Hypertherm Automation Family Instruction Manual (IM)

MicroEDGE® Pro

HyPath
Picopath
SERCOS II
SERCOS III

Shape cutting control

Instruction manual

807290 – Revision 4

MicroEDGE Pro

Shape cutting control

Instruction Manual

807290

Revision 4 – January 2016

Hypertherm Inc.

Hanover, NH USA

www.hypertherm.com

© Copyright 2016 Hypertherm Inc.

All Rights Reserved

ArcGlide, EDGE, HPR, Hypertherm, MicroEDGE, Phoenix, and Sensor are trademarks of Hypertherm Inc.

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

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 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
[e-mail] (Technical Service Email)

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 Email)

Hypertherm (Singapore) Pte Ltd.

82 Genting Lane
Media Centre
Annexe Block #A01-01
Singapore 349567, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
[e-mail] (Marketing Email)
[e-mail] (Technical Service Email)

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 Email)
[e-mail] (Technical Service Email)

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 Email)

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 Email)

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 Email)

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 Email)
[e-mail]
(Technical Service Email)

Hypertherm Pty Limited

GPO Box 4836
Sydney NSW 2001, Australia
61 (0) 437 606 995 Tel
61 7 3219 9010 Fax
[e-mail] (Main Office Email)
[e-mail]
(Technical Service Email)

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 Email)
[e-mail]
(Technical Service Email)

1/28/16

CONTENTS

Contents ........................................................................................................................................................................................ i

Safety .................................................................................................................................................................................... SC-1

Recognize safety information .............................................................................................................................................................. SC-2

Follow safety instructions .....................................................................................................................................................................SC-2

Inspect equipment before using .........................................................................................................................................................SC-2

Responsibility for safety........................................................................................................................................................................SC-2

A plasma arc can damage frozen pipes ...........................................................................................................................................SC-2

Static electricity can damage printed circuit boards ..................................................................................................................... SC-2

Grounding safety ...................................................................................................................................................................................SC-3

Electrical hazards ...................................................................................................................................................................................SC-3

Electric shock can kill ............................................................................................................................................................................SC-3

Cutting can cause fire or explosion ...................................................................................................................................................SC-4

Machine motion can cause injury .......................................................................................................................................................SC-4

Compressed gas equipment safety ................................................................................................................................................... SC-5

Gas cylinders can explode if damaged .............................................................................................................................................SC-5

Toxic fumes can cause injury or death ..............................................................................................................................................SC-5

A plasma arc can cause injury and burns .........................................................................................................................................SC-6

Arc rays can burn eyes and skin .........................................................................................................................................................SC-6

Pacemaker and hearing aid operation ..............................................................................................................................................SC-6

Noise can damage hearing .................................................................................................................................................................. SC-7

Dry dust collection information ........................................................................................................................................................... SC-7

Laser radiation ........................................................................................................................................................................................SC-8

Additional safety information ...............................................................................................................................................................SC-8

Product Stewardship ......................................................................................................................................................... SC-9

Introduction .............................................................................................................................................................................................SC-9

National and local safety regulations ................................................................................................................................................. SC-9

Certification test marks .........................................................................................................................................................................SC-9

Differences in national standards ....................................................................................................................................................... SC-9

Safe installation and use of shape cutting equipment ..................................................................................................................SC-9

Procedures for periodic inspection and testing ........................................................................................................................... SC-10

Qualification of test personnel ......................................................................................................................................................... SC-10

MicroEDGE Pro Instruction Manual 807290 i

TABLE OF CONTENTS

Residual current devices (RCDs) ................................................................................................................................................... SC-10

Higher-level systems .......................................................................................................................................................................... SC-10

Environmental Stewardship ...........................................................................................................................................SC-11

Introduction .......................................................................................................................................................................................... SC-11

National and local environmental regulations ............................................................................................................................... SC-11

The RoHS directive ............................................................................................................................................................................ SC-11

Proper disposal of Hypertherm products ...................................................................................................................................... SC-11

The WEEE directive ........................................................................................................................................................................... SC-11

The REACH regulation ...................................................................................................................................................................... SC-11

Proper handling and safe use ofchemicals .................................................................................................................................. SC-12

Fumes emission and air quality ........................................................................................................................................................ SC-12

Electromagnetic Compatibility (EMC) ......................................................................................................................EMC-1

Introduction ......................................................................................................................................................................................... EMC-1

Installation and use ............................................................................................................................................................................ EMC-1

Assessment of area ........................................................................................................................................................................... EMC-1

Methods of reducing emissions ..................................................................................................................................................... EMC-1

Maintenance of cutting equipment ................................................................................................................................................ EMC-1

Cutting cables .................................................................................................................................................................................... EMC-1

Equipotential bonding ....................................................................................................................................................................... EMC-1

Earthing of the workpiece ................................................................................................................................................................ EMC-2

Screening and shielding ................................................................................................................................................................... EMC-2

Warranty .................................................................................................................................................................................. W-1

Attention .....................................................................................................................................................................................................W-1

General .......................................................................................................................................................................................................W-1

Patent indemnity .......................................................................................................................................................................................W-1

Limitation of liability..................................................................................................................................................................................W-1

National and local codes ........................................................................................................................................................................W-1

Liability cap ................................................................................................................................................................................................W-2

Insurance....................................................................................................................................................................................................W-2

Transfer of rights ......................................................................................................................................................................................W-2

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

Main features of an automated cutting system ...................................................................................................................................1-2

CNC ...................................................................................................................................................................................................1-3

Cutting table .....................................................................................................................................................................................1-3

Plasma arc cutting (PAC) system ................................................................................................................................................1-3

Control box .......................................................................................................................................................................................1-4

Drive system .....................................................................................................................................................................................1-4

Torch height control (THC) ...........................................................................................................................................................1-4

Oxyfuel torch ....................................................................................................................................................................................1-4

Marker ................................................................................................................................................................................................1-4

Overview of MicroEDGE Pro ..................................................................................................................................................................1-5

Common features ............................................................................................................................................................................1-5

ii MicroEDGE Pro Instruction Manual 807290

TABLE OF CONTENTS

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

Rear panel .........................................................................................................................................................................................1-6

System specifications .....................................................................................................................................................................1-7

Machine interface configurations ...........................................................................................................................................................1-8

HyPath configuration ......................................................................................................................................................................1-8

Picopath configuration ...................................................................................................................................................................1-9

SERCOS II configuration ...........................................................................................................................................................1-10

SERCOS III configuration ..........................................................................................................................................................1-11

Integrated Sensor THC ...............................................................................................................................................................1-12

Secondary enclosure requirements .................................................................................................................................................... 1-13

Interior temperature ......................................................................................................................................................................1-13

Air circulation ................................................................................................................................................................................. 1-13

AC input..........................................................................................................................................................................................1-13

Symbols and marks ................................................................................................................................................................................ 1-14

S mark........................................................................................................................................................................................................1-14

CSA mark .................................................................................................................................................................................................1-14

CE mark ....................................................................................................................................................................................................1-14

Eurasian Customs Union (CU) mark .................................................................................................................................................. 1-14

GOST-TR mark ....................................................................................................................................................................................... 1-14

C-Tick mark .............................................................................................................................................................................................. 1-14

CCC mark ................................................................................................................................................................................................1-14

UkrSEPRO mark .....................................................................................................................................................................................1-14

Serbian AAA mark ..................................................................................................................................................................................1-14

Installation ................................................................................................................................................................................2-1

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

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

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

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

Mounting the CNC ....................................................................................................................................................................................2-4

Mounting hole patterns on the bottom of the CNC ................................................................................................................2-4

AC power .....................................................................................................................................................................................................2-5

Power cable ......................................................................................................................................................................................2-5

Chassis grounding .....................................................................................................................................................................................2-6

Interface ports .............................................................................................................................................................................................2-7

Hypernet interface ...........................................................................................................................................................................2-7

LAN interface ....................................................................................................................................................................................2-7

USB interface (5) ............................................................................................................................................................................2-7

Serial ports (4) .................................................................................................................................................................................2-7

VGA Port 1 .......................................................................................................................................................................................2-7

Picopath connections ...............................................................................................................................................................................2-8

Picopath I/O connections ..............................................................................................................................................................2-8

Picopath I/O connector .................................................................................................................................................................2-9

Picopath I/O circuit examples ...................................................................................................................................................2-10

Picopath drive/encoder connectors ......................................................................................................................................... 2-11

Picopath pin-outs for servo drive connectors .................................................................................................................2-12

MicroEDGE Pro Instruction Manual 807290 iii

TABLE OF CONTENTS

Encoder voltage options on the Picopath interface ........................................................................................................................ 2-13

Encoder jumper options ..............................................................................................................................................................2-13

HyPath connections ............................................................................................................................................................................... 2-16

HyPath I/O .....................................................................................................................................................................................2-16

HyPath inputs ................................................................................................................................................................................ 2-17

HyPath input circuit examples .............................................................................................................................................. 2-17

HyPath outputs .............................................................................................................................................................................2-19

HyPath output circuit examples ........................................................................................................................................... 2-19

HyPath I/O connectors ...............................................................................................................................................................2-22

HyPath I/O pin-outs ................................................................................................................................................................2-23

HyPath 4-axis servo connectors ............................................................................................................................................... 2-24

HyPath servo connector ........................................................................................................................................................ 2-24

Drive/Encoder pin-outs .......................................................................................................................................................... 2-25

Analog connections ................................................................................................................................................................................2-26

Sensor THC connector ............................................................................................................................................................... 2-26

THC cables .................................................................................................................................................................................... 2-27

Pin-outs for voltage divider board 3 (VDC3) connectors .............................................................................................. 2-27

Joystick and speedpot connector ............................................................................................................................................. 2-28

Pin-outs for joystick and speedpot connector .................................................................................................................2-28

Joystick and speedpot cable adapter for MicroEDGE CNC (223252) .......................................................................... 2-29

SERCOS II I/O configuration ...............................................................................................................................................................2-30

SERCOS III I/O configuration ..............................................................................................................................................................2-31

SERCOS III Cable ....................................................................................................................................................................... 2-31

Serial port configuration ........................................................................................................................................................................ 2-32

Serial ports 1 and 2 ..................................................................................................................................................................... 2-32

Serial ports 3 and 4 ..................................................................................................................................................................... 2-32

Remote on/off cable ............................................................................................................................................................................... 2-34

Wireless network card ........................................................................................................................................................................... 2-35

Preparing to install the antenna .................................................................................................................................................2-35

Installing the antenna ................................................................................................................................................................... 2-35

Checking the wireless network in Windows .......................................................................................................................... 2-36

Mapping a network drive ............................................................................................................................................................2-37

Adding a folder in Phoenix .........................................................................................................................................................2-38

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

Operating the CNC ...................................................................................................................................................................................3-2

Operator console ............................................................................................................................................................................3-2

Touch screen LCD ..........................................................................................................................................................................3-2

LCD display ......................................................................................................................................................................................3-2

Screen navigation ............................................................................................................................................................................3-3

Help ....................................................................................................................................................................................................3-4

View additional manuals ................................................................................................................................................................3-4

Show bookmarks .............................................................................................................................................................................3-5

Automated operations...............................................................................................................................................................................3-5

Align Wizard .....................................................................................................................................................................................3-5

CutPro Wizard .................................................................................................................................................................................3-6

Using Phoenix without a touch screen ..................................................................................................................................................3-6

iv MicroEDGE Pro Instruction Manual 807290

TABLE OF CONTENTS

PC keyboard .....................................................................................................................................................................................3-6

Updating Phoenix software ......................................................................................................................................................................3-7

Updating the software ....................................................................................................................................................................3-7

Updating the Help ...........................................................................................................................................................................3-7

Updating the cut charts .................................................................................................................................................................3-8

Maintenance and Diagnostics ............................................................................................................................................4-1

Introduction .................................................................................................................................................................................................4-3

Diagnostic tests..........................................................................................................................................................................................4-4

Serial test ..........................................................................................................................................................................................4-6

USB test ............................................................................................................................................................................................4-7

I/O test ...............................................................................................................................................................................................4-8

Axis test ..........................................................................................................................................................................................4-10

THC test ......................................................................................................................................................................................... 4-11

LAN and Hypernet tests .............................................................................................................................................................4-12

Joystick and speedpot test .........................................................................................................................................................4-13

Troubleshooting.......................................................................................................................................................................................4-14

Introduction .................................................................................................................................................................................... 4-14

MicroEDGE Pro troubleshooting tables ..................................................................................................................................4-15

Power up ................................................................................................................................................................................... 4-15

Display ....................................................................................................................................................................................... 4-15

Field power failure ................................................................................................................................................................... 4-15

Input failure ............................................................................................................................................................................... 4-16

Output failure ...........................................................................................................................................................................4-16

Hypernet .................................................................................................................................................................................... 4-17

LAN connection ....................................................................................................................................................................... 4-17

Motion issues ........................................................................................................................................................................... 4-18

THC ............................................................................................................................................................................................ 4-20

Serial communication issues ................................................................................................................................................ 4-21

USB issues ............................................................................................................................................................................... 4-21

Cut quality ................................................................................................................................................................................. 4-21

CNC temperature ...................................................................................................................................................................4-22

CNC is slow ............................................................................................................................................................................. 4-22

Wireless troubleshooting ...................................................................................................................................................................... 4-23

Component locations and information ............................................................................................................................................... 4-24

HyPath 24 I/O board (141070) ................................................................................................................................................ 4-25

Motherboard (141110) ............................................................................................................................................................... 4-27

SERCOSII master board (141116) ........................................................................................................................................4-28

SERCOSIII master board (141310) .......................................................................................................................................4-29

Picopath 4-axis servo board (141122) ................................................................................................................................... 4-30

Analog board (141125) .............................................................................................................................................................. 4-34

Power distribution board (141153) ......................................................................................................................................... 4-36

SERCOSII and SERCOSIII serial isolation and utility board (141194/141307) ....................................................... 4-38

HyPath 4-axis servo board (141197) ...................................................................................................................................... 4-40

CPC analog breakout board (141210) ..................................................................................................................................4-42

HyPath and Picopath 4-axis MCC, utility, and serial isolation board (141222) ............................................................ 4-44

Picopath 2-axis servo board (141254) ................................................................................................................................... 4-47

Picopath 2-axis MCC, utility, and serial isolation board (141256) ...................................................................................4-50

MicroEDGE Pro Instruction Manual 807290 v

TABLE OF CONTENTS

VDC for integrated Sensor THC (141201) ......................................................................................................................................4-53

Parts List ...................................................................................................................................................................................5-1

Common MicroEDGE Pro parts .............................................................................................................................................................5-2

Picopath MicroEDGE Pro parts .............................................................................................................................................................5-4

HyPath MicroEDGE Pro parts ................................................................................................................................................................5-5

SERCOS II and SERCOS III MicroEDGE Pro parts .........................................................................................................................5-6

Common test plugs ...................................................................................................................................................................................5-7

Picopath test plugs ....................................................................................................................................................................................5-8

HyPath test plugs.......................................................................................................................................................................................5-9

Cable connector kits .............................................................................................................................................................................. 5-10

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

Introduction .................................................................................................................................................................................................6-1

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

vi MicroEDGE Pro Instruction Manual 807290

Section 1

SAFETY

In this section:

Recognize safety information .............................................................................................................................................................. SC-2

Follow safety instructions .....................................................................................................................................................................SC-2

Inspect equipment before using .........................................................................................................................................................SC-2

Responsibility for safety........................................................................................................................................................................SC-2

A plasma arc can damage frozen pipes ...........................................................................................................................................SC-2

Static electricity can damage printed circuit boards ..................................................................................................................... SC-2

Grounding safety ...................................................................................................................................................................................SC-3

Electrical hazards ...................................................................................................................................................................................SC-3

Electric shock can kill ............................................................................................................................................................................SC-3

Cutting can cause fire or explosion ...................................................................................................................................................SC-4

Machine motion can cause injury .......................................................................................................................................................SC-4

Compressed gas equipment safety ................................................................................................................................................... SC-5

Gas cylinders can explode if damaged .............................................................................................................................................SC-5

Toxic fumes can cause injury or death ..............................................................................................................................................SC-5

A plasma arc can cause injury and burns .........................................................................................................................................SC-6

Arc rays can burn eyes and skin .........................................................................................................................................................SC-6

Pacemaker and hearing aid operation ..............................................................................................................................................SC-6

Noise can damage hearing .................................................................................................................................................................. SC-7

Dry dust collection information ........................................................................................................................................................... SC-7

Laser radiation ........................................................................................................................................................................................SC-8

Additional safety information ...............................................................................................................................................................SC-8

Safety and Compliance SC-1

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.

SC-2 Safety and Compliance

GROUNDING SAFETY

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.

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.

ELECTRIC SHOCK CAN KILL

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.

Safety and Compliance SC-3

SAFETY

CUTTING CAN CAUSE FIRE OR EXPLOSION

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.

WARNING

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.

WARNING

Explosion Hazard

Argon-Hydrogen and Methane

Hydrogen and methane are flammable gases that present an explosion
hazard. Keep flames away from cylinders and hoses that contain
methane or hydrogen mixtures. Keep flames and sparks away from the
torch when using methane or argon-hydrogen plasma.

WARNING

Explosion Hazard

Underwater Cutting with Fuel Gases

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.

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.

• 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.

SC-4 Safety and Compliance

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.

Safety and Compliance SC-5

SAFETY

A PLASMA ARC CAN CAUSE INJURY AND BURNS

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

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.

Minimum protective shade

number

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 A 10 14 10 N/A

(ANSIZ49.1:2012)

Suggested shade

number for comfort

(ANSI Z49.1:2012)

• 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.

OSHA 29CFR

1910.133(a)(5)

EN168:2002

Europe

PACEMAKER AND HEARING AID OPERATION

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

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

To reduce magnetic field hazards:

• Keep both the work 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.

SC-6 Safety and Compliance

NOISE CAN DAMAGE HEARING

SAFETY

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.

Safety and Compliance SC-7

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/

SC-8 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.

Safety and Compliance SC-9

PRODUCT STEWARDSHIP

Procedures for periodic inspection and
testing

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

Hypertherm also removes some protective devices that would cause
false test results. Where required by local national regulations, a label
shall be attached to the equipment to indicate that it has passed the
tests prescribed by 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.

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.

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.

SC-10 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.

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.

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.

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.

Safety and Compliance SC-11

ENVIRONMENTAL STEWARDSHIP

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

Proper handling and safe use ofchemicals

Chemical Regulations in the USA, Europe, and other locations require
that Material Safety Data Sheets (MSDS) be made available for all
chemicals. The list of chemicals is provided by Hypertherm. 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-12 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.

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.

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

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 EMC-1

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 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.

EMC-2 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.

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 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 W-1

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.

W-2 Safety and compliance

Section 1

SPECIFICATIONS

In this section:

Main features of an automated cutting system ...................................................................................................................................1-2

CNC ...................................................................................................................................................................................................1-3

Cutting table .....................................................................................................................................................................................1-3

Plasma arc cutting (PAC) system ................................................................................................................................................1-3

Control box .......................................................................................................................................................................................1-4

Drive system .....................................................................................................................................................................................1-4

Torch height control (THC) ...........................................................................................................................................................1-4

Oxyfuel torch ....................................................................................................................................................................................1-4

Marker ................................................................................................................................................................................................1-4

Overview of MicroEDGE Pro ..................................................................................................................................................................1-5

Common features ............................................................................................................................................................................1-5

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

Rear panel .........................................................................................................................................................................................1-6

System specifications .....................................................................................................................................................................1-7

Machine interface configurations ...........................................................................................................................................................1-8

HyPath configuration ......................................................................................................................................................................1-8

Picopath configuration ...................................................................................................................................................................1-9

SERCOS II configuration ...........................................................................................................................................................1-10

SERCOS III configuration ..........................................................................................................................................................1-11

Integrated Sensor THC ...............................................................................................................................................................1-12

Secondary enclosure requirements .................................................................................................................................................... 1-13

Interior temperature ......................................................................................................................................................................1-13

Air circulation ................................................................................................................................................................................. 1-13

AC input..........................................................................................................................................................................................1-13

Symbols and marks ................................................................................................................................................................................ 1-14

MicroEDGEPro Instruction Manual 807290 1-1

SPECIFICATIONS

Main features of an automated cutting system

The following diagram illustrates the relationship between the components of an automated cutting system. The
following sections describe these components and their relationships more fully.

Products available from

Operator console

Operator console

Cutting table and

drive system

Cutting table and

drive system

Control box

Control box

Oxyfuel cutting

system

Oxyfuel cutting

system

Products available from

Hypertherm

Hypertherm

CNC

CNC

THC
THC

Plasma cutting

system

Plasma cutting

system

Plasma arc

cutting (PAC)

system

Components of an Automated Cutting System

Torch Height

Controller

Gantry

Rail

Shape cutting system configured with a MicroEDGE Pro CNC

Display and

operator console

MicroEDGE Pro

Rail

Cutting table

1-2 MicroEDGEPro Instruction Manual 807290

SPECIFICATIONS

CNC

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

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

• Installation and Setup Manual (806410)

• Operator’s Manual (806400)

• Programmer’s Reference (806240)

Cutting table

The cutting table is the frame that supports the plate of material 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 controller (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 plate. Additional equipment can be added to the
cutting table to permit beveling 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.

Plasma arc cutting (PAC) 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.

Your cutting system may include a Hypertherm plasma system. Refer to the appropriate manual for additional
information. Electronic (PDF) versions of many Hypertherm manuals are available on the CNC.

If your plasma supply or cutting system is manufactured by another company, refer to the appropriate manual.

MicroEDGEPro Instruction Manual 807290 1-3

SPECIFICATIONS

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, drive
amplifiers, THC, gears, rails, servo motors, and how well they are integrated (tuned) by the table manufacturer. The
MicroEDGEPro is typically used with drives and motors selected by the table manufacturer.

For more information on the drive system for your cutting system, refer to the manual supplied by the table manufacturer.

Torch height control (THC)

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

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

• Sensor™PHC (806150)

• Sensor™THC (806400, 806410, and 806420)

• Command®THC (802780)

• ArcGlide®THC (806450)

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

Oxyfuel torch

Automated cutting systems can also be configured with oxyfuel torches by adding 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 other devices, refer to the appropriate manual.

Refer to the manual supplied by the table manufacturer for more information about an oxyfuel torch.

Marker

A marker can be any device or process that marks a plate rather than piercing or cutting it. If the Hypertherm ArcWriter
is configured in your system, refer to the ArcWriter manual (802520) for information about installation and operation.
Any HPR plasma system can also be used for marking. See the appropriate HPR manual for more information.
For other devices or processes, refer to the appropriate manual.

1-4 MicroEDGEPro Instruction Manual 807290

SPECIFICATIONS

Overview of MicroEDGE Pro

The controller is a PC-based CNC that uses Hypertherm’s Phoenix software to control one or more cutting or marking
systems.

Common features

The HyPath, Picopath, and SERCOSII and SERCOSIII models of the MicroEDGEPro CNC are configured with the
following types of communication ports:

• Serial (2RS-232 and 2 RS-422)

• Ethernet (1)

• Hypernet (1)

• USB (5)

• Networking for part program download or remote diagnostic utilities

• Remote on/off interface

For more information about MicroEDGEPro features, see System Specifications, in this section.

System options

MicroEDGE Pro features can be expanded with the addition of the following options that are available from Hypertherm
or your system integrator:

• LCD touchscreen monitor (with 1024 x 768 resolution and 4:3 aspect ratio) and 2m (6ft) cables for power, USB,
and VGA

• Touchscreen extension cable of up to 50m (160ft) for keyboard, video, and mouse

• Multiple drive axes

• Sensor THC or ArcGlide THC interface

• Analog joystick and speedpot interface

• Wireless card for Ethernet LAN

Front view of the MicroEDGEPro CNC (all models)

MicroEDGEPro Instruction Manual 807290 1-5

SPECIFICATIONS

Rear panel

The rear panel of the CNC has cable connectors for power, motion control feedback, I/O, and communication ports.
These connectors are clearly labeled with their function. There are four configurations available: HyPath, Picopath,
SERCOSII, and SERCOSIII.

For more information about the electrical installation of the MicroEDGEPro CNC, see Section3, Installation.

Note: The rear panel shown below is for reference only. The rear panel on individual CNC units depends on which

configuration is ordered.

AC

power

input

LAN

port

I/O port

Remote On/Off

Antenna ports

for optional

wireless I/O

Hypernet

port

USB
ports

Drive/encoder ports

Serial

portson the

motherboard

(RS-232)

Rear panel of the Picopath MicroEDGE Pro CNC

VGA

port

Optional joystick and

speedpot port

Serial

ports on

the serial

isolation board

(RS-422or

RS-232)

Optional

SensorTHC

ports (2)

1-6 MicroEDGEPro Instruction Manual 807290

SPECIFICATIONS

System specifications

System Features

Processor Intel® Processor
Operating system Windows® XPe™
Software Phoenix version 9.7.1 or later
LAN ports 1 Ethernet port for general use
Hypernet port 1 for communication with Hypernet-enabled systems
USB ports 5 USB 2.0ports
Serial ports 4 (2 RS-232 and 2 isolated RS-232/RS-422 configurable ports) with D-sub 9-pin

connectors
VGA port 1 standard 15-pin port for monitor
Onboard monitoring devices Hardware monitoring, including fan, CPU, temperature, voltage, POST display
Hard drive SATA drive
THC support 2 Sensor THCs or 4 ArcGlide THCs (over Hypernet or discrete connections)
Certification cCSAus, CE GOST-TR, c-Tick, UkrSEPRO

Configuration HyPath Picopath SERCOS II SERCOS III

Number of I/O 24/24 12/12 512/512 512/512
I/O type Input: positive logic

Output: contact

closure
Axes available 2-4 2-4 2-12 2-12

Power

AC input Voltage: 100 VAC to 240VAC

Current: 1.3 A at 100VAC / 0.6A at 240VAC

Frequency: 50/60Hz
Slow blow fuse 2 A, 250 VAC

HyPath Picopath SERCOS II SERCOS III

DC available for I/O 24 V at 1.5 A 24 V at 1.5 A – –
Transient over-voltage at

mains installation

Environmental

Temperature 0ºC to 40ºC (32ºF to 104ºF)
Humidity 50% relative humidity at 40ºC (104ºF), 90% relative humidity at 20ºC (68ºF)
Ingress protection IP2X according to IEC 60529. Protect the equipment from exposure to excessive

Altitude Operational up to 2,000m (6,561.68feet)
Environmental pollution

degree

Mechanical

Height 238 mm (9.38 in.)
Width 463 mm (18.22 in.)
Depth 332 mm (13.08 in.)
Weight 15.9 kg (35 lbs)

Category II

moisture.

Level 2

Input and output:
Negative logic

Fiber optic ring Ethernet

MicroEDGEPro Instruction Manual 807290 1-7

SPECIFICATIONS

Machine interface configurations

The CNC machine interface is the connection from the CNC to devices on the cutting table to achieve command motion
and to send or receive operational signals (I/O). The selection of a machine interface is based on the total number of
axes (motors) and I/O that you need for your application and that are supported by the CNC software. In addition to the
number of I/O signals required, the style of I/O should be considered to understand what devices and ratings you need
to operate external devices on the table, such as a Cut On signal or lifter station.

HyPath configuration

The HyPath interface is available in multiple configurations. The basic system offers 2 to 4axes with 24inputs and
24outputs. The following table lists configuration options

Part Number Number of Axes Number of I/O Integrated

Sensor THC

090118 2 24/24 No Yes No
090119 3 24/24 No Yes No

0990120 4 24/24 No Yes No

090121 2 24/24 2 Yes Yes
090122 3 24/24 2 Yes Yes
090123 4 24/24 2 Yes Yes

Wireless Analog

Rear panel of 090123

1-8 MicroEDGEPro Instruction Manual 807290

SPECIFICATIONS

Picopath configuration

The Picopath Interface offers 2 to 4 axes of motion control with 12 inputs and 12 outputs. This interface can be used to
retrofit an existing system with a compatible Picopath interface.

The Picopath interface can be configured to supply encoder power at 5 VDC, 12 VDC, or to supply externally
supplied (standalone) voltage encoders. See the circuit example in the Installation section that shows the
PicopathI/Oconnections.

Part Number Number of Axes Number of I/O Integrated

Sensor THC

090124 2 12/12 NO No No
090125 2 12/12 2 No Yes
090126 2 12/12 NO Yes No
090127 2 12/12 2 Yes Yes
090128 3 12/12 No No No
090129 3 12/12 2 No Yes
090130 3 12/12 NO Yes No
090131 3 12/12 2 Yes Yes
090132 4 12/12 No No No
090133 4 12/12 2 No Yes
090134 4 12/12 No Yes No
090135 4 12/12 2 Yes Yes

Wireless Analog

Rear panel of 090135

MicroEDGEPro Instruction Manual 807290 1-9

SPECIFICATIONS

SERCOS II configuration

SERCOS (SErial Real time COmmunication System) servo drive interface communicates with the drive amplifiers using
a fiber optic ring. SERCOSII replaces the traditional +/- 10VDC analog output motion control card (MCC) with a fiber
optic driver card. This configuration allows you to expand your system and accommodate 12axes and 512 I/O.

Notes:

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

• SERCOSII compatible (digital) drives must be used with this configuration.

• All SERCOSII MicroEDGEPro configurations offer 512 I/O and wireless networking.

Part

Number

090107 2 Yes
090108 3 Yes
090109 4 Yes
090110 5 Yes
090111 6 Yes
090112 7 Yes
090113 8 Yes
090114 9 Yes
090115 10 Yes
090116 11 Yes
090117 12 Yes

Number

of Axes

Wireless

Rear panel for all SERCOSII models

1-10 MicroEDGEPro Instruction Manual 807290

SPECIFICATIONS

SERCOS III configuration

SERCOS stands for SErial Real time COmmunication System servo drive interface. This approach to communication
with the drive amplifiers uses Ethernet 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.

Notes:

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

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

• All SERCOSIII MicroEDGE Pro configurations offer 512I/O and wireless networking.

Part

Number

090172 2 Yes
090173 3 Yes
090174 4 Yes
090175 5 Yes
090176 6 Yes
090177 7 Yes
090178 8 Yes
090179 9 Yes
090180 10 Yes
090181 11 Yes
090182 12 Yes

Number

ofAxes

Wireless

Rear panel for all SERCOSIII models

MicroEDGEPro Instruction Manual 807290 1-11

SPECIFICATIONS

Integrated Sensor THC

If your MicroEDGEPro configuration includes the optional integrated Sensor THC, the CNC includes an analog input
for the HyPath and Picopath configuration and the following printed circuit boards (PCBs):

• Analog PCB (141125) for 1 to 2 Sensor THCs

• Breakout PCB (141210) for 1 to 2 Sensor THCs, 1 joystick, and 1 to 2 speedpots

• VDC 3 PCB (141201) for 1 Sensor THC

For more information, see Installation.

Refer to the following Phoenix software manuals for detailed information on the software that operates on the
MicroEDGEPro CNC:

• Installation and Setup Manual (806410)

• Operator’s Manual (806400)

• Programmer’s Reference (806420)

Sensor THC connectors (THC 1 and THC 2)

THC 1

THC 2

1-12 MicroEDGEPro Instruction Manual 807290

SPECIFICATIONS

Secondary enclosure requirements

If the MicroEDGEPro CNC is installed in a secondary enclosure, the secondary enclosure must maintain the
environmental specifications for operation that are listed in System specifications in this section. In particular, the
temperature within the primary MicroEDGEPro enclosure must not exceed 60°C (140°F).

The addition of auxiliary cooling may be required to insure that the internal temperature of the MicroEDGEPro enclosure
remains within the system specification.

Interior temperature

During operation, the temperature of the utility PCB (141194, 141222, 141256, 141307) within the enclosure must
remain below 60°C (140°F).

The temperature of the utility PCB is reported on the Control Information screen in Phoenix software. The utility PCB
temperature can also be displayed in the Watch Window. To add this temperature monitor to the Watch Window:

1. From the Main screen, choose Setups > Watch.

2. Select Temperature from the Lower Location dropdown list.

3. Choose OK.

Air circulation

A space of 5cm (2in.) must be maintained on the top and on all sides between the primary and secondary enclosures
to allow air to circulate adequately around the MicroEDGEPro chassis.

AC input

The range for AC power entering the enclosure must be maintained within 50/60Hz, 100 – 240VAC.

MicroEDGEPro Instruction Manual 807290 1-13

SPECIFICATIONS

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

s

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.

1-14 MicroEDGEPro Instruction Manual 807290

Section 2

INSTALLATION

In this section:

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

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

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

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

Mounting the CNC ....................................................................................................................................................................................2-4

Mounting hole patterns on the bottom of the CNC ................................................................................................................2-4

AC power .....................................................................................................................................................................................................2-5

Power cable ......................................................................................................................................................................................2-5

Chassis grounding .....................................................................................................................................................................................2-6

Interface ports .............................................................................................................................................................................................2-7

Hypernet interface ...........................................................................................................................................................................2-7

LAN interface ....................................................................................................................................................................................2-7

USB interface (5) ............................................................................................................................................................................2-7

Serial ports (4) .................................................................................................................................................................................2-7

VGA Port 1 .......................................................................................................................................................................................2-7

Picopath connections ...............................................................................................................................................................................2-8

Picopath I/O connections ..............................................................................................................................................................2-8

Picopath I/O connector .................................................................................................................................................................2-9

Picopath I/O circuit examples ...................................................................................................................................................2-10

Picopath drive/encoder connectors ......................................................................................................................................... 2-11

Encoder voltage options on the Picopath interface ........................................................................................................................ 2-13

Encoder jumper options ..............................................................................................................................................................2-13

HyPath connections ............................................................................................................................................................................... 2-16

HyPath I/O .....................................................................................................................................................................................2-16

HyPath inputs ................................................................................................................................................................................ 2-17

HyPath outputs .............................................................................................................................................................................2-19

HyPath I/O connectors ...............................................................................................................................................................2-22

HyPath 4-axis servo connectors ............................................................................................................................................... 2-24

Analog connections ................................................................................................................................................................................2-26

Sensor THC connector ............................................................................................................................................................... 2-26

MicroEDGEPro Instruction Manual 807290 2-1

INSTALLATION

THC cables .................................................................................................................................................................................... 2-27

Joystick and speedpot connector ............................................................................................................................................. 2-28

Joystick and speedpot cable adapter for MicroEDGE CNC (223252) .......................................................................... 2-29

SERCOS II I/O configuration ...............................................................................................................................................................2-30

SERCOS III I/O configuration ..............................................................................................................................................................2-31

SERCOS III Cable ....................................................................................................................................................................... 2-31

Serial port configuration ........................................................................................................................................................................ 2-32

Serial ports 1 and 2 ..................................................................................................................................................................... 2-32

Serial ports 3 and 4 ..................................................................................................................................................................... 2-32

Remote on/off cable ............................................................................................................................................................................... 2-34

Wireless network card ........................................................................................................................................................................... 2-35

Preparing to install the antenna .................................................................................................................................................2-35

Installing the antenna ................................................................................................................................................................... 2-35

Checking the wireless network in Windows .......................................................................................................................... 2-36

Mapping a network drive ............................................................................................................................................................2-37

Adding a folder in Phoenix .........................................................................................................................................................2-38

2-2 MicroEDGEPro Instruction Manual 807290

INSTALLATION

Upon receipt

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

• MicroEDGEPro CNC

• AC power input cable (North America)

• AC power input cable connector (all other regions)

• Joystick and speedpot adapter cable for analog option

• MicroEDGEPro CNC instruction manual

• Phoenix software instruction manuals (3)

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

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 Hypertherm 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.

Direct any technical questions to your authorized Hypertherm distributor or the nearest Hypertherm Technical Service
Department (listed in the front of this manual).

Placement of system components

• Place all system components in position prior to making electrical and interface connections.

• Ground all system components to earth. See Recommended grounding and shielding practices in this section for
details.

• Insure that the forced air ventilation opening is not blocked.

• Do not restrict operator access to the AC power connector for connection and disconnection of the power cord.
The AC power connector is the primary means for disconnection of power to the equipment.

MicroEDGEPro Instruction Manual 807290 2-3

INSTALLATION

Mounting the CNC

Before you configure the MicroEDGEPro CNC, mount all system components using the appropriate instructions.

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

463 mm

(18.22 in)

238 mm

9.38 in

332 mm

(13.08 in)

Front and Side Views of the MicroEDGEPro CNC

Mounting hole patterns on the bottom of the CNC

If you are upgrading from a MicroEDGE CNC to a MicroEDGEPro, the mounting bolt patterns are the same on both
systems.

483 mm

(19 in)

279 mm

(11 in)

.281 in. diameter

for1/4 in.

or 6mm bolts

MicroEDGE Pro mounting pattern

2-4 MicroEDGEPro Instruction Manual 807290

INSTALLATION

AC power

Fuse size – 2 Amp, 250 V slow-blow

Ground nut and

AC Power

connector

Power cable

An AC power cable is standard equipment for North America, and is shipped with the MicroEDGEPro CNC. For other
regions, the CNC is shipped with a power connector only to allow you to create a connector and cable combination that
meet the requirements of local code and power connections.

To create a power cable, use the plug (108842) that ships with the MicroEDGEPro CNC and connect a 3-wire cable
for line, neutral, and ground signals according to local electrical codes. For more electrical specifications, see the Power
section of the System Specifications table in the Specifications section. Also see the drawings below for examples.

lockwasher
#10-32

Note: The fuse block is universal and holds 1fuse to comply with local electrical codes

Customer-supplied power

(without neutral)

L1 – line

L2 – line

PE ground

MicroEDGEPro CNC
(as shipped)

Power entry

module

1 fuse: 2 amp,

5 x 20 mm or

0.25" x 1.25"

Customer-supplied power

(with neutral)

L1 – line

Neutral

PE ground

VAC input wiring examples

MicroEDGEPro CNC
(as shipped)

Power entry

module

1 fuse: 2 amp,

5 x 20 mm or

0.25" x 1.25"

MicroEDGEPro Instruction Manual 807290 2-5

INSTALLATION

Chassis grounding

The CNC must be properly grounded according to national and local electrical codes for safe operation. Use a number
6AWG (13mm2) wire between the ground stud on the rear of the CNC to the cutting table as shown below.

WARNING

ELECTRICAL SHOCK CAN KILL

This ground connection must be wired to insure safe and reliable operation.

To the star ground on the cutting table

Ground cable on the CNC

2-6 MicroEDGEPro Instruction Manual 807290

INSTALLATION

Interface ports

Hypernet interface

The Hypernet interface allows a Hypernet connection to a Hypernet-enabled system, such as the ArcGlide THC.

LAN interface

The RJ-45 Ethernet interface allows the MicroEDGEPro to connect to a local area network (LAN) for downloading
parts and using Remote Help.

For more information on LAN setup, see the Phoenix Software Installation and Setup Manual.

USB interface (5)

The USB 2.0 ports can be used to load programs or connect a USB keyboard, mouse, or touchscreen.

Serial ports (4)

The MicroEDGEPro has 4 serial ports that use D-sub 9-pin connectors.

Two RS-232 serial ports (COM1 and COM2) are located on the motherboard.

Two more serial ports (COM3 and COM4) are located on all versions of the serial isolation board:

• 141222 for 4-axis HyPath and Picopath

• 141256 for 2-axis Picopath

• 141194/141307 for SERCOSII and SERCOS III

Transmission rate is up to 115KBaud. Both ports are preset with RS-422 as the default but both can be configured
for RS-232. For more information, see Serial port configuration in this section and in the Maintenance and Diagnostics
section.

VGA Port 1

The VGA port allows connection of an video monitor (touchscreen, LCD, or CRT).

MicroEDGEPro Instruction Manual 807290 2-7

INSTALLATION

Picopath connections

Picopath I/O connections

I/O assignments are made in the Phoenix software on the Machine Setups > I/O screen. For more information, see the

Phoenix Software Installation and Setup Manual.

Rear view of the MicroEDGEPro CNC with Picopath I/O configuration

Picopath I/O offers:

• 12 negative logic inputs rated at 24 VDC

• 12 negative logic outputs, rated at 24 VDC for up to 1 A loads

• 24 VDC field power supply on the Picopath PCB with a total usage of 1.5 A

2-8 MicroEDGEPro Instruction Manual 807290

Picopath I/O connector

Use the following information to create Picopath I/O cables.

The Picopath I/O mating connector is a 37-pin circular connector:

• Cable connector: AMP #208470-1

• Sockets contacts: AMP 66101-3 (16–18 ga), AMP 66105-3 (20–24 ga)

• Hypertherm kit: 228490

INSTALLATION

Pin no. Signal

1 Input 1
2 Input 2
3 Input 3
4 Input 4
6 Input 6
8 Input 8
9 Input 9

10 Input 10
11 Input 11
12 Input 12
13 N/C
14 +24 VDC
15 +24 VDC
16 N/C
17 24 V Common
18 24 V Common
19 N/C
20 N/C
21 Output 1
22 Output 2
23 Output 3
24 Output 4
25 Output 5
26 Output 6
27 Output 7
28 Output 8
29 Output 9
30 Output 10
31 Output 11
32 Output 12
33 I/O Shield
34 +24 VDC
35 +24 VDC
36 24 V Common
37 24 V Common

16

10

5

1

4

9

15

23

28

29

33

34

37

22

Picopath I/O connector J8

Z/W AXIS

DRV/ENC

Picopath I/O connector

X/Y AXIS

DRV/ENC I/O

MicroEDGEPro Instruction Manual 807290 2-9

INSTALLATION

Picopath I/O circuit examples

+5 VDC

+24 VDC

Input

Common

Shield

Switch

(normally open)

37

Customer supplied cable

FET

+24 VDC

MicroEDGE Pro

Input

Common

Shield

37

Customer circuit

Input – CNC sinking

24 VDC coil

with diode

Customer supplied cable

MicroEDGE Pro

Customer circuit

Output, 24 VDC coil – CNC sinking

2-10 MicroEDGEPro Instruction Manual 807290

INSTALLATION

Picopath drive/encoder connectors

Picopath axis assignments are made in Phoenix software on the Machine Setups > Axis screen. For more information,
see the Phoenix Software Installation and Setup Manual.

Use the following information to create Picopath drive/encoder cables.

The Picopath drive/encoder mating connector is a 37-pin, circular connector:

• Cable connector: AMP #208472-1

• Pin contacts: AMP 66099-3 (16–18 ga), AMP 66103-3 (20–24 ga)

• Cabling: Belden # 9504 or equivalent for encoder signals

• Cabling: Belden # 9501 or equivalent for drive signals

• Hypertherm kit: 228489

Notes:

• Enable individual drives for each axis for proper operation.

• Connect cable shields to the metal shell of the connector for optimum noise immunity and to keep signal commons
separate from the ground.

16

23

10

5

1

4

9

15

22

28

29

33

34

37

Picopath drive/encoder

connector J6 and J7

J6
Z/W AXIS
DRV/ENC

Picopath drive/encoder connectors

J7
X/Y AXIS
DRV/ENC

I/O

MicroEDGEPro Instruction Manual 807290 2-11

INSTALLATION

Picopath pin-outs for servo drive connectors

Connector J6

Pin no. for

Z Axis

2 2 +5 VDC or +12 VDC sourced for encoder power
3 3 Encoder power common
4 1 Encoder power output (available if needed)
7 7 Encoder power shield
8 6 Encoder power common (available if needed)

9 5 Encoder channel A input
14 11 Encoder channel /A Input
15 10 Encoder channel B Input
21 17 Encoder channel /B Input
22 16 Encoder channel Z Input
28 23 Encoder channel /Z Input
13 12 Encoder shields
24 26 Drive enable in (relay contact closure)
25 27 Drive enable out (relay contact closure)
37 34 Drive power input (+12 VDC or +15 VDC)
33 29 Servo output (± 10 VDC)
32 30 Drive power common
36 35 Drive power input (-12 VDC or -15 VDC)

20 18 Servo output common
19 31 Drive/servo shield

Pin no. for

W Axis

Signal

Connector J7

Pin no. for

X Axis

2 2 +5 VDC or +12 VDC sourced for encoder power

3 3 Encoder power common

4 1 Encoder power output (available if needed)

7 7 Encoder power shield

8 6 Encoder power common (available if needed)

9 5 Encoder channel A input
14 11 Encoder channel /A Input
15 10 Encoder channel B Input
21 17 Encoder channel /B Input
22 16 Encoder channel Z Input
28 23 Encoder channel /Z Input
13 12 Encoder Shields
24 26 Drive enable in (relay contact closure)
25 27 Drive enable out (relay contact closure)
37 34 Drive power input (+12 VDC or +15 VDC)
33 29 Servo output (± 10 VDC)
32 30 Drive power common
36 35 Drive power input (-12 VDC or -15 VDC)
20 18 Servo output common
19 31 Drive/servo shield

Pin no. for

Y Axis

Signal

Note: See the jumpers on the

Picopath 4-axis backdoor interface
board to select one of the following:

• 5 VDC sourced encoder power
(default).

• 12 VDC sourced encoder power.

• Customer supplied encoder and
field power.

For more information, see Maintenance
and Diagnostics.

2-12 MicroEDGEPro Instruction Manual 807290

INSTALLATION

Encoder voltage options on the Picopath interface

The Picopath interface in the MicroEDGEPro is similar to and compatible with the Picopath interface in an EDGE or
MicroEDGE CNC except that the MicroEDGEPro Picopath interface provides jumper settings that allow the user to
select how the field power supply voltages are routed on the board.

The jumper is set to 5 VDC sourced encoder power in the factory and uses the MicroEDGEPro internal field power
supply to power the encoder, analog, and 24I/O circuits.

The drive/encoder and I/O connections on the back of the Picopath interface provide voltages that you can use to
power an external encoder, provide analog power to a drive, or provide DC power for the cutting system’s I/O.

Encoder power is frequently used in DC drive systems because the motors’ encoder is usually wired directly to the
drive/encoder connector of the CNC. Most modern encoders use 5VDC for power while older cutting systems use
12VDC for encoder power. The jumper blocks on the MicroEDGEPro Picopath interface allow you to replace an older
CNC with the MicroEDGE Pro CNC without having to replace encoders or to rewire the drive circuit of the cutting
system.

Encoder jumper options

The encoder jumper blocks allow you to chose between 5V encoders, 12V encoders, or to supply external voltages to
the MicroEDGEPro. The jumper must be installed on one of these encoder jumper blocks.

5 V sourced encoders use the MicroEDGE Pro internal field power supply to provide 5VDC on pin 2 of each
drive/ encoder connector to power an external encoder. It also puts 5 VDC on the pull-up resistor for each encoder input
signal. This voltage should match the signal voltage of the encoder channels.

12 V sourced encoders use the MicroEDGEPro internal field power supply to provide 12VDC on pin2 of each
drive/ encoder connector to power an external encoder. It also puts 12VDC on the pull-up resistor for each encoder
input signal. This voltage should match the switching voltage of the motor’s encoder.

External encoder voltage provides the MicroEDGEPro with field power to supply encoder power (5VDC or 12VDC),
voltage on the pull-up resistor on the encoder channel, drive analog power (+/- 12VDC), and I/O power (24VDC) to
the Picopath interface. This option is common when a MicroEDGEPro CNC is replacing a CNC that did not have an
internal field power supply (D80).

MicroEDGEPro Instruction Manual 807290 2-13

INSTALLATION

!

J13

12 V encoder

power (out)

J12

5 V encoder

J12

power (out)

+5Vf

J14

External encoder, drive

and I/O voltage

J3

Encoder jumper blocks on the Picopath interface

+Ve +Va -Va

+12Vf -12Vf +24Vf

1

3

5

J12
5 V encoder power (out)
Default setting, shown with
jumper

+24Vf

7

/AXISWDOG_HDR

/AXISWDOG

9

J13

J13

12 V

encoder

power (out)

+12Vf

2

1

2

4

3

4

6

5

6

8

7

8

10

9

10

J14

J14

External

encoder, drive,

and I/O voltage

1

2

Encoder power (in)

+ Drive power (in)

3

4

5

6

- Drive power (in)

7

8

I/O power (in)

10

Circuit layout of the jumper blocks

2-14 MicroEDGEPro Instruction Manual 807290

9

INSTALLATION

The following illustration shows an encoder circuit in which the jumper setting puts voltage on Ve which supplies voltage
to the pull-up resistor on the encoder channels. The Ve voltage should equal the voltage on the encoder channel.

Refer to the instruction manual for your encoder to verify the encoder channel voltage or contact your table supplier.

Ve

Encod er Cha nne l A

Encoder channel A

Encod er Cha nne l /A

Encoder channel /A

Encod er Cha nne l B

Encoder channel B

Encod er Cha nne l // B

Encoder channel /B

From drive/encoder connectors

1

2 7

3 6

4 5

8

1 2

1 2

1 2

1 2

Ve

Ve

Ve

3

1

11

13

10

4

+

-

+

-

+5Vf

6

+5Vf

8

Encoder circuit with jumper settings for voltage on encoder channels

MicroEDGEPro Instruction Manual 807290 2-15

INSTALLATION

HyPath connections

HyPath I/O

The HyPath I/O PCB provides 24 inputs and 24 outputs through four circular plastic connectors (CPCs), each
containing 6 inputs and 6 outputs.

HyPath I/O assignments are made in Phoenix software, on the I/O Setup screen. For more information, see the Phoenix
Software Installation and Setup Manual.

View of the MicroEDGEPro CNC with HyPath 24 I/O, 4-axis servo configuration and 2 Sensor THCs

2-16 MicroEDGEPro Instruction Manual 807290

INSTALLATION

HyPath inputs

• Use positive logic that requires a positive voltage to activate the input.

• Are opto-coupled and have a range of +4.7V minimum to +32V maximum. Internal series resistor = 4.7KOhm.

• +24VDC field power supply on the HyPath and 4-axis servo PCB with a total external usage of 1.5 A.

HyPath input circuit examples

• Connection to a limit switch, a push-button switch, a home switch, a station select switch (toggle switch), a relay
contact, or an emergency-stop button

+5 VDC +24 VDC

4.7 k

MicroEDGEPro

Input

Common

Shield

37

Customer supplied cable

Customer-supplied, normally open switch

• Connection to an opto-isolator, typically found in a THC and a plasma supply.

+5 VDC +24 VDC

4.7 k

Input

Common

Shield

37

Customer supplied cable

Customer circuit

VDC

MicroEDGEPro

Customer circuit

Customer-supplied opto-isolator switch

MicroEDGEPro Instruction Manual 807290 2-17

INSTALLATION

• Typical connection to a PNP-style proximity sensor input (PNP)

+5 VDC +24 VDC

4.7 k

MicroEDGEPro

Customer supplied proximity switch – PNP sourced

Input

Common

Shield

37

Customer supplied cable

Control

circuit

Customer circuit

2-18 MicroEDGEPro Instruction Manual 807290

INSTALLATION

HyPath outputs

• Use relay contact closure (003179). The relay outputs are normally open contacts. Outputs can be set to normally
closed by setting the output logic in the I/O screen in the Phoenix software.

• 5 V to 32 V switching voltage; 5A continuous-resistive load; 2A continuous-inductive load.

HyPath output circuit examples

Connection to a relay coil (1a, 1b, and 1c). Notice that the commons are connected together and a diode (supplied
bythe customer) is used between DC coil connections.

1a.

+24 VDC

1b.

Relay

003179

Relay

003179

MicroEDGE Pro

+24 VDC

Output A
Output B
Common

Output A

Output B

Common

Shield

Shield

VAC

AC coil

37

Customer supplied cable

Customer circuit

AC coil – supplied by customer

24VDC coil,

withdiode

37

Customer supplied cable

MicroEDGE Pro

Customer circuit

24 VDC coil – CNC sourced

MicroEDGEPro Instruction Manual 807290 2-19

INSTALLATION

1c.

+24 VDC

Output A
Output B

Relay

003179

Common

Shield

37

Customer supplied cable

24 VDC coil – CNC sourced

Connection to a relay coil (2a and 2b). The field voltage is supplied by the customer.

2a.

24 VDC coil,

withdiode

Customer circuitMicroEDGE Pro

+24 VDC

Relay

003179

Output A
Output B
Common

Shield

37

Customer supplied cable

VAC

AC relay

Customer circuitMicroEDGE Pro

AC relay – supplied by customer

2-20 MicroEDGEPro Instruction Manual 807290

2b.

INSTALLATION

+24 VDC

Output A

Output B

Relay

003179

MicroEDGE Pro

Common

Shield

37

Customer supplied cable

Opto-relay – supplied by customer

3. Typical connection to an opto-isolator. The input is typical for a THC or PAC System.

VDC

Opto-relay

Customer circuit

+24 VDC

VDC

Opto-relay

Customer circuitMicroEDGE Pro

Relay

003179

Output A
Output B
Common

Shield

37

Customer supplied cable

Opto-relay – CNC sourced

MicroEDGEPro Instruction Manual 807290 2-21

INSTALLATION

HyPath I/O connectors

Notes:

• Isolate all external commons from the chassis ground.

• If external voltage is used to activate I/O, connect the external source’s common to the internal +24V common.

• HyPath systems have the I/O for each connector printed above the connectors.

Use the following information to create HyPath I/O cables.

The HyPath I/O mating connector is a 37-pin, circular connector:

• Cable connector: AMP 206305-1

• Pin contacts: AMP 66098 (16–18AWG), AMP 66331 (20–24AWG)

• Hypertherm kit: 228492

The following pages provide additional specifications and pinout information for the HyPath interface boards.

34

29

23

16

10

5

1

37

4

HyPath I/O connector

33

28

22

15
9

J6 I/O 7–12 J7 I/O 1–6

J5 I/O 13–18J4 I/O 19–24

HyPath I/O connectors

Location of the I/O connectors

2-22 MicroEDGEPro Instruction Manual 807290

HyPath I/O pin-outs

INSTALLATION

Connector J7 – I/O 1 to 6

Pin no. Inputs Pin no. Outputs

1 +24VDC Source 19 +24VDC Source
2 Input 1 20 Output 1A
3 Common 21 Output 1B
4 +24 VDC Source 22 +24V Field
5 Input 2 23 Output 2A
6 Common 24 Output 2B
7 +24VDC Source 25 +24 V Field
8 Input 3 26 Output 3A

9 Common 27 Output 3B
10 +24VDC Source 28 +24 V Field
11 Input 4 29 Output 4A
12 Common 30 Output 4B
13 +24VDC Source 31 +24 V Field
14 Input 5 32 Output 5A
15 Common 33 Output 5B
16 +24VDC Source 34 +24 V Field
17 Input 6 35 Output 6A
18 Common 36 Output 6B

37 Shield

Connector J6 – I/O 7 to 12

Pin no. Inputs Pin no. Outputs

1 +24VDC Source 19 +24 VDC Source
2 Input 7 20 Output 7A
3 Common 21 Output 7B
4 +24VDC Source 22 +24 V Field
5 Input 8 23 Output 8A
6 Common 24 Output 8B
7 +24VDC Source 25 +24 V Field
8 Input 9 26 Output 9A

9 Common 27 Output 9B
10 +24 VDC Source 28 +24 V Field
11 Input 10 29 Output 10A
12 Common 30 Output 10B
13 +24 VDC Source 31 +24 V Field
14 Input 11 32 Output 11A
15 Common 33 Output 11B
16 +24VDC Source 34 +24 V Field
17 Input 12 35 Output 12A
18 Common 36 Output 12B

37 Shield

Connector J5 – I/O 13 to 18

Pin no. Inputs Pin no. Outputs

1 +24 VDC Source 19 +24 VDC Source
2 Input 13 20 Output 13A
3 Common 21 Output 13B
4 +24 VDC Source 22 +24 V Field
5 Input 14 23 Output 14A
6 Common 24 Output 14B
7 +24 VDC Source 25 +24 V Field
8 Input 15 26 Output 15A

9 Common 27 Output 15B
10 +24 VDC Source 28 +24 V Field
11 Input 16 29 Output 16A
12 Common 30 Output 16B
13 +24 VDC Source 31 +24 V Field
14 Input 17 32 Output 17A
15 Common 33 Output 17B
16 +24 VDC Source 34 +24 V Field
17 Input 18 35 Output 18A
18 Common 36 Output 18B

37 Shield

Connector J4 – I/O 19 to 24

Pin no. Inputs Pin no. Outputs

1 +24 VDC Source 19 +24 VDC Source
2 Input 19 20 Output 19A
3 Common 21 Output 19B
4 +24 VDC Source 22 +24 V Field
5 Input 20 23 Output 20A
6 Common 24 Output 20B
7 +24 VDC Source 25 +24 V Field
8 Input 21 26 Output 21A

9 Common 27 Output 21B
10 +24 VDC Source 28 +24 V Field
11 Input 22 29 Output 22A
12 Common 30 Output 22B
13 +24 VDC Source 31 +24 V Field
14 Input 23 32 Output 23A
15 Common 33 Output 23B
16 +24 VDC Source 34 +24 V Field
17 Input 24 35 Output 24A
18 Common 36 Output 24B

37 Shield

MicroEDGEPro Instruction Manual 807290 2-23

INSTALLATION

HyPath 4-axis servo connectors

The HyPath 4-axis servo PCB provides the drive and encoder connections for up to 4 independent servo axes.
Theboard provides two circular connectors. Each connector provides connections for two independent servo axes.

Axis assignments are made in Phoenix software on the Axes screen. For more information, see the Phoenix Software
Installation and Setup Manual.

HyPath servo connector

Use the following information to create HyPath servo cables.

The HyPath servo connector is a 37-pin, circular connector:

• Cable connector: AMP 206150-1

• Socket contacts: AMP 164164 (16–18AWG), AMP 164163 (20–24AWG)

• Hypertherm kit: 228491

J3 Axes 1–2

J4 Axes 3–4

Location of the 4-axis servo connectors

HyPath servo

connectors

2-24 MicroEDGEPro Instruction Manual 807290

Drive/Encoder pin-outs

Notes:

• Z Channel is the marker pulse channel which is 1 pulse/revolution.

• Not all axes may be available. Verify how many axes are available on your CNC in the
Diagnostics > Control Information screen in Phoenix software.

HyPath servo connectors J3, J4

INSTALLATION

37

33

28

22

15

9

4

34

29

23

16

10

5

1

Connector J3 (Axes 1 and 2)

Pin no.

for Axis 1

Pin no.

for Axis 2

Signal

1 20 Axis shield
2 21 Encoder +5 V out
3 22 Encoder common
4 23 Encoder +12 V out
5 24 Encoder common
6 25 Encoder +24 V out
7 26 Encoder common
8 27 Encoder Axis A

9 28 Encoder Axis A\
10 29 Encoder Axis B
11 30 Encoder Axis B\
12 31 Encoder Axis Z
13 32 Encoder Axis Z\
14 33 Axis enable A
15 34 Axis enable B
16 35 Axis servo output
17 36 Analog common
18 37 Axis shield
19 Shield

Connector J4 (Axes 3 and 4)

Pin no.

for Axis 3

Pin no.

for Axis 4

Signal

1 20 Axis shield
2 21 Encoder +5 V out
3 22 Encoder common
4 23 Encoder +12 V out
5 24 Encoder common
6 25 Encoder +24 V out
7 26 Encoder common
8 27 Encoder Axis A

9 28 Encoder Axis A\
10 29 Encoder Axis B
11 30 Encoder Axis B\
12 31 Encoder Axis Z
13 32 Encoder Axis Z\
14 33 Axis enable A
15 34 Axis enable B
16 35 Axis servo output
17 36 Analog common
18 37 Axis shield
19 Shield

The following illustration shows the axis-enable relay contacts for each axis on the 4-axis servo board.

A

Customer

4

B

3

1

CNC

2

Relay SPST

HyPath 4-axis servo – axis enable output relay contacts

MicroEDGEPro Instruction Manual 807290 2-25

INSTALLATION

Analog connections

The MicroEDGE Pro CNC includes connectors for the Sensor THC, as well as a joystick and speedpot so that a table
manufacturer can add these features.

Sensor THC connector

In configurations with integrated Sensor THCs, the MicroEDGEPro has dedicated connectors for THC 1, and THC 2.

Notes:

• Analog inputs for the speed pots are rated at 0 to +10VDC.

• Connect cable shields to the external PE studs for optimum noise
immunity.

• The Series 1 PCI analog card is named PCI-AIC RevX on the CNC

3

7

11 12 13 14

15

Information Diagnostic screen in the Phoenix software

THC connector:

• Cable connector: AMP 206708-1

• Pin contacts: AMP 65105-3

1
4
7

• Cabling: Belden # 9540 or equivalent for encoder signals

• Hypertherm kit: 228495

1 2
4
7

Pin-outs for Integrated Sensor THC 1 and 2 connectors

Pin no. CNC I/O configuration Signal

1 Common Common
2 Input + Nozzle Contact Sense + ( relay contact )
3 Input - Nozzle Contact Sense - ( relay contact )
4 Output + Nozzle Contact Enable + ( relay contact )
5 Output - Nozzle Contact Enable - ( relay contact )
6 Analog input + THC +
7 Analog input - THC ­8 Output + Hold Ignition ( relay contact )
9 Output - Hold Ignition ( relay contact )

Connector ground Shield

2

1

4

6

5

8

9

10

Joystick and speedpot
interface

16

2

3
5 6
8

5
8

9

3

6

9

THC 1 interface

THC 2 interface

2-26 MicroEDGEPro Instruction Manual 807290

INSTALLATION

THC cables

The following tables provide the pin-out details for the connectors on the Sensor THC amplifier, the MicroEDGEPro
CNC, and the voltage divider board (VDC3). Use these tables to manufacture the cables that connect these devices in
your configuration.

Pin-outs for voltage divider board 3 (VDC3) connectors

J1 Power connector on VDC3
Pin no. Signal

1 120 VAC line
2 120 VAC neutral

J3 Field connector on VDC3 (black terminal strip)
Pin no. Signal

1 EMI chassis ground*
2 Electrode (connection to negative connection inside plasma system)
3 Work (connection to the positive connection inside of the plasma system)
4 No connection
5 Ohmic contact wire connection

* This pin is not connected under normal conditions. If your cutting system has excess noise with this configuration, connect the pin to

an adjacent metal chassis.

Pin-out for the cable between J2 on VDC3 and THC1 on the CNC
J2 I/O Connector on VDC3 THC 1 Connector on the CNC
Pin no. Signal Pin no. Outputs

1 24 VDC common (out) 1 24 VDC Common (in)
2 +24 VDC (out) 2 Nozzle Contact Sense +
3 Nozzle contact sense (output) 3 Nozzle Contact Sense ­4 Nozzle contact enable (input) 4 Nozzle Contact Enable +
5 24 VDC common (out) 5 Nozzle Contact Enable ­6 + Analog out 6 + Analog in
7 - Analog out (analog common) 7 - Analog in
8 Chassis ground (cable shield) – –

8 Hold +
9 Hold -

MicroEDGEPro Instruction Manual 807290 2-27

INSTALLATION

Joystick and speedpot connector

• Cable connector: AMP 206037-1

• Pin contacts: AMP 65105-3

• Cabling: Belden # 8308 or equivalent for encoder signals

• Hypertherm kit: 228837

Pin-outs for joystick and speedpot connector

Pin no. Signal

1 Joystick up
2 Joystick down
3 Joystick left
4 Joystick right
5 Common
6 10 V reference
7 Speed pot 1+
8 Speed pot 1-

9 Common
10 10 V reference
11 Speed pot 2+
12 Speed pot 2­13 Common
14 Common
15 Common
16 Common

2-28 MicroEDGEPro Instruction Manual 807290

INSTALLATION

Joystick and speedpot cable adapter for MicroEDGE CNC (223252)

If the MicroEDGEPro CNC is replacing a Hypertherm MicroEDGE CNC, an adapter cable is required to allow the cable
for the MicroEDGE joystick and speedpot to connect to the MicroEDGEPro.

Side A

Connect to the MicroEDGE joystick and

speedpot cable

1 3

2

64

5

7 9

8

Side A Pin no. Wire color Signal Side B Pin no.*

1 Black Joystick up 1
2 White Joystick down 2
3 Red Joystick left 3
4 Green Joystick right 4
5 Brown Common 5
6 Blue Speed pot 1+ 7
7 Orange Speed pot 1- 8
8 Yellow Speed pot 2+ 11
9 Purple Speed pot 2- 12

Side B

Connect to the MicroEDGEPro joystick and

speedpot connector

2 1

4

12

3

7

8

11

5

*On Side B, there are no connections on pins 6, 10 and 13 to 16.

MicroEDGEPro Instruction Manual 807290 2-29

INSTALLATION

SERCOS II I/O configuration

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

Rear view of the SERCOSII MicroEDGE ProCNC

2-30 MicroEDGEPro Instruction Manual 807290

INSTALLATION

SERCOS III I/O configuration

The MicroEDGEPro SERCOSIII I/O configuration conforms to the SERCOSIII standard. The full details of this
specification cannot be addressed in this manual. Refer to the Phoenix Software V9 Series Installation and Setup
Guide (806410) for instructions about how to set up your EDGEPro SERCOSIII CNC. For complete information about
SERCOS technology and specifications, refer to: http://www.sercos.com.

Port 1

Port 2

Rear view of the SERCOSIII MicroEDGEPro CNC

SERCOS III Cable

A shielded 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.

Part number Length Part number Length

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

MicroEDGEPro Instruction Manual 807290 2-31

INSTALLATION

Serial port configuration

The serial ports in the MicroEDGEPro are designed to operate with a standard 9-pin serial port connector. The
following list provides specifications for these ports. For more information, see the Phoenix Software Installation and
Setup manual.

Serial isolation specifications (see Machine Setups > Ports In Phoenix software)

Channel Type Optically isolated RS-422 or RS-232
Information Code ASCII
Baud Rate User-selectable up to 115.2K baud
Number of Start Bits 1
Number or Stop Bits 1
Word Length User-selectable 7 or 8 bits
Parity User-selectable none, even or odd
Data Synchronization XON (Control-Q) / XOFF (Ctrl/S)
Time Out User-selectable in one-second increments
Transmit Delay User-selectable in 0.01-second increments
Rear Panel Connector IBM-PC/AT compatible 9-pin D-type female

Serial ports 1 and 2

The default configuration for serial ports 1 and 2 on the motherboard is RS-232. These ports cannot be reconfigured.

Serial ports 3 and 4

Both serial ports on the following boards are shipped in the RS-422 wiring configuration:

• HyPath and Picopath 4-axis MCC, utility, and serial isolation board (141222)

• Picopath 2-axis MCC, utility, and serial isolation board (141256)

• SERCOSII and SERCOSIII utility and serial isolation board
(141194/141307)

To change either port to an RS-232 configuration, you must find the jumper
for the appropriate port and move the jumper from the RS-422 position to the
RS-232 position. These positions are clearly marked on the board.

Configure the port for RS-232 operation before connecting RS-232 compatible
devices.

Serial port

3

Serial port

4

RS-422

RS-232

Jumpers in

RS-422 position

RS-422

RS-232RS-232

2-32 MicroEDGEPro Instruction Manual 807290

CNC RS-422 DB-9 Pin-out

Pin no. Signal Name Description

1 Shield Chassis ground
2 TxD- Transmit data - to external device
3 RxD- Receive data - from external device
4 TxD+ Transmit data + to external device
5 Common Ground
6 No connection
7 RxD+ Receive data + from external device
8 No connection
9 No connection

CNC RS-232 DB-9 Pin-out (reference only)

Pin no. Signal Name Description

1 Shield Chassis ground
2 TxD Transmit data to external device
3 RxD Receive data from external device
4 No connection
5 Common Ground
6 No connection
7 No connection
8 No connection
9 No connection

INSTALLATION

MicroEDGEPro Instruction Manual 807290 2-33

INSTALLATION

Remote on/off cable

Hypertherm does not supply a cable that connects to the remote on/off connector on the following boards:

• 141222 for 4-axis HyPath and Picopath

• 141256 for 2-axis Picopath

• 141194/141307 for SERCOSII and SERCOSIII

However, Hypertherm provides the cable connector which shipped with the system in the remote on/off port, as shown
in the following illustrations. You can use this connector to terminate a custom-built cable of the appropriate length.

Picopath and HyPath SERCOSII and SERCOSIII

Location of the remote on/off connector on the MicroEDGEPro

To build the remote on/off cable, remove the connector from the port and attach purchased wires, a switch, and an LED.
Use the circuit diagram below for details.

1

Remote on/off +

2

Remote on/off -

Customer supplied wiring, switch

and LED

On/Off

3

Common

LED

4

+12 V

5

Shield

Circuit diagram for the remote on/off cable

2-34 MicroEDGEPro Instruction Manual 807290

INSTALLATION

Wireless network card

The MicroEDGEPro supports an optional wireless network card for part downloads, Remote Help, and other network
tasks. The wireless network card is installed in PCI slot2 on the motherboard. Two antennas extend from the card on
the back of the MicroEDGEPro. Unfold and adjust the antennas to a 45degree angle.

When the MicroEDGE Pro is installed within a secondary enclosure, the antennas may be extended up to 3m (10ft)
from the wireless network card. When using the 3m antenna extension cables (223251), only 2.4 GHz frequency can
be used at the router or access point.

Preparing to install the antenna

Follow these guidelines before mounting the antennas on a secondary CNC enclosure:

• The antennas must exit to room air, preferably without metallic obstructions blocking signal transmission (such as

equipment cabinets, circuit breaker panels, transformers, etc).

• Antennas should not be located near the floor.

• Use a plastic protective barrier if necessary to prevent accidental bumping of antenna orientation.

• When mounting the antennas on a secondary CNC enclosure, you will need to drill two holes to accommodate

the threaded, bulkhead-mount antenna connectors. Be sure the connectors make contact with the metal on the
enclosure, or use a lock washer to penetrate any coating on the enclosure. Metal-to-metal contact ensures that the
antennas are grounded to the chassis.

• The antenna connections are not waterproof.

Installing the antenna

Before you begin the antenna installation:

• Make sure not to twist or kink the extension cables.

• The extension cables should reside entirely inside the enclosure. Only the antenna itself should be on the outside of

the enclosure.

• Route the cable away from noise generating sources such as power supplies, motor amplifiers, and AC circuits.

• Use a service loop of at least 10cm (4in.) diameter to coil excess coaxial antenna cable.

MicroEDGEPro Instruction Manual 807290 2-35

INSTALLATION

1. After selecting a suitable antenna mounting location, drill two 6.35mm (.25in.) holes into the secondary CNC
enclosure as shown below (drawing not to scale). Remove any burrs inside and outside.

6.35 mm (.25 in)
diameter

36 mm (1.4 in)

2. Thread each bulkhead-mount antenna base through a hole and secure with a lock washer and nut. Be sure the
antenna base makes contact with unpainted metal on the enclosure to ensure proper grounding.

3. Connect the antennas to the bases and point them skyward.

4. Connect the cables to the coaxial connectors on the wireless network card. Be sure to avoid twisting or kinking
the cables. The entire extension cable should be within the CNC enclosure. Only the antennas are mounted on the
outside of the enclosure.

5. Restore AC power to the CNC.

Checking the wireless network in Windows

The MicroEDGEPro comes from the factory with the wireless network card drivers installed. To check the wireless
network in Windows:

1. Turn on the MicroEDGEPro.

2. Choose Setups>Password and enter the Special Setups password.

3. Choose System>Network Tools. The Network Connections dialog opens showing all network connections.

2-36 MicroEDGEPro Instruction Manual 807290

INSTALLATION

Mapping a network drive

Phoenix requires a network drive to be defined in Windows. After you define the network drive, you can add it as a folder
in Phoenix.

Before you begin, connect a USB keyboard to the MicroEDGEPro.

1. Press Alt+F4 to exit the Phoenix software.

2. Choose Start Menu>Windows Explorer>Tools>Map Network Drive.

3. Choose a drive letter, then the folder. Make note of the folder path. When you connect to the folder in Phoenix, you

will need to enter the folder path.

4. Choose Reconnect at Logon.

5. Choose Finish to save the mapped network drive.

MicroEDGEPro Instruction Manual 807290 2-37

INSTALLATION

Adding a folder in Phoenix

Note: The Add Folders feature must be enabled in the Special Setups screen before you can perform these steps.

1. Restart the Phoenix software.

2. From the Main Screen, choose the Files soft key.

3. Double-click the blue message to add a folder.

4. In the dialog, choose Mapped Drive.

5. Enter a Drive Name. This is the name that appears in the Load Files list.

6. Enter the actual path to the drive, not a drive letter. The drive path is formatted \\servername\foldername.

7. Choose OK.

2-38 MicroEDGEPro Instruction Manual 807290

Section 3

OPERATION

In this section:

Operating the CNC ...................................................................................................................................................................................3-2

Operator console ............................................................................................................................................................................3-2

Touch screen LCD ..........................................................................................................................................................................3-2

LCD display ......................................................................................................................................................................................3-2

Screen navigation ............................................................................................................................................................................3-3

Help ....................................................................................................................................................................................................3-4

View additional manuals ................................................................................................................................................................3-4

Show bookmarks .............................................................................................................................................................................3-5

Automated operations...............................................................................................................................................................................3-5

Align Wizard .....................................................................................................................................................................................3-5

CutPro Wizard .................................................................................................................................................................................3-6

Using Phoenix without a touch screen ..................................................................................................................................................3-6

PC keyboard .....................................................................................................................................................................................3-6

Updating Phoenix software ......................................................................................................................................................................3-7

Updating the software ....................................................................................................................................................................3-7

Updating the Help ...........................................................................................................................................................................3-7

Updating the cut charts .................................................................................................................................................................3-8

MicroEDGE Pro Instruction Manual 807290 3-1

OPERATION

Operating the CNC

Phoenix software runs on the Hypertherm computer numerical controls (CNCs) including the EDGE® Pro and
MicroEDGE® Pro. Phoenix supports either a touch screen or LCD display with a USB-connected keyboard and mouse
for entering information and navigating the software. For more information, see the Phoenix Software Operator’s Manual.

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

Operator console

An optional operator console provided by an OEM or a system integrator 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.

Touch screen LCD

The Phoenix software is designed for touch screens with 1024 x 768 resolution and a 4:3 aspect ratio. When your CNC
is equipped with a touch screen, you can enter data into the software by touching the window controls and fields. Any
field that requires data input automatically displays an onscreen keypad when you touch it.

LCD display

The MicroEDGE Pro can support an LCD display and requires 1024 x 768 resolution with a 4:3 aspect ratio.

3-2 MicroEDGE Pro Instruction Manual 807290

OPERATION

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.

Refer to the Phoenix Software Operator’s Manual for more details.

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 with an example machine configuration.

Phoenix Main screen

MicroEDGE Pro Instruction Manual 807290 3-3

OPERATION

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.

The Show Bookmarks soft key opens the navigation pane. On a keyboard, press Ctrl+F to use full text search.

View additional manuals

The Help screen may also display buttons 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 buttons to view this additional information.

3-4 MicroEDGE Pro Instruction Manual 807290

OPERATION

Show bookmarks

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.

Note: If you are operating the MicroEDGE Pro with a keyboard, use the Page Up/Page Down keys to scroll through

the document on screen.

Automated operations

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

Align Wizard

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

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

For more information, see Align Wizard in the Arranging Parts chapter of the Phoenix Software Operator’s Manual.

MicroEDGE Pro Instruction Manual 807290 3-5

OPERATION

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 plate, 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 the Cutting Parts chapter.

Using Phoenix without a touch screen

Phoenix software supports using a built-in keypad or a USB, PC keyboard to perform functions and data entry in the
Phoenix software.

PC keyboard

Hypertherm CNCs can support a USB, PC keyboard. You can use a keyboard to perform functions and data entry in the
Phoenix software.

A label (210047) is included with the MicroEDGE Pro to modify a PC keyboard to use with Phoenix software, as shown
in the following illustration.

3-6 MicroEDGE Pro Instruction Manual 807290

OPERATION

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 > Controls for Automation > Software 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)

Follow the instructions on the web page to download the updates in your language.

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 the

section Saving System Files in Chapter 11 Diagnostics and Troubleshooting for more information.

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

• 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. If you are not using a keyboard, double-tap the screen to display

an onscreen keyboard.

3. Enter updatesoftware (all lower 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. If you are not using a keyboard, double-tap the screen to display

an onscreen keyboard.

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

memory stick and installs the new help file.

MicroEDGE Pro Instruction Manual 807290 3-7

OPERATION

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 of .usr cut charts. Before installing the update, back up your modified cut charts.

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’s Manual for instructions.

To back up modified cut charts:

1. At the CNC, plug 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 Torch 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 folder of the memory stick.

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.

3-8 MicroEDGE Pro Instruction Manual 807290

Section 4

MAINTENANCE AND DIAGNOSTICS

In this section:

Introduction .................................................................................................................................................................................................4-3

Diagnostic tests..........................................................................................................................................................................................4-4

Serial test ..........................................................................................................................................................................................4-6

USB test ............................................................................................................................................................................................4-7

I/O test ...............................................................................................................................................................................................4-8

Axis test ..........................................................................................................................................................................................4-10

THC test ......................................................................................................................................................................................... 4-11

LAN and Hypernet tests .............................................................................................................................................................4-12

Joystick and speedpot test .........................................................................................................................................................4-13

Troubleshooting.......................................................................................................................................................................................4-14

Introduction .................................................................................................................................................................................... 4-14

MicroEDGE Pro troubleshooting tables ..................................................................................................................................4-15

Power up ................................................................................................................................................................................... 4-15

Display ....................................................................................................................................................................................... 4-15

Field power failure ................................................................................................................................................................... 4-15

Input failure ............................................................................................................................................................................... 4-16

Output failure ...........................................................................................................................................................................4-16

Hypernet .................................................................................................................................................................................... 4-17

LAN connection ....................................................................................................................................................................... 4-17

Motion issues ........................................................................................................................................................................... 4-18

THC ............................................................................................................................................................................................ 4-20

Serial communication issues ................................................................................................................................................ 4-21

USB issues ............................................................................................................................................................................... 4-21

Cut quality ................................................................................................................................................................................. 4-21

CNC temperature ...................................................................................................................................................................4-22

CNC is slow ............................................................................................................................................................................. 4-22

Wireless troubleshooting ...................................................................................................................................................................... 4-23

MicroEDGEPro Instruction Manual 807290 4-1

MAINTENANCE AND DIAGNOSTICS

Component locations and information ............................................................................................................................................... 4-24

HyPath 24 I/O board (141070) ................................................................................................................................................ 4-25

Motherboard (141110) ............................................................................................................................................................... 4-27

SERCOSII master board (141116) ........................................................................................................................................4-28

SERCOSIII master board (141310) .......................................................................................................................................4-29

Picopath 4-axis servo board (141122) ................................................................................................................................... 4-30

Analog board (141125) .............................................................................................................................................................. 4-34

Power distribution board (141153) ......................................................................................................................................... 4-36

SERCOSII and SERCOSIII serial isolation and utility board (141194/141307) ....................................................... 4-38

HyPath 4-axis servo board (141197) ...................................................................................................................................... 4-40

CPC analog breakout board (141210) ..................................................................................................................................4-42

HyPath and Picopath 4-axis MCC, utility, and serial isolation board (141222) ............................................................ 4-44

Picopath 2-axis servo board (141254) ................................................................................................................................... 4-47

Picopath 2-axis MCC, utility, and serial isolation board (141256) ...................................................................................4-50

VDC for integrated Sensor THC (141201) ......................................................................................................................................4-53

4-2 MicroEDGEPro Instruction Manual 807290

MAINTENANCE AND DIAGNOSTICS

DANGER

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before performing any maintenance.

See the Safety section in this manual 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, refer to the Safety section for operating precautions and warning formats.

MicroEDGEPro Instruction Manual 807290 4-3

MAINTENANCE AND DIAGNOSTICS

Diagnostic tests

Note: Test kits are required to perform the following diagnostic tests.

Machine interface tests

If you are using a MicroEDGEPro CNC, you can perform diagnostic tests with the following connectors and Phoenix
software to test the interface ports on the CNC (228831):

• Serial interface RS-232 on the motherboard

• Serial interface RS-422 on the serial isolation board

• Ethernet and Hypernet

• USB

Note: This is the only kit needed for SERCOSII and SERCOS III systems and it is included in the HyPath and

Picopath kits.

The HyPath version of the MicroEDGEPro CNC offers the following, additional testers (228832):

• I/O (2)

• Axes

• THC

• Joystick and speedpot

The Picopath version of the MicroEDGEPro CNC offers the following, additional testers (228833):

• I/O (2)

• Axes

• THC

• Joystick and speedpot

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To begin an interface test:

1. From the Main screen, select 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 sections below and on the screen.

Machine interface test screen

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MAINTENANCE AND DIAGNOSTICS

Serial test

The MicroEDGEPro is equipped with four serial ports. Serial 1 and 2 support RS-232 communications. Serial 3 and 4
support RS-422 or RS-232 communications.

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:

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. On the Machine Interface screen, press Test. A message informs you if the test is successful.

In the event of a test failure, contact your OEM or system integrator with the following information:

• Serial 1 or 2 failure: replace motherboard.

• Serial 3 or 4 failure: replace serial isolation card.

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USB test

Conduct this test if the memory stick is not shown as an option when you try to load part programs or update cut charts,
software, or help. Use this test to check all the USB ports: the four on the back and the one on the front of the CNC.

To test the USB port:

1. On the Machine Interface screen, choose a USB port.

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

3. On the Machine Interface screen, press Test. A message informs you if the test is successful.

4. Repeat the test on the remaining USB ports.

If the test fails on multiple USB ports, contact your OEM or system integrator to replace the motherboard.

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MAINTENANCE AND DIAGNOSTICS

I/O test

Conduct this test if:

• An I/O point is malfunctioning.

• You need to eliminate CNC I/O operation as a problem in the system.

• A continuous fault is occurring, such as a limit switch that is not turning on or clearing.

To test I/O:

1. On the Machine Interface screen, choose the I/O port you want to test.

2. Follow the instructions on the screen to connect the Picopath (white) or HyPath (green) test plug into the I/O port
you selected on the back of the MicroEDGEPro.

3. On the Machine Interface screen, press Test. A message informs you if the test is successful.

4. If the test fails, follow the instructions on the screen to connect the second Picopath (orange) or HyPath (red) test
plug to isolate the I/O point that is causing the problem.

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5. On the Machine Interface screen, press Test. The screen reports the number of the failed input or output.

6. Contact your OEM or system integrator with the following information:

Picopath:

• Rewire the I/O to a free I/O point and reassign the I/O function in the Phoenix software.

HyPath:

• If an input has failed, rewire the input to a free input point, then reassign the input function in the Phoenix software.

• If an output has failed, you can remove a relay from a spare output and swap it with the relay at the failed output. No

rewiring is required.

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MAINTENANCE AND DIAGNOSTICS

Axis test

WARNING!

To prevent motion on the table, disconnect all axis cables from the CNC before conducting this test.

This test verifies axis operation. Conduct this test if there is:

• A runaway axis

• No motion

• Erratic motion

• A high number of position errors

• Multiple parts are not cut the correct size

To test an axis:

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

2. Follow the instructions on the screen to connect the HyPath (green) or Picopath (blue) axis simulator board to the
CNC axis port you selected.

3. On the Machine Interface screen, choose Test. A message informs you if the test is successful.

If the test fails, contact your OEM or system integrator to check or replace these parts in the following order:

1. 4-axis servo field interface

2. Ribbon cable

3. MCC card

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THC test

WARNING!

To prevent motion on the table, disconnect all axis cables from the CNC before conducting this test.

Conduct this test if:

• Nozzle contact is not functioning properly. For example, IHS using ohmic contact is not sensing the plate or is not

accurate, the torch is running into the plate during cutting without retracting, or the torch is firing in the air.

• Arc voltage feedback is not functioning properly.

• The torch is rising off the plate or driving into the plate during the first part of a cut after piercing.

To test a THC port:

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

2. Follow the instructions on the screen to connect the THC test cable to the THC port you selected and to the Axis

1 – 2 port (Hypath) or X/Y port (Picopath). Use the blue tester for HyPath and the yellow tester (not shown) for
Picopath.

3. On the Machine Interface screen, choose Test. A message informs you if the test is successful.

If the test fails, contact your OEM or system integrator to check or replace these parts in the following order:

1. Analog field interface card

2. Ribbon cable

3. Analog input card

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MAINTENANCE AND DIAGNOSTICS

LAN and Hypernet tests

The LAN and Hypernet tests both use the same tester.

Conduct this test if:

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

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

To test a LAN 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. On the Machine Interface screen, choose Test. A message informs you if the test is successful.

If either test fails, contact your OEM or system integrator to replace the motherboard.

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Joystick and speedpot test

WARNING!

To prevent motion on the table, disconnect all axis cables from the CNC before conducting this test.

To test the joystick and speedpot port:

1. On the Machine Interface screen, choose the joystick/speedpot port.

2. Follow the instructions on the screen to connect the HyPath (purple) tester to the Joystick/Speedpot port, Axis1-2

port and the I/O 1-6port.
For a Picopath system, connect the brown tester to the Joystick/Speedpot port, the X/Y port and the I/O port.

3. On the Machine Interface screen, choose Test. A message informs you if the test is successful.

If the test fails, contact your OEM or system integrator to check or replace these parts in the following order:

1. Analog field interface card

2. Ribbon cable

3. Analog interface card

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MAINTENANCE AND DIAGNOSTICS

Troubleshooting

Introduction

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, maintenance personnel must perform all tests with safety in
mind. Refer to the Safety section for operating precautions and warning formats.

DANGER

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

Before using the “Drive Diagnostics” screen, disconnect the motor drive mechanics responsible for
table and component movement to avoid unexpected machine motion, which can cause personal
injury. Use extreme caution when selecting the TEST THC button or the TEST ALL button on the
“Drive Diagnostics” screen, to avoid damage to the THC and motors.

Caution: The CNC must be turned OFF whenever a cable is removed or reconnected.

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