Hypertherm Automation Family Instruction Manual (IM)

Powermax® EtherCAT® Interface for

®

EDGE

Connect

Installation and Setup Manual

810330 – REVISION 1

ENGLISH

Register your new Hypertherm system

Benefits of registration

5 Safety: Registration allows us to contact you in the unlikely event a safety or quality notification

is required.

5 Education: Registration gives you free access to online product training content via the

Hypertherm Cutting Institute.

5 Confirmation of ownership: Registration can serve as proof of purchase in case of an

insurance loss.

Go to www.hypertherm.com/registration for easy and fast registration.

If you experience any problems with the product registration process, please contact
[e-mail].

For your records

Serial number: __________________________________________________________________________

Purchase date: __________________________________________________________________________

Distributor: _____________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

Maintenance notes: ______________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

EDGE, Powermax, SYNC, Phoenix, and Hypertherm are trademarks of Hypertherm, Inc. and may be registered in the United
States and other countries. All other trademarks are the property of their respective holders.

Environmental stewardship is one of Hypertherm’s core values.www.hypertherm.com/environment

© 2022 Hypertherm, Inc. 100% Associate-owned.

Powermax® EtherCAT® Interface for

EDGE® Connect

Installation and Setup Manual

810330

REVISION 1

ENGLISH

Original instructions

September 2022

Hypertherm, Inc.

Hanover, NH 03755 USA

www.hypertherm.com

Hypertherm, Inc.

21 Great Hollow 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)

800-643-9878 Tel (Technical Service)

[e-mail] (Technical Service)

800-737-2978 Tel (Customer Service)

[e-mail] (Customer Service)

Hypertherm México, S.A. de C.V.

52 55 5681 8109 Tel
52 55 5681 7978 Tel
[e-mail] (Technical Service)

Hypertherm Plasmatechnik GmbH

Sophie-Scholl-Platz 5
63452 Hanau
Germany
00 800 33 24 97 37 Tel
00 800 49 73 73 29 Fax

31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)

[e-mail] (Technical Service)

Hypertherm (Singapore) Pte Ltd.

Solaris @ Kallang 164
164 Kallang Way #03-13
Singapore 349248, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
[e-mail] (Marketing)
[e-mail] (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
[e-mail] (Main Office)
[e-mail] (Technical Service)

Hypertherm Europe B.V.

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

31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)

[e-mail] (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

B301, 495 ShangZhong Road
Shanghai, 200231
PR China
86-21-80231122 Tel
86-21-80231120 Fax

86-21-80231128 Tel (Technical Service)

[e-mail] (Technical Service)

South America & Central America: Hypertherm Brasil Ltda.

Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP – Brasil
CEP 07115-030
55 11 2409 2636 Tel
[e-mail] (Technical Service)

Hypertherm Korea Branch

#3904. APEC-ro 17. Heaundae-gu. Busan.
Korea 48060
82 (0)51 747 0358 Tel
82 (0)51 701 0358 Fax
[e-mail] (Marketing)
[e-mail] (Technical Service)

Hypertherm Pty Limited

GPO Box 4836
Sydney NSW 2001, Australia
61 7 3103 1695 Tel
61 7 3219 9010 Fax
[e-mail] (Main Office)
[e-mail] (Technical Service)

Hypertherm (India) Thermal Cutting Pvt. Ltd

A-18 / B-1 Extension,
Mohan Co-Operative Industrial Estate,
Mathura Road, New Delhi 110044, India
91-11-40521201/ 2/ 3 Tel
91-11 40521204 Fax
[e-mail] (Main Office)
[e-mail] (Technical Service)

For training and education resources, go to the Hypertherm Cutting Institute (HCI) online at

www.hypertherm.com/hci.

ENGLISH

WARNING! Before operating any Hypertherm equipment, read the safety
instructions in your product’s manual, the Safety and Compliance Manual (80669C),

Waterjet Safety and Compliance Manual (80943C), and Radio Frequency Warning
Manual (80945C). Failure to follow safety instructions can result in personal injury

or in damage to equipment.
Copies of the manuals can come with the product in electronic and printed formats.

Electronic copies are also on our website. Many manuals are available in multiple
languages at www.hypertherm.com/docs.

BG (БЪЛГAPCКИ/BULGARIAN)

ПРЕДУПРЕЖДЕНИЕ! Преди да работите с което и да е оборудване
Hypertherm, прочетете инструкциите за безопасност в ръководството на вашия
продукт, „Инструкция за безопасност и съответствие“ (80669C), „Инструкция
за безопасност и съответствие на Waterjet“ (80943С) и „Инструкция
за предупреждение за радиочестота“ (80945С).

Продуктът може да е съпроводен от копия на ръководствата в електронен
и в печатен формат. Тези в електронен формат са достъпни също на уебсайта
ни. Много ръководства са налице на няколко езика
на адрес www.hypertherm.com/docs.

CS (ČESKY/CZECH)

VAROVÁNÍ! Před uvedením jakéhokoli zařízení Hypertherm do provozu si přečtěte
bezpečnostní pokyny v příručce k produktu a v Manuálu pro bezpečnost

a dodržování předpisů (80669C), Manuálu pro bezpečnost a dodržování
předpisů při řezání vodním paprskem (80943C) a Manuálu varování ohledně
rádiových frekvencí (80945C).

Kopie příruček mohou být součástí dodávky produktu, a to v elektronické i tištěné
formě. Elektronické kopie jsou k dispozici i na našich webových stránkách. Mnoho
příruček je k dispozici v různých jazycích na stránce www.hypertherm.com/docs.

DA (DANSK/DANISH)

ADVARSEL! Inden Hypertherm udstyr tages i brug skal sikkerhedsinstruktionerne
i produktets manual og i Manual om sikkerhed og overholdelse af krav (80669C),
Manual om sikkerhed og overholdelse af krav for vandstråleskæring (80943C),
og Manual om radiofrekvensadvarsel (80945C), gennemlæses.

Kopier af manualerne kan leveres med produktet i elektronisk og trykt format.
Elektroniske kopier findes også på vores hjemmeside. Mange manualer
er tilgængelige på flere sprog på www.hypertherm.com/docs.

DE (DEUTSCH/GERMAN)

WARNUNG! Bevor Sie ein Hypertherm-Gerät in Betrieb nehmen, lesen Sie bitte die
Sicherheitsanweisungen in Ihrer Bedienungsanleitung, das Handbuch für Sicherheit

und Übereinstimmung (80669C), das Handbuch für Sicherheit und Compliance bei
Wasserstrahl-Schneidanlagen (80943C) und das Handbuch für Hochfrequenz­Warnung (80945C).

Bedienungsanleitungen und Handbücher können dem Gerät in elektronischer Form
oder als Druckversion beiliegen. In elektronischer Form liegen sie auch auf unserer
Website vor. Viele Handbücher stehen in verschiedenen Sprachen auf

www.hypertherm.com/docs zur Verfügung.

ES (ESPAÑOL/SPANISH)

¡ADVERTENCIA! Antes de operar cualquier equipo Hypertherm, lea las
instrucciones de seguridad del manual de su producto, del Manual de seguridad

y cumplimiento (80669C), del Manual de seguridad y cumplimiento en corte con
chorro de agua (80943C) y del Manual de advertencias de radiofrecuencia

(80945C).
El producto puede incluir copias de los manuales en formato digital e impreso.

Las copias digitales también están en nuestra página web. Hay diversos manuales
disponibles en varios idiomas en www.hypertherm.com/docs.

ET (EESTI/ESTONIAN)

HOIATUS! Enne Hyperthermi mis tahes seadme kasutamist lugege läbi toote
kasutusjuhendis olevad ohutusjuhised ning Ohutus- ja vastavusjuhend (80669C),
Veejoa ohutuse ja vastavuse juhend (80943C) ja Raadiosageduse hoiatusjuhend
(80945C). Ohutusjuhiste eiramine võib põhjustada vigastusi ja kahjustada
seadmeid.

Juhiste koopiad võivad tootega kaasas olla elektrooniliselt või trükituna.
Elektroonilised koopiad on saadaval ka meie veebilehel. Paljud kasutusjuhendid
on erinevates keeltes saadaval veebilehel www.hypertherm.com/docs.

FI (SUOMI/FINNISH)

VAROITUS! Ennen minkään Hypertherm-laitteen käyttöä lue tuotteen
käyttöoppaassa olevat turvallisuusohjeet, turvallisuuden ja vaatimustenmukaisuuden

käsikirja (80669C), vesileikkauksen turvallisuuden ja vaatimustenmukaisuuden
käsikirja (80943C) ja radiotaajuusvaroitusten käsikirja (80945C).

Käyttöoppaiden kopiot voivat olla tuotteen mukana sähköisessä ja tulostetussa
muodossa. Sähköiset kopiot ovat myös verkkosivustollamme. Monet käyttöoppaat
ovat myös saatavissa useilla kielillä www.hypertherm.com/docs.

FR (FRANÇAIS/FRENCH)

AVERTISSEMENT! Avant d’utiliser tout équipement Hypertherm, lire les consignes
de sécurité dumanuel de votre produit, duManuel de sécurité et de conformité
(80669C), du Manuel de sécurité et de conformité du jet d’eau (80943C)
et du Manuel d'avertissement relatif aux radiofréqunces (80945C).

Les exemplaires des manuels qui accompagnent le produit peuvent être sous forme
électronique ou papier. Les manuels sous forme électronique se trouvent également
sur notre site Internet. Plusieurs manuels sont offerts en plusieurs langues
à www.hypertherm.com/docs.

GR (ΕΛΛΗΝΙΚΆ/GREEK)

ΠΡΟΕΙΔΟΠΟΙΗΣΗ! Πριν θέσετε σε λειτουργία οποιονδήποτε εξοπλισμό της
Hypertherm, διαβάστε τις οδηγίες ασφαλείας στο εγχειρίδιο του προϊόντος και στο

εγχειρίδιο ασφάλειας και συμμόρφωσης (80669C), στο εγχειρίδιο ασφάλειας και
συμμόρφωσης του waterjet (80943C) και στο εγχειρίδιο προειδοποιήσεων για τις
ραδιοσυχνότητες (80945C).

Το προϊόν μπορεί να συνοδεύεται από αντίγραφα των εγχειριδίων σε ηλεκτρονική
και έντυπη μορφή. Τα ηλεκτρονικά αντίγραφα υπάρχουν επίσης στον ιστότοπό μας.
Πολλά εγχειρίδια είναι διαθέσιμα σε διάφορες γλώσσες στο

www.hypertherm.com/docs.

HU (MAGYAR/HUNGARIAN)

VIGYÁZAT! Mielőtt bármilyen Hypertherm berendezést üzemeltetne,
olvassa el a biztonsági információkat a termék kézikönyvében, a Biztonsági

és szabálykövetési kézikönyvben (80669C), a Vízsugaras biztonsági
és szabálykövetési kézikönyvben (80943C) és a Rádiófrekvenciás
figyelmeztetéseket tartalmazó kézikönyvben (80945C).

A termékhez a kézikönyv példányai elektronikus és nyomtatott formában is mellékelve
lehetnek. Az elektronikus példányok webhelyünkön is megtalálhatók. Számos
kézikönyv áll rendelkezésre több nyelven a www.hypertherm.com/docs weboldalon.

ID (BAHASA INDONESIA/INDONESIAN)

PERINGATAN! Sebelum mengoperasikan peralatan Hypertherm, bacalah petunjuk
keselamatan dalam manual produk Anda, Manual Keselamatan dan Kepatuhan
(80669C), Manual Keselamatan dan Kepatuhan Jet Air (80943C), dan Manual
Peringatan Frekuensi Radio (80945C). Kegagalan mengikuti petunjuk keselamatan
dapat menyebabkan cedera pribadi atau kerusakan pada peralatan.

Produk mungkin disertai salinan manual atau petunjuk dalam format elektronik
maupun cetak. Salinan elektronik juga tersedia di situs web kami. Berbagai manual
tersedia dalam beberapa bahasa di www.hypertherm.com/docs.

IT (ITALIANO/ITALIAN)

AVVERTENZA! Prima di usare un’attrezzatura Hypertherm, leggere le istruzioni sulla
sicurezza nel manuale del prodotto, nel Manuale sulla sicurezza e la conformità
(80669C), nel Manuale sulla sicurezza e la conformità Waterjet (80943C) e nel
Manuale di avvertenze sulla radiofrequenza(80945C).

Copie del manuale possono accompagnare il prodotto in formato cartaceo
o elettronico. Le copie elettroniche sono disponibili anche sul nostro sito web. Molti
manuali sono disponibili in diverse lingue all’indirizzo www.hypertherm.com/docs.

JA (日本語/JAPANESE)

警告 ! Hypertherm 機器を操作する前に、この製品説明書にある安全情報、「安全
とコンプライアンスマニュアル」 (80669C) 、「ウォータージェットの安全とコ
ンプライアンス」 (80943C)、「高周波警告」 (80945C) をお読みください。

説明書のコピーは、電子フォーマット、または印刷物として製品に同梱されて
います。電子コピーは当社ウェブサイトにも掲載されています。説明書の多く
は www.hypertherm.com/docs にて複数の言語でご用意しています。

KO (뼑뼑霢꽩 KOREAN)

陲隕+\SHUWKHUP녚ꟹꌱꩡ끞뼍韥놹꾅뇑븽꫙ꐺ꫑꿵껽놹ꗄ鞑뇊늵ꯍ
꫙ꐺ꫑&낁뫥뇤껽놹ꗄ鞑뇊늵ꯍ꫙ꐺ꫑&鞭ꍡ隕ꓩ꫕늱볁ꯍ
陲隕꫙ꐺ꫑&꾅驍꿵넽鱉껽놹덵렝냹넲냱겢겑꿙

놹녅뿊겒隱넭ꭹ鷑뿊겒냱ꈑ꫙ꐺ꫑ꩡꚭ넩뇑븽隱뼝颍뇑險鷕ꯍ넽걪鱽鲙
놹녅ꩡꚭ鵹+\SHUWKHUP낮ꩡ넩뱭꾅꫑ꚩ겙ꯍ넽냱ꐥ꫙ꐺ꫑ꩡꚭ냵

www.hypertherm.com/docs꾅꫑꾡ꆡ꽭꽩ꈑ뇑險鷞鱽鲙

NE (NEDERLANDS/DUTCH)

WAARSCHUWING! Lees voordat u Hypertherm-apparatuur gebruikt
de veiligheidsinstructies in de producthandleiding, in de Veiligheids-

en nalevingshandleiding (80669C) in de Veiligheids- en nalevingshandleiding
voor waterstralen (80943C) en in de Waarschuwingshandleiding radiofrequentie

(80945C).
De handleidingen kunnen in elektronische en gedrukte vorm met het product worden

meegeleverd. Elektronische versies zijn ook beschikbaar op onze website. Veel
handleidingen zijn in meerdere talen beschikbaar via www.hypertherm.com/docs.

NO (NORSK/NORWEGIAN)

ADVARSEL! Før du bruker noe Hypertherm-utstyr, må du lese
sikkerhetsinstruksjonene i produktets håndbok, håndboken om sikkerhet og
samsvar (80669C), håndboken om vannjet sikkerhet og samsvar (80943C),
og håndboken om radiofrekvensadvarsler (80945C).

Eksemplarer av håndbøkene kan følge med produktet i elektronisk og trykt form.
Elektroniske eksemplarer finnes også på nettstedet vårt. Mange håndbøker
er tilgjengelig i flere språk på www.hypertherm.com/docs.

PL (POLSKI/POLISH)

OSTRZEŻENIE! Przed rozpoczęciem obsługi jakiegokolwiek systemu
firmy Hypertherm należy się zapoznać z instrukcjami bezpieczeństwa zamieszczonymi
w podręczniku produktu, w podręczniku bezpieczeństwa i zgodności (80669C),
podręczniku bezpieczeństwa i zgodności systemów strumienia wody (80943C)
oraz podręczniku z ostrzeżeniem o częstotliwości radiowej (80945C).

Do produktu mogą być dołączone podręczniki użytkownika wformie elektronicznej
idrukowanej. Kopie elektroniczne znajdują się również wnaszej witrynie internetowej.
Wiele podręczników jest dostępnych wróżnych językach pod adresem

www.hypertherm.com/docs.

PT (PORTUGUÊS/PORTUGUESE)

ADVERTÊNCIA! Antes de operar qualquer equipamento Hypertherm,
leia as instruções de segurança no manual do seu produto, no Manual

de Segurança e de Conformidade (80669C), no Manual de Segurança
e de Conformidade do Waterjet (80943C) e no Manual de Advertência
de radiofrequência (80945C).

Cópias dos manuais podem vir com o produto nos formatos eletrônico e impresso.
Cópias eletrônicas também são encontradas em nosso website. Muitos manuais
estão disponíveis em vários idiomas em www.hypertherm.com/docs.

RO (ROMÂNĂ/ROMANIAN)

AVERTIZARE! Înainte de utilizarea oricărui echipament Hypertherm, citiți
instrucțiunile de siguranță din manualul produsului, manualul de siguranță
și conformitate (80669C), manualul de siguranță și conformitate Waterjet (80943C)
și din manualul de avertizare privind radiofrecvența (80945C).

Produsul poate fi însoțit de copii ale manualelor în format tipărit și electronic.
Exemplarele electronice sunt disponibile și pe site-ul nostru web.
Numeroase manuale sunt disponibile în mai mult limbi la adresa:

www.hypertherm.com/docs.

RU (PУССКИЙ/RUSSIAN)

БЕРЕГИСЬ! Перед работой с любым оборудованием Hypertherm ознакомьтесь
с инструкциями по безопасности, представленными в руководстве, которое
поставляется вместе с продуктом, в Руководстве по безопасности и

соответствию (80669С), в Руководстве по безопасности и соответствию для
водоструйной резки (80943C) и Руководстве по предупреждению о
радиочастотном излучении (80945С).

Копии руководств, которые поставляются вместе с продуктом, могут быть
представлены в электронном и бумажном виде. Электронные копии также
доступны на нашем веб-сайте. Целый ряд руководств доступны на нескольких
языках по ссылке www.hypertherm.com/docs.

SK (S LOVENČINA/SLOVAK)

VÝSTRAHA! Pred použitím akéhokoľvek zariadenia od spoločnosti Hypertherm si
prečítajte bezpečnostné pokyny v návode na obsluhu vášho zariadenia a v Manuáli

o bezpečnosti a súlade s normami (80669C), Manuáli o bezpečnosti a súlade
snormami pre systém rezania vodou (80943C) avManuáli sinformáciami
orádiofrekvencii (80945C).

Návod na obsluhu sa dodáva spolu sproduktom velektronickej atlačenej podobe.
Jeho elektronický formát je dostupný aj na našej webovej stránke. Mnohé znávodov
na obsluhu sú dostupné vo viacjazyčnej mutácii na stránke

www.hypertherm.com/docs.

SL (S LOVENŠČINA/SLOVENIAN)

OPOZORILO! Pred uporabo katerekoli Hyperthermove opreme preberite varnostna
navodila v priročniku vašega izdelka, v Priročniku za varnost in skladnost (80669C),
v Priročniku za varnost in skladnost sistemov rezanja z vodnim curkom (80943C)
in v Priročniku Opozorilo o radijskih frekvencah (80945C).

Izvodi priročnikov so lahko izdelku priloženi v elektronski in tiskani obliki. Elektronski
izvodi so na voljo tudi na našem spletnem mestu. Številni priročniki so na voljo
v različnih jezikih na naslovu www.hypertherm.com/docs.

SR (SRPSKI/SERBIAN)

UPOZORENJE! Pre rukovanja bilo kojom Hyperthermovom opremom pročitajte
uputstva o bezbednosti u svom priručniku za proizvod, Priručniku o bezbednosti

i usaglašenosti (80669C), Priručniku o bezbednosti i usaglašenosti Waterjet
tehnologije (80943C) i Priručniku sa upozorenjem o radio-frekvenciji (80945C).

Уз производ се испоручују копије приручника у електронском или штампаном
формату. Електронске копије су такође доступне на нашем веб-сајту. Многи
приручници су доступни на више језика на адреси www.hypertherm.com/docs.

SV (SVENSKA/SWEDISH)

VARNING! Läs häftet säkerhetsinformationen i din produkts säkerhets- och
efterlevnadsmanual (80669C), säkerhets- och efterlevnadsmanualen för Waterjet

(80943C) och varningsmanualen för radiofrekvenser (80945C) för viktig
säkerhetsinformation innan du använder eller underhåller Hypertherm-utrustning.

Kopior av manualerna kan medfölja produkten i elektroniskt och tryckt format.
Elektroniska kopior finns också på vår webbplats. Många manualer finns på flera
språk på www.hypertherm.com/docs.

THࡗࡩࡠࡩࡷࡎ࡙THAI

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Contents

Electromagnetic Compatibility (EMC) ............................................................................................................. 5

Warranty.................................................................................................................................................................. 7

Introduction............................................................................................................................................................. 9

Purpose ....................................................................................................................................................... 9

Necessary tools and materials ............................................................................................................... 9

Kit 429010 contents............................................................................................................................... 10

Cables and wires ................................................................................................................................................ 12

Cables available from Hypertherm...................................................................................................... 13

External RS-485 serial interface cables ............................................................................... 13

External machine interface cables.......................................................................................... 13

External EtherCAT cables......................................................................................................... 14

Ohmic contact wire ............................................................................................................................... 14

Additional cables and wires (customer-supplied)........................................................................... 15

Machine interface receptacle with internal cables and voltage divider PCB ....................................... 15

Installation positions and dimensions............................................................................................................. 16

Installation positions ............................................................................................................................... 16

Dimensions for position 1*.................................................................................................................... 17

Dimensions for positions 2 and 3*...................................................................................................... 17

Before you begin................................................................................................................................................. 18

Installation task overview................................................................................................................................... 19

Attach the strain relief bracket ......................................................................................................................... 19

Attach the installation brackets........................................................................................................................ 20

Position 1.................................................................................................................................................. 20

Position 2 and 3 ...................................................................................................................................... 20

Attach the Powermax EtherCAT Interface..................................................................................................... 21

Powermax EtherCAT Interface for EDGE Connect Installation and Setup Manual 810330 3

Contents

Connect the cables and wires......................................................................................................................... 21

Connect the EtherCAT cable ............................................................................................................... 22

Connect the Powermax EtherCAT Interface to the Powermax plasma supply ......................... 23

Connect the machine interface cable..................................................................................... 23

Connect the RS-485 serial interface cable.......................................................................... 23

Connect the ohmic contact and work lead connection wires...................................................... 24

Connect the EMI ground cable ........................................................................................................... 25

Supply electrical power ......................................................................................................................... 25

Configure the EtherCAT

®

network................................................................................................................... 25

Monitor the status of inputs and outputs....................................................................................................... 26

4 810330 Installation and Setup Manual Powermax EtherCAT Interface for EDGE Connect

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.

Safety and compliance 5

Electromagnetic Compatibility (EMC)

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.

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 increase
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.

6 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 Connect CNC,
EDGE Connect T CNC, EDGE Connect TC CNC, 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.

All third-party engines, engine accessories, alternators, and alternator
accessories are covered by the respective manufacturers’ warranties and
not covered by this warranty.

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.

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. Hypertherm shall not be liable for
any losses to Distributor based on down time, lost production or
lost profits. It is the intention of the Distributor and Hypertherm
that this provision be construed by a court as being the
broadest limitation of liability consistent with applicable law.

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.

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.

Safety and compliance 7

Warranty

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.

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.

Waterjet product warranty coverage

Product Parts coverage

HyPrecision pumps 27 months from the ship date, or 24 months

from the date of proven installation, or
4,000 hours, whichever occurs first

PowerDredge
abrasive removal
system

EcoSift abrasive
recycling system

Abrasive metering
devices

On/off valve air
actuators

Diamond orifices 600 hours of use with the use of a thimble

Consumable parts are not covered by this warranty. Consumable parts
include, but are not limited to, high-pressure water seals, check valves,
cylinders, bleed-down valves, low-pressure seals, high-pressure tubing,
low- and high-pressure water filters and abrasive collection bags. All
third-party pumps, pump accessories, hoppers, hopper accessories,
dryer boxes, dryer box accessories and plumbing accessories are
covered by the respective manufacturers’ warranties and not covered by
this warranty.

15 months from the ship date or 12 months
from the date of proven installation,
whichever occurs first

15 months from the ship date or 12 months
from the date of proven installation,
whichever occurs first

15 months from the ship date or 12 months
from the date of proven installation,
whichever occurs first

15 months from the ship date or 12 months
from the date of proven installation,
whichever occurs first

filter and compliance with Hypertherm’s
water quality requirements

8 Safety and compliance

Introduction

Purpose

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electric power before doing installation or maintenance. You can
get a serious electric shock if electric power is not disconnected. Electric
shock can seriously injure or kill you.

All work that requires removal of the plasma power supply outer cover or
panels must be done by a qualified technician.

Refer to the Safety and Compliance Manual (80669C) for more safety
information.

This document gives the steps to connect a Powermax45 XP/65/85/105/125 or

®

Powermax65/85/105 SYNC

with an EDGE Connect CNC using the Powermax EtherCAT®

Interface.

Necessary tools and materials

 Cables and wires (Refer to page 12.)
 A supported voltage divider assembly (Refer to page 15.)
 AC-DC power supply with a 24 VDC output with a 1 A minimum rating

 Use a UL/CSA and/or CE certified AC-DC power supply or one that meets local

requirements.

 The 24 VDC output must be isolated from mains and be floating.
 T15 and T20 TORX
 Blade screwdriver

®

drivers

Powermax EtherCAT Interface for EDGE Connect Installation and Setup Manual 810330 9

Powermax EtherCAT Interface for EDGE Connect

2

3

1

4

5

1 Powermax EtherCAT Interface
2 Strain relief bracket for EtherCAT cable*
3 Quick-connect terminals for ohmic contact and

work lead wires with heatshrink (not shown)

4 Terminal block**
5 Installation brackets

†

Kit 429010 contents

Part number Description Quantity

429014 Powermax EtherCAT Interface 1

Strain relief bracket for EtherCAT cables 1

Cable tie for strain relief bracket 1

Quick-connect terminals for ohmic contact and work lead wires
(with heatshrink)

Installation brackets 2

208137 Terminal block: 2-position for 24 V input power 1

Figure 1 – Kit 429010 contents

2

* Refer to Attach the strain relief bracket on page 19.

** It is the customer’s responsibility to supply power to the Powermax EtherCAT Interface. Refer to Necessary

tools and materials on page 9.

† Installation brackets can be attached to the rear or bottom of the Powermax EtherCAT Interface. Refer to

Installation positions on page 16.

10 810330 Installation and Setup Manual Powermax EtherCAT Interface for EDGE Connect

Powermax EtherCAT Interface for EDGE Connect

s

Symbols and marks

Your product may have one or more of the following marks on or near the data plate. Because of 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 comply with European Directives. Applicable directives may include the European
Low Voltage Directive, the European Electromagnetic Compatibility (EMC) Directive, the Radio
Equipment Directive (RED), and the Restriction of Hazardous Substances (RoHS) Directive.
See the European CE Declaration of Conformity for details.

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.

RCM mark

CE versions of products with an RCM mark comply with the EMC and safety 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.

RoHS mark

The RoHS mark indicates that the product meets the requirements of the European Restriction of
Hazardous Substances (RoHS) Directive.

United Kingdom Conformity Assessed mark

CE versions of products that include a UKCA mark of conformity meet the product safety, EMC,
RF, and RoHS requirements for export to the UK.

Powermax EtherCAT Interface for EDGE Connect Installation and Setup Manual 810330 11

12 810330 Installation and Setup Manual Powermax EtherCAT Interface for EDGE Connect

_

+

7

1

2

3

4

5

6

Drives and I/O

modules

1 External machine interface cable

2

External RS-485 serial interface cable

3

EtherCAT cable

4

Ohmic contact wire to torch tip

5

Work lead connection wire

6

EMI ground cable from the M6 ground
screw

7

24 VDC power input cable from the green
terminal block to the customer-supplied
AC-DC power supply

Cables and wires

Powermax EtherCAT Interface for EDGE Connect

All 7 connections shown below are necessary to install the Powermax EtherCAT Interface. These cables and wires are not included in kit 429010.

Figure 2 – System diagram of necessary cables and wires

Powermax EtherCAT Interface for EDGE Connect

1

2

3

1

2

Cables available from Hypertherm

The cables that follow are necessary to install kit 429010 and are available from Hypertherm.

Figure 3

1 External RS-485 serial interface cable
2 External machine interface cable
3 EtherCAT cable
4 Ohmic contact wire (not shown)

External RS-485 serial interface cables

Part number Length

223818 0.9 meters (3 feet)

223770 3 meters (10 feet)

223758 7.6 meters (25 feet)

223771 15 meters (50 feet)

External machine interface cables

Part number Length

223817 0.9 meters (3 feet)

223772 3 meters (10 feet)

223759 7.6 meters (25 feet)

223773 15 meters (50 feet)

Powermax EtherCAT Interface for EDGE Connect Installation and Setup Manual 810330 13

Powermax EtherCAT Interface for EDGE Connect

3

4

External EtherCAT cables

Part number Length

223506 0.3 meters (1 feet)

223507 0.6 meters (2 feet)

223508 1.5 meters (5 feet)

223672 2.5 meters (8 feet)

223509 3.0 meters (10 feet)

223510 6.0 meters (19.5 feet)

223511 7.5 meters (24.5 feet)

223512 10 meters (33 feet)

223513 15 meters (49 feet)

223514 22.5 meters (74 feet)

223515 30 meters (98.5 feet)

223516 45 meters (147.5 feet)

223517 60 meters (197 feet)

223714 75 meters (246 feet)

All EtherCAT cables used in the cutting system must follow the guidelines



in the EDGE Connect Installation and Setup Manual available at

www.hypertherm.com/docs

these guidelines and are listed above.

Ohmic contact wire

Part number Length

223766 3 meters (10 feet)

223767 7.6 meters (25 feet)

223768 15 meters (50 feet)

223769 22.5 meters (75 feet)

. All Hypertherm cables are manufactured to

14 810330 Installation and Setup Manual Powermax EtherCAT Interface for EDGE Connect

Powermax EtherCAT Interface for EDGE Connect

1

2

1

2

Additional cables and wires (customer-supplied)

The additional cables that follow are necessary to install kit 429010. These cables are not available
from Hypertherm.

 Work lead connection wire (Necessary for ohmic contact continuity. Hypertherm

recommends an 18 AWG wire.)

Connecting wires for the ohmic contact and work lead wires are installed



with kit 429010. Heat shrink is included. Refer to page 24.

 EMI ground cable
 24 VDC power input cable (A 2-position terminal block is supplied.)

Machine interface receptacle with internal cables and voltage divider PCB

The Powermax EtherCAT Interface is only compatible with the latest version of the
Powermax voltage divider PCB and machine interface receptacle. If you have an old version,
you must remove it and install the latest version.

Look at the machine interface receptacle on the rear of the Powermax plasma power supply. Refer
to Figure 4.

 If sockets 1 and 2 are installed, then you have the correct voltage divider PCB and machine

interface receptacle for the Powermax EtherCAT Interface.

 If sockets 1 and 2 are empty, replace the voltage divider PCB and machine interface

receptacle using one of the kit numbers below.

 Powermax45 XP (428653)

 Powermax65/85 and Powermax65/85 SYNC (228697)

 Powermax105/125 (228884)

 Powermax105 SYNC (528045)

Figure 4 – Correct voltage divider receptacle (first image) and incorrect voltage divider receptacle (second image)

Powermax EtherCAT Interface for EDGE Connect Installation and Setup Manual 810330 15

Powermax EtherCAT Interface for EDGE Connect

1

2

3

1 Vertical surface with cables pointing out
2 Vertical surface with cables pointing down

3 Horizontal surface with cables pointing out

Installation positions and dimensions

You can install the Powermax EtherCAT Interface in a few positions. Select the position that best fits
your equipment and space.

Installation positions

To minimize the strain on the cables and wires, Hypertherm recommends that you install the
Powermax EtherCAT Interface in one of the positions shown in Figure 5.

Figure 5 – Recommended installation positions

The dimensions for position 1 (shown in Figure 5) are different than the dimensions for positions 2
and 3.

16 810330 Installation and Setup Manual Powermax EtherCAT Interface for EDGE Connect

Dimensions for position 1*

256 mm

(11.7 inch)

283 mm

(11.15 inch)

169 mm (6.7 inch)

232 mm (9.1 inch)

45 mm

(1.77 inch)

76 mm (3 inch)

6.4 mm
(.25 inch)

4.5 mm (.18 inch)

227 mm

(8.9 inch)

82 mm

(3.2 inch)

164 mm

(6.5 inch)

45 mm (1.77 inch)

6.4 mm (.25 inch)

4.5 mm (.18 inch)

283 mm (11.15 inch)

296 mm (11.7 inch)

Powermax EtherCAT Interface for EDGE Connect

Dimensions for positions 2 and 3*

* Positions 1, 2, and 3 are shown on page 16.

Powermax EtherCAT Interface for EDGE Connect Installation and Setup Manual 810330 17

Powermax EtherCAT Interface for EDGE Connect

XPR OR

HPRXD

EtherCAT

Interface

PCB

Powermax

EtherCAT

Interface

Drives and motors

Last on the network

Second-to-last

on the network

First on the network (for EDGE Connect TC)

Generic I/O

Before you begin

Before you install the Powermax EtherCAT Interface, it is important to know these guidelines:

 Each Powermax EtherCAT Interface supports one Powermax plasma power supply. A

maximum of four Powermax EtherCAT Interfaces can be installed on the EtherCAT network.

 When installing a Powermax EtherCAT interface with one or more EtherCAT plasma power

supplies, make sure the XPR or HPR is before the Powermax EtherCAT interface.

Figure 6 – Physical sequence of an XPR (or HPRXD) and a Powermax on an EtherCAT network

 Do not install XPR and HPR plasma supplies on the same EtherCAT network.
 On the Station Configuration screen in Phoenix, set up the EtherCAT plasma power

supplies first, starting with Station 1. Set up tools with discrete connections on remaining

stations.

For common Station Configuration examples, refer to Cut with Powermax



on an EDGE Connect CNC (810290) available at

www.hypertherm.com/docs

 Make sure that the arc voltage ratio on your Powermax plasma power supply is set to the

.

factory default setting of 50:1. Refer to Figure 7.

Figure 7 – The DIP switches on the voltage divider PCB are set to the factory default of 50:1.

For more information, refer to these Field Service Bulletins:



 Powermax45 XP Machine Interface Receptacle with Voltage Divider PCB

(809940)

 Machine Interface Receptacle with Voltage Divider PCB (806980)

18 810330 Installation and Setup Manual Powermax EtherCAT Interface for EDGE Connect

Installation task overview

Do these tasks when you install the Powermax EtherCAT Interface.

 Attach the strain relief bracket for the EtherCAT cable to the Powermax EtherCAT Interface.

Refer to the next section.

 Attach the installation brackets to the Powermax EtherCAT Interface. Refer to page 20.
 Attach the Powermax EtherCAT Interface.
 Connect the cables and wires. Refer to page 21.
 Configure the EtherCAT
 Monitor the status of inputs and outputs. Refer to page 26.

®

network. Refer to page 25.

Attach the strain relief bracket

1. Remove the 2 screws below the EtherCAT ports.

Powermax EtherCAT Interface for EDGE Connect

2. Use the 2 screws to install the strain relief bracket.

Powermax EtherCAT Interface for EDGE Connect Installation and Setup Manual 810330 19

Powermax EtherCAT Interface for EDGE Connect

Attach the installation brackets

Attach the brackets to the rear OR to the bottom of the Powermax EtherCAT Interface. Select the
installation position that is necessary for your equipment.

Position 1

To install the Powermax EtherCAT Interface in position 1 (on page 16), do these steps.

1. Remove the 4 screws from the rear of the Powermax EtherCAT Interface.

2. Use the 4 screws to attach the brackets to the Powermax EtherCAT Interface.

Position 2 and 3

To install the Powermax EtherCAT Interface in position 2 or 3 (on page 16), do these steps.

1. Remove the 4 screws from the bottom of the Powermax EtherCAT Interface.

20 810330 Installation and Setup Manual Powermax EtherCAT Interface for EDGE Connect

2. Use the 4 screws to attach the brackets to the Powermax EtherCAT Interface.

Attach the Powermax EtherCAT Interface

Powermax EtherCAT Interface for EDGE Connect

The Powermax EtherCAT Interface is almost the same shape as a drive amplifier, so that you can
attach it to a drive cabinet if possible. However, you can attach it to any vertical or horizontal surface
if necessary. Screws are not included.

Refer to Installation positions and dimensions on page 16.

Connect the cables and wires

This section gives a short overview of how to connect the necessary cables and wires.

 EtherCAT cable
 External machine interface cable
 RS-485 serial interface cable
 Ohmic contact and work lead connection wires
 EMI ground cable
 24 VDC power input

Powermax EtherCAT Interface for EDGE Connect Installation and Setup Manual 810330 21

Powermax EtherCAT Interface for EDGE Connect

Drive and I/O modules

1

2

3

123

Connect the EtherCAT cable

Figure 8

1. Connect one end of the EtherCAT cable to the port marked “IN” on the Powermax EtherCAT

Interface.

2. Connect the other end of the cable to the EtherCAT port on the rear side of the EDGE
Connect CNC.

3. Use a cable tie to attach the EtherCAT cable to the bracket as a strain relief.

For information about supported EtherCAT cables, refer to page 14.



22 810330 Installation and Setup Manual Powermax EtherCAT Interface for EDGE Connect

Powermax EtherCAT Interface for EDGE Connect

1

2

3

4

1

2

3

4

Connect the Powermax EtherCAT Interface to the Powermax plasma supply

Figure 9

Connect the machine interface cable

1. Connect the machine interface cable to the machine interface receptacle on the rear of the
Powermax plasma power supply. Refer to Figure 9.

2. Connect the other end of the machine interface cable to the machine interface receptacle on
the Powermax EtherCAT Interface.

For information about machine interface cables, refer to page 13.



Connect the RS-485 serial interface cable

1. Connect the RS-485 serial interface cable to the RS-485 receptacle on the rear of the
Powermax plasma power supply. Refer to Figure 9.

2. Connect the 26-pin D-sub connector end of the RS-485 serial interface cable to the serial
interface receptacle on the Powermax EtherCAT Interface.

3. Use a blade screwdriver to attach the connector to the Powermax EtherCAT Interface.

For information about RS-485 serial interface cables, refer to page 13.



Powermax EtherCAT Interface for EDGE Connect Installation and Setup Manual 810330 23

Powermax EtherCAT Interface for EDGE Connect

1

1

2

2

Figure 10 – The heatshrink is installed.

Connect the ohmic contact and work lead connection wires

The ohmic contact wire is available from Hypertherm. Refer to Cables and



wires on page 12.

The work lead connection wire is customer-supplied. Hypertherm



recommends an 18 AWG wire.

1. Connect the connector for the ohmic contact wire to the quick-connect receptacle for ohmic
contact .

2. Connect the connector for the arc voltage (work) wire to the quick-connect receptacle .

3. Install the heatshrink as follows:

a. Put the heatshrink on the quick-connects for the ohmic

contact and work lead connection wires.

b. Apply heat. Refer to Figure 10.

4. Make sure that the ohmic contact wire is correctly

connected to the torch tip.

5. Make sure that the work lead wire is connected in the
correct location. Refer to Figure 2 – System diagram of

necessary cables and wires on page 12.

24 810330 Installation and Setup Manual Powermax EtherCAT Interface for EDGE Connect

Powermax EtherCAT Interface for EDGE Connect

Connect the EMI ground cable

Connect an EMI ground cable to the M6 screw on the
Powermax EtherCAT Interface.

Refer to the EDGE Connect Installation and Setup Manual
(809340) for information about grounding and shielding.
Technical documentation is available at

www.hypertherm.com/docs

.

Supply electrical power

Supply AC-DC electrical power with a 24 VDC output to the green terminal block on the Powermax
EtherCAT Interface. The terminal block is shown in Figure 2 on page 12.

Refer to Necessary tools and materials on page 9 to see more power



supply requirements.

Configure the EtherCAT® network

After you install the Powermax EtherCAT Interface, reconfigure the EtherCAT network. Refer to the
EDGE Connect Installation and Setup Manual (809340) for instructions. Technical documentation
is available at www.hypertherm.com/docs

After you reconfigure the network, make sure that the Powermax shows in the list of connected
devices in Hypertherm EtherCAT studio.

Figure 11 – List of connected devices includes Powermax

.

Phoenix® 10.19.2 or later must be installed on the CNC.



Powermax EtherCAT Interface for EDGE Connect Installation and Setup Manual 810330 25

Powermax EtherCAT Interface for EDGE Connect

1

2

3

4

1 The 24 VDC green LED comes on when the

Powermax EtherCAT Interface is receiving 24
VDC from an external source.

2 The green START LED comes on when the

CNC sends a Start signal to the plasma power
supply.

3 The red OHMIC LED comes on when the

ohmic contact wire (torch tip) touches the
workpiece, such as during initial height
sensing or collision sensing.

4 The MOTION LED comes on when the arc

transfers to the workpiece and motion can
begin.

Monitor the status of inputs and outputs

The Powermax EtherCAT Interface includes light-emitting diodes (LEDs) so that you can monitor the
status of the inputs and outputs.

Figure 12 – Powermax EtherCAT Interface LEDs

26 810330 Installation and Setup Manual Powermax EtherCAT Interface for EDGE Connect