PICOPATH

INTERFACE

AL

SHEET

17 - C1

PICO PATH 229255

6

5 4 3

2

1

BRN

RED

BLU

YEL

BLK

BLK

SHEET

15-B1

SHEET

14-D2
SHEET

14-C2

AE

AF

AH

24 I/O 229253

24 I/O 229254

SERVO 229255

BRN

RED

BLU

YEL

BLK

BLK

BLK

NC

NC

NC

RED

BRN

BLK

NC

NC

RED

J7

3 GROUND

2 FLD PWR GD

1 FAN DISABLE

J2 J1 J6

J5 J4

4 GROUND

3 +12V FUSED

2 -12V FUSED

1 +5V FUSED

6

5 4 3

2

1

1

2

3

4 5 6

1

2

3

4

1 +5V FUSED

2 -12V FUSED

3 +12V FUSED

4 GROUND

J3

8 GROUND

7 GROUND

6 GROUND

5 -12V

4 +12V

3 +12V

2 +12V

1 +5V

PCB2

POWER DISTRIBUTION PCB

14115 3

4 GROUND

3 +12V FUSED

2 -12V FUSED

1 +5V FUSED

4

3

2

1

8

7

5

D

C

B

A

8

7

5

4

3

2

1

D

C

B

A

4

3

2

1

8

7

5

D

C

B

A

8

7

5

4

3

2

1

D

C

B

A

6

6

Sheet 6 – Power distribution board, field and clean power out (J4 – J6) (141153)

EDGE Pro SERCOS III CNC Instruction Manual 807650 91

6 – Wiring Diagrams

PCB3

OPERATOR PANEL PCB

141058

34

33

32

31

30

29

28

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

229277

229277

228463

228463

229241

228463

228463

228463

228463

229279

229278

229278

SHEET

8-B2

SHEET

8-B1

L

SHEET

8-B4

SHEET

8-A4

K

J

SHEET

8-A5

SHEET

8-C3

C

SHEET

8-D7

F

SHEET

8-B7

I

SHEET

8-B5

H

229276

229275

M

N

SHEET

8-D2

O

B

SHEET

8-C4

SHEET

8-C5

A

D

SHEET

8-B2

SHEET

8-B2

E

PWR SWITCHBACK UP

FORWARD

UTILITY

START STOP STATI ON 1 STATI ON 2

CUT POT

RAISE 1

LOWER 1 LOWER 2

RAISE 2

JOYSTICK

BLU

G

2 RAISE

RED

WHT

BLK

J2

1

2

3

1 GROUND

2 JOG SPEED

3 4.096V

2 RAISE 2

1 GROUND

2
1

BLK

BLK

J9

J11

BLK
BLK

1

2

1 GROUND

2 MANUAL

J7

J6

2

1

2 START

1 GROUND

BLK

BLK

BLK

BLK

1 GROUND

2 STOP

1

2

J5

J4

3

2

1

3 4.096V

2 CUT SPD

1 GROUND

RED

WHT

BLK

YEL

BLK

BLU

1 AUTO SEL 1

2 GROUND

3 MAN SEL 1

4 NC

1

2

3

4

J3

1 GROUND

2 LOWER 2

2

1

BLK

BLK

1 GROUND

2 LOWER 1

2

1

BLK

BLK

BLK

BLK

J10

1

2

1 GROUND

1 GROUND

2 FORWARD

2

1

J14

BLK

BLK

BLK

BLK

J15

1

2

2 BACK UP

1 GROUND

6 GROUND
5 GROUND
4 RIGHT
3 LEFT
2 DOWN

1 UP

6
5

4
3
2
1

J8

RED

WHT

GRN

BLK

BLK

1 +12V

2 MB ON/OFF 1

3 MB ON/OFF 2

4 GROUND

4

3

2

1

J16

YEL

GRN

WHT

BLK

J1

4

3

2

1

4 NC

3 MAN SEL 2

2 GROUND

1 AUTO SEL 2

BLU

BLK

YEL

+12V 34

LOWER TORCH 2 25
STATION ENABLE LED 1 26
STATION ENABLE LED 2 27

MB ON/OFF 1 28
MB ON/OFF 2 29

CUT SPEED 30
JOG SPEED 31

4.096 V 32
+5V 33

RAISE TORCH 2 24

MANUAL SELECT 2 23

AUTO SELECT 2 22

LOWER TORCH 1 21

RAISE TORCH 1 20

MANUAL SELECT 1 19

AUTO SELECT 1 18

FRONT PANEL ID2 17

GROUND 16

GROUND 15

START 1

STOP 2

MANUAL 3

FORWARD ON PATH 4

FRONT PANEL ID1 14

FRONT PANEL ID0 13

FRONT PANEL ID1 12

GROUND 11

GROUND 10

JOYSTICK +X 9

JOYSTICK -X 8

JOYSTICK -Y 7

JOYSTICK +Y 6

BACK UP ON PATH 5

229252

223013

U

SHEET

12-D8

J13 J12

MANUAL

JOG POT

SHEET

8-C8

4

3

2

1

8

7

5

D

C

B

A

8

7

5

4

3

2

1

D

C

B

A

4

3

2

1

8

7

5

D

C

B

A

8

7

5

4

3

2

1

D

C

B

A

6

6

Sheet 7 – Operator console board (141058)

92 EDGE Pro SERCOS III CNC Instruction Manual 807650

6 – Wiring Diagrams

B

SHEET

7-C5

BLU

BLK

YEL

229277

229277

YEL

BLK

BLU

BLKBLK BLKBLK BLK BLK BLKBLK

BLK BLK

BLKBLK

BLK

RED

WHT

BLK

LED'S LOCATED

ON 141058

PCB

SHEET

7-C6

B

POWER ON/OFF

229252

WHT

GRN

BLK

YEL

SHEET

7-A3

O

3

2

8 7

D

SHEET

7-D4

229276

STOP

FORWARD ON PATH

228463

SHEET

7-A4

M

N

SHEET

7-A3

228463

BACKWARD ON PATH

START

229276

SHEET

7-D3

E

BLK

WHT

RED

229278

PROGRAM SPEED POT.

229278

C

SHEET

7-C5

STATION 1 PROGRAM

L

SHEET

7-A5

228463

STATION 1 RAISE

STATION 1 LOWER

228463

SHEET

7-A6

K

J

SHEET

7-A6

228463

STATION 2 LOWER

STATION 2 RAISE

228463

BLK

SHEET

7-B8

H

STATION 2 PROGRAM

STATION 1 LED

STATION 2 LED

I

SHEET

7-B8

SHEET

7-D7

F

G

SHEET

7-C8

BLK BLK

228463

MANUAL FUNCTION

JOYSTICK

229279

JOG SPEED POT.

229278

229278

GRN

BLU

WHT

RED

BLK

BLK

BLK

3

42 13

2

1

2

1

2

4

1

43

34

32 14

4

3

2

1

8

7

5

D

C

B

A

8

7

5

4

3

2

1

D

C

B

A

4

3

2

1

8

7

5

D

C

B

A

8

7

5

4

3

2

1

D

C

B

A

6

6

Sheet 8 – Operator console components (141058)

EDGE Pro SERCOS III CNC Instruction Manual 807650 93

6 – Wiring Diagrams

NOTES:

1. (4) USB CONNECTIONS TO MOTHERBOARD MUST FOLLOW THIS DIAGRAM.

2. (2) ETHERNET CONNECTIONS TO MOTHERBOARD MUST FOLLOW THIS DIAGRAM

HYPERNET
RJ-45 JACK

108751

MOTHERBOARD ON/OFF

PICOPATH

PCB11

PCB4 UTIL/SER

J12

ATX PWR

SHEET

5-B1

AJ

SHEET

10- C2

W

AA

SHEET

5-C8

V

SHEET

11 - C 4

J1 CPU FAN

J17

J14

J10

J13

J11

J9

J6 AUX
12VDC

J6

MB FAN

DIMM 1

DIMM 2

DIMM 3

DIMM 4

SHEET

12 - C2

AC

PCI EXPRESS (NOT USED)

PCI EXPRESS (NOT USED)

VIEW A-A

A

A

FOR PCI PCB

LOCATION SEE CHART

PCB4 UTIL/SER

PCB9 ANALOG

PCB9 ANALOG

PCB13 SERCOS 2

PCB5 MCC 6

PCI 5

PCI 4

PCI 3

PCB4 UTIL/SER

PCB4 UTIL/SER

PICOPATH

W/ SENSOR

SERCOS 2HYPATH

PCI 1

PCI 2

PCI 3

FROM ATX POWER SUPPLY 229403

229273

SATA DATA 223026

INTERIOR FAN

229307

229245

USB CABLE FROM DISPLAY KIT

LAN

RJ-45 JACK

108751

USB

USB

EDGE PRO (REAR)

HARDWARE KEY

12 719 2

EDGE PRO

(FRONT)

223028

223029

DUAL SERIAL PCB

TOUCHSCREEN USB

223011 (RED)

223010 (BLU)

223029

PCI 4

PCB1

MOTHERBOARD

1 4 111 0

PCI 5

HYPATH

W/ SENSOR

PCB4 UTIL/SER

PCB5

TOUCHSCREEN VGA

SHEET

5-C8

AB

CNC TYPE

CPU

SERCOS 3

PCB15 SERCOS 3

PCB4 UTIL/SER

PCI 2

PCB16 WRLS

MCC 6

OR

MCC 2

MCC 6

OR

MCC 2-4

PCB5

MCC 6

OR

MCC 2-4

PCB16 WRLS

PCB16 WRLS

PCB16 WRLS

PCB16 WRLS

PCB16 WRLS

4

3

2

1

8

7

5

D

C

B

A

8

7

5

4

3

2

1

D

C

B

A

4

3

2

1

8

7

5

D

C

B

A

8

7

5

4

3

2

1

D

C

B

A

6

6

Sheet 9 – Motherboard (141110)

94 EDGE Pro SERCOS III CNC Instruction Manual 807650

6 – Wiring Diagrams

100-240VAC

POWER

INPUT

W

SHEET

9-D7

SHEET

5-B8

AD

AI

SHEET

5-C3

ATX DC POWER & WIRE COLOR CODE

DC COM

BLK

+3.3 V

ORN

+5 V

RED

+5 V STAND-BY

VIO

-5 V

WHT

+12 V

YEL

- 12 V

BLU

+24 V

BRN

PWR GOOD (PGD)

GRY

PS_ON

GRN

229348

(NOT USED)

MOTHERBORD AUX 12V DC POWER

PCB1

MOTHERBORD POWER

PCB1

229403

ATX POWER SUPPLY

BLK

GND

2

1

+5V

RED

BLK

GND

+12V

5

YEL

1
2

YEL

6

+12V

GND

BLK

3

7

NC

NC

4

8

NC

NC

ORN

+3.3V

GND

24

BLK

12

YEL

+12V

NC 23

11

YEL

+12V

NC

22

10

VIO

+5VSB

+5V

21

RED

9

GRY

PGD

NC 20

8

BLK

GND

GND 19

BLK

7

RED

+5V

GND 18

BLK

6

BLK

GND

GND

17

BLK

5

RED

+5V +S

PS-ON 16

GRN

4

BLK

GND

GND 15

BLK

3

ORN

+3.3V

-12V 14

BLU

2

1

ORN

13+3.3V +S

+3.3V

ORN

DC OUTPUT

HARNESS

POWER DISTRIBUTION PCB

PCB2

SHEET

9-D7

W

4

3

2

1

8

7

5

D

C

B

A

8

7

5

4

3

2

1

D

C

B

A

4

3

2

1

8

7

5

D

C

B

A

8

7

5

4

3

2

1

D

C

B

A

6

6

Sheet 10 – ATX power supply (229403)

EDGE Pro SERCOS III CNC Instruction Manual 807650 95

6 – Wiring Diagrams

RS232

RS232

RS422

RS422

5

CHASSIS/SHLD

REMOTE ON/OFF -

4

REMOTE ON/OFF +

COMMON

J2 REMOTE ON/OFF

5C RECT

+12V

1
2
3

NC

NC

GROUND

5

TXDA-

NC

J5 SERIAL 1

9C DSUB

RXDA+

TXDA+

2

7

6

NC

3
4

1

8

RXDA-

9

AC

SHEET

5-B8

SHEET

9-D3

AC

U

SHEET

7-D1

V

SHEET

9-B7

CLEAN GND 1
ARC VOLTS 2

N/C 3

TXDB-

J8 SERIAL 2

9C DSUB

RXDB+
NC
NC

TXDB+
GROUND
NC

RXDB-

NC
2
3

7

6

9

8

4

1

5

J7

J4

J11
(NOT USED)

223013

TO MOTHERBOARD

TO POWER

DISTRIBUTION PCB

229273

229245

GROUND 1

DR_A 2

/RXD_INA 3

TS_A 4

/TXD_OUTA 5

TS_A 6

DR_A 7
GROUND 8
GROUND 9

N/C 10

GROUND 11

DR_B 12

/RXD_INB 13

TS_B 14

/TXD_OUTB 15

TS_B 16

DR_B 17
GROUND 18
GROUND 19

N/C 20

(NOT USED)

J6

FIELD PWR 1

N/C 2

GROUND 3

MOTHERBOARD ON/OFF2 4

MOTHERBOARD ON/OFF1 5

J8 (SERIAL 2)

J5 (SERIAL 1)

J2 (NOT USED)

J10

J3

1
2
3
4
5

YEL
BLU
BLK

WHT

GRN

34

33

32

31

30

29

28

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

543

2

1

J1

26 STATION ENABLE LED 1

27 STATION ENABLE LED 2

28 MB ON/OFF 1

29 MB ON/OFF 2

30 CUT SPEED

31 JOG SPEED

32 4.096 V

33 +5 VDC

34 +12 VDC

24 RAISE TORCH 2

23 MANUAL SELECT 2

22 AUTO SELECT 2

21 LOWER TORCH 1

20 RAISE TORCH 1

19 MANUAL SELECT 1

18 AUTO SELECT 1

17 FRONT PANEL ID2

16 GROUND

15 GROUND

1 START

2 STOP

3 MANUAL

4 FORWARD ON PATH

14 FRONT PANEL ID1

13 FRONT PANEL ID0

12 FRONT PANEL ID1

11 GROUND

10 GROUND

9 JOYSTICK +X

8 JOYSTICK -X

7 JOYSTICK -Y

5 BACK UP ON PATH

6 JOYSTICK +Y

25 LOWER TORCH 2

1
2
3
4
5
6
7
8

9

10
11
12
13
14
15
16
17
18
19
20

PCB4

UTILITY/SERIAL PCB

1413 07

4

3

2

1

8

7

5

D

C

B

A

8

7

5

4

3

2

1

D

C

B

A

6

6

Sheet 12 – Utility and serial isolation board (141307)

96 EDGE Pro SERCOS III CNC Instruction Manual 807650

6 – Wiring Diagrams

EDGE Pro SERCOS III CNC Instruction Manual 807650 97