Pipe and Tube Cutting on
®
EDGE
Connect CNCs
Application Note
810790 | Revision 0 | March 2020
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Pipe and tube cutting on EDGE Connect CNCs
Contents
Introduction............................................................................................................................................................. 5
Recent changes to pipe and tube cutting........................................................................................... 5
Requirements......................................................................................................................................................... 6
About axes assignments on the CNC.............................................................................................................. 8
Axes assignments and passwords........................................................................................................ 9
4-axis (analog-only) I-cutting on pipe or tube, no Dual Gantry, NRT password ............ 9
5-axis I-cutting on pipe or tube, with Dual Gantry, NRT password................................... 9
6-axis, 2-station, I-cutting on flat plate, with Dual Gantry, NRT password ................... 10
6-axis bevel cutting on pipe or tube, no Dual Grantry, 1RT password........................... 10
7-axis bevel cutting on pipe or tube, with Dual Gantry, 1RT password ......................... 10
8-axis, 2-station, bevel and I-cutting on flat plate, 1RT password .................................. 11
3-axis pipe-only cutting system, NTH password ................................................................. 11
4-axis pipe-only cutting system with dual gantry, NTH password................................... 11
3-axis pipe and 4-axis pipe or tube setups................................................................................................... 12
How to setup 3-axis pipe and 4-axis pipe or tube .......................................................................... 13
Cutting system orientation................................................................................................................................ 15
Chuck placement in a combination flat-plate and pipe cutting system.................................................. 18
Pipe axis movement............................................................................................................................................ 19
Cutting speeds ........................................................................................................................................ 21
Transverse 2 setup for stock rotation ............................................................................................................. 21
Hardware overtravel switch and homing for Transverse 2............................................................. 22
Disabling Auto Torch Spacing ......................................................................................................................... 22
About park inputs.................................................................................................................................... 23
Operation .............................................................................................................................................................. 24
Homing the axes...................................................................................................................................... 24
Centering the torch over the stock ..................................................................................................... 25
Running a part program......................................................................................................................... 26
Restarting a part program ..................................................................................................................... 27
Canceling a program.............................................................................................................................. 27
Pipe Cutting Program examples...................................................................................................................... 28
Cutting a feature into a pipe................................................................................................................. 28
Cutting off the end of a pipe................................................................................................................. 29
EDGE Connect Application Note 810790 3
Pipe and tube cutting on EDGE Connect CNCs
Tube cutting.......................................................................................................................................................... 29
Torch height control for tube cutting................................................................................................... 31
HPR tube cutting program examples................................................................................................. 32
XPR tube cutting program example.................................................................................................... 37
4 810790 Application Note EDGE Connect
Introduction
Round pipe
Rectangular or square tube: Flat
sides and rounded corners
The Hypertherm EDGE® Connect CNCs provide support for round pipe and square or rectangular
tube-cutting applications for plasma cutting.
These applications use a dual transverse setup on the CNC. The Dual Transverse Setup and
Operation Application Note (807610) provides information on setting up the Dual Transverse axis
(also called the Transverse 2 axis).
Pipe and tube stock profiles are shown below:
Pipe and tube cutting on EDGE Connect CNCs
This document describes the requirements for controlling a rotating Transverse 2 axis. It also
provides part programming examples for doing cut-off and feature cutting operations on rotating
metal stock.
Throughout this document, Transverse 2 is also referred to as the Pipe
axis, even though it can be used to rotate both pipe and tube material.
Recent changes to pipe and tube cutting
Park and unpark codes M86, M87, M88, M89 are no longer required in pipe and tube part
programs. However, Phoenix can still run any part program that includes park and unpark
codes.
When a pipe or tube part is loaded, the CNC turns off all vent control outputs except for the
lowest numbered vent output to avoid fan noise issues.
EDGE Connect Application Note 810790 5
Pipe and tube cutting on EDGE Connect CNCs
Requirements
Pipe and tube cutting on Hypertherm CNCs has the following requirements and restrictions:
Purchase one of the pipe software features from the Xnet (https://xnet.hypertherm.com/)
that are needed for the application.
To check the software features installed, choose Setups > Password and type the
password INSTALLEDFEATURES. Under Pipe and Tube, make sure one of the pipe
features appears.
If your CNC doesn't have pipe features installed, contact the Hypertherm Product
Application Engineer in your region. Refer to page 2 for a list of Hypertherm regional offices.
EDGE Connect CNCs use software features to turn on items purchased
through the Xnet. Throughout the document there are references to axis
count, by default the correct axes are available if the correct features are
purchased.
The Transverse 2 (Pipe) axis must be parallel to the Rail axis. The CNC uses the Transverse
2 axis as the pipe or tube axis.
Motor drives for Transverse 2 should be configured as standard linear
axes. Do not use special module features for rotational axes available in
some motor drives. These features do not work correctly with Phoenix
software.
A combination flat plate and pipe-cutting system requires both Rail and Transverse axes.
A pipe-only cutting system can run without a Transverse axis, using only the Rail, Sensor
THC, and Transverse 2 (Pipe) axes, but the torch does not move left or right.
As of Phoenix 10.7.1.88CR or later, EDGE Connect CNCs support 3 and 4-axis tube
cutting setup and operation.
6 810790 Application Note EDGE Connect
Pipe and tube cutting on EDGE Connect CNCs
The Transverse (torch) axis must be positioned in the center of the stock at the start of the
part program for both pipe and tube cutting.
Do not use the following features on the CNC for pipe or tube cutting:
Plate alignment features (Shape Manager > Shape Wizard > Shape Options > Align and
Align Wizard)
Return to start can be selected in two different ways:
From the Manual screen
In response to the Return to Start message that appears at the end of a part program,
when the part program doesn’t include a traverse move to the start of the part.
Move to pierce (Pause screen)
Save or Resume part (Pause screen)
Mirror, Rotate, Scale, Nester, or Repeat Part
Multi-tasking
Nest limit checks with the Pipe axis
EDGE Connect Application Note 810790 7
Pipe and tube cutting on EDGE Connect CNCs
About axes assignments on the CNC
Hypertherm CNCs are hard-coded with the axis assignments and common letter identifiers for the
axes shown in the table below.
Axis Axis assignment
1 Transverse or Rail (X)
2 Rail or Transverse (Y)
3 Dual Gantry (W)
4Sensor THC 1 (Z)
5 Rotate 1 (B or C)
6Tilt 1 (A)
7 Transverse 2
8 Rotate 2
9Tilt 2
10 Sensor THC 2
11 Sensor THC 3
12 Sensor THC 4
Most cutting systems require both Transverse and Rail axes, but you can assign either axis
to X or Y.
A 3-axis or 4-axis pipe cutting system with a Dual Gantry axis does not require a
Transverse axis. However, a 3-axis pipe cutting system is preferred and recommended.
A Dual Gantry axis is parallel to the Rail axis (think of it as a Rail 2 axis). In a dual gantry
cutting system, the second rail axis is powered by its own motor using the same signal as
the Rail axis.
Bevel cutting uses Rotate and Tilt axes.
8 810790 Application Note EDGE Connect
Pipe and tube cutting on EDGE Connect CNCs
Axes assignments and passwords
Using special passwords NRT (No Rotate Tilt) and 1RT (1 Rotate Tilt) redirects certain axes signals
to different axis numbers. For example, a 2-station cutting system on a 6-axis CNC requires the
NRT password so that the Transverse 2 and Sensor THC 2 signals are output on axes 5 and 6
instead of 7 and 10.
Additional examples:
To enable the Transverse 2 axis for pipe or tube cutting using 3, 4, or 5-axes and no bevel
heads, enter the NRT password.
To set up a pipe or tube cutting system with a bevel head, enter the 1RT password. Both
dual gantry and a second straight torch can be included.
The following tables identify the application, password, and axis assignments for common cutting
system axis configurations.
4-axis (analog-only) I-cutting on pipe or tube, no Dual Gantry, NRT password
Axis Axis assignment
1 Transverse or Rail
2 Rail or Transverse
3 Sensor THC
4 Transverse 2
5-axis I-cutting on pipe or tube, with Dual Gantry, NRT password
Axis Axis assignment
1 Transverse or Rail
2 Rail or Transverse
3 Dual Gantry
4 Sensor THC
5 Transverse 2
EDGE Connect Application Note 810790 9
Pipe and tube cutting on EDGE Connect CNCs
6-axis, 2-station, I-cutting on flat plate, with Dual Gantry, NRT password
Axis Axis assignment
1 Transverse or Rail
2 Rail or Transverse
3 Dual Gantry
4 Sensor THC
5 Transverse 2
6 Sensor THC 2
6-axis bevel cutting on pipe or tube, no Dual Grantry, 1RT password
Axis Axis assignment
1 Transverse or Rail
2 Rail or Transverse
3 Sensor THC
4 Transverse 2
5 Rotate
6Tilt
7-axis bevel cutting on pipe or tube, with Dual Gantry, 1RT password
Axis Axis assignment
1 Transverse or Rail
2 Rail or Transverse
3 Dual Gantry
4 Sensor THC
5 Rotate
6Tilt
7 Transverse 2
10 810790 Application Note EDGE Connect
8-axis, 2-station, bevel and I-cutting on flat plate, 1RT password
Axis Axis assignment
1 Transverse or Rail
2 Rail or Transverse
3 Dual Gantry
4 Sensor THC
5 Rotate
6Tilt
7 Transverse 2
8 Sensor THC 2
3-axis pipe-only cutting system, NTH password
Axis Axis assignment
1Not used
Pipe and tube cutting on EDGE Connect CNCs
2 Rail
3 Sensor THC
4 Transverse 2
Axes 1 and 2 can be reversed so that Rail is Axis 1 and Axis 2 is not used.
4-axis pipe-only cutting system with dual gantry, NTH password
Axis Axis assignment
1Not used
2 Rail
3 Dual Gantry
4 Sensor THC
5 Transverse 2
Axes 1 and 2 can be reversed so that Rail is Axis 1 and Axis 2 is not used.
A 3-axis or 4-axis pipe-only cutting system has the following requirements:
The NTH password disables the Transverse axis and requires that Park Head 1 input be
forced on at all times. Define both Park 1 and Park 2 inputs .
The RT password can be used to turn off the NRT or 1RT passwords and re-enable the
bevel axes. The TH password can be used to turn off the NTH password and re-enable the
Trans verse axis.
EDGE Connect Application Note 810790 11
Pipe and tube cutting on EDGE Connect CNCs
3-axis pipe and 4-axis pipe or tube setups
As of Phoenix 10.7.1.88CR, you can configure and run 3-axis pipe and 4-axis pipe or tube
configurations in Phoenix and over EtherCAT.
The following axes are used for 3-axis pipe or 4-axis pipe or tube:
1. Transverse (only used for 4-axis pipe or tube configuration)
2. Rail
3. Sensor THC
4. Transverse 2 (Pipe axis)
12 810790 Application Note EDGE Connect
How to setup 3-axis pipe and 4-axis pipe or tube
1. Go to the Machine Setup screen.
2. Disable Dual Gantry Installed.
3. Enable Tilt Rotator Installed, Dual Tilt Rotator Installed, and Dual Transverse.
4. Set Sensor THCs Installed to 1.
5. Choose Axis 3 for Installed on.
Pipe and tube cutting on EDGE Connect CNCs
6. Go to the Transverse 2 screen.
7. Enable Rotating Transverse.
8. Enter the NRT password to disable the 4 bevel axes.
9. If you are using a 3-axis pipe system, enter the NTH password to disable the Transverse axis. If
you are using Transverse with a 4-axis pipe or tube system, do not enter the NTH password.
10. Turn OFF and turn ON the CNC.
EDGE Connect Application Note 810790 13
Pipe and tube cutting on EDGE Connect CNCs
Your axes screens should look like this for 3-axis pipe setup:
If you have a 4-axis pipe or tube setup, the Transverse button is not grayed out.
Notes:
For the pipe and pipe and tube setups, pipe part programs with a G96 Pipe Diameter code,
or for Tube, a code with a Pipe Corner Radius, must be loaded in order for the Pipe axis to
be manually rotated. Otherwise both Park 1 and Park 2 inputs must be defined and the Park
1 input must be on, in order for the pipe or tube to be manually rotated.
14 810790 Application Note EDGE Connect
In the future, if you need to reprogram a CNC to not be pipe or pipe and tube do the
+Y Up
0,0
+X Right
CNC
Rail
Gantry
The gray square represents the area
of positive motion in the cutting
system (+X and +Y moves)
following:
Use the 'RT' password to turn off the 'NRT' password.
Use the 'TH' password to turn off the NTH password.
Do not turn on the Dual Gantry axes in a 4-axes, Pipe-only system, or in a 5-axes Pipe/Tube
system. The Dual Gantry should not be needed on these machines.
Cutting system orientation
When you use two Transverse axes (both a torch axis and a pipe axis) the cutting system must be
set up for positive motion in the X and Y axes relative to the 0,0 position on the cutting system.
Hypertherm CNCs allow you to assign X to either the Transverse (torch) axis or the Rail axis. When
X is the Transverse axis, positive motion is represented as shown below. On the Machine Setups
screen, you would set Up = +Y and Right = +X, relative to the position of the CNC in the cutting
system.
Pipe and tube cutting on EDGE Connect CNCs
EDGE Connect Application Note 810790 15
Pipe and tube cutting on EDGE Connect CNCs
Pipe
Transverse 2 axis
To rc h
Transverse axis
CNC
0,0
+X Right
+Y Up
-Y Right
0,0
CNC
Gantry
Rail
The gray square represents the area
of positive motion in the cutting
system (+X and +Y moves)
+X Up
The torch axis is Transverse 1 and the pipe axis is Transverse 2.
Another common orientation assigns X to the Rail. In this orientation, set Up = +X and Right = -Y,
relative to the position of the CNC, to create positive motion from 0,0.
16 810790 Application Note EDGE Connect
Pipe and tube cutting on EDGE Connect CNCs
Pipe
Transverse 2 axis
To rc h
Transverse axis
CNC
0,0
-Y Rig ht
+X Up
+Y
The torch axis is Transverse 1 and the pipe axis is Transverse 2, but they are positioned differently
when Transverse is Y.
EDGE Connect Application Note 810790 17
Pipe and tube cutting on EDGE Connect CNCs
+X
-X Transverse (torch)
home direction
+X is the Pipe (Transverse 2)
home direction
Transverse (Torch)
Transverse 2 (Pipe)
X0, Y0
Home position
for torch
(Transverse)
-X
Chuck placement in a combination flat-plate and pipe cutting system
The examples in this document that show machine orientation and chuck
placement are for illustration purposes and may differ from your
configuration.
The Transverse and Transverse 2 axes must home in opposite directions. The table orientation, and
home position and direction, determine the placement of the chuck in a combination flat-plate and
pipe cutting system. In the example below, the chuck is placed to the right of the cutting table
because the Torch axis (Transverse) homes in the -X direction and the Pipe axis (Transverse 2)
always homes in the opposite direction of the Transverse axis (+X).
18 810790 Application Note EDGE Connect
Pipe and tube cutting on EDGE Connect CNCs
-Y
-Y Transverse (torch) home direction
+Y is the Pipe (Transverse 2)
home direction
Transverse (Torch)
Pipe (Transverse)
X0, Y0
Home position
for torch
(Transverse)
+Y
In another example, Assigning Y as Transverse, would place the chuck to the left of the cutting table.
Pipe axis movement
The Pipe axis, Transverse 2 axis, has these characteristics when it is set up as a rotational axis:
Trans verse 2 alway s rotates about the Rail axis.
During pipe cutting, all motion is initiated from the center of the pipe where the Transverse
For pipe cutting, the full amount of rotation of Transverse 2 is determined by the
The CNC executes both clockwise and counterclockwise rotation when cutting a contour.
The CNC executes clockwise or counterclockwise rotation for a cut-off.
A move by the Transverse 2 is a linear distance, not an angular distance (measured in
The speed of Transverse 2 is in inches per minutes or millimeters per minute, not revolutions
(torch) is parked. The CNC moves the Transverse 2 axis (rotates the pipe) and Rail axis
(moves the gantry along the rails).
circumference of the pipe.
degrees).
per minute.
EDGE Connect Application Note 810790 19
Pipe and tube cutting on EDGE Connect CNCs
+Z
+Y
+X
-X
Gantry motion is +Y and -Y.
Transverse 2 motion is +X and -X
when the stock rotates about Y.
To rc h
The CNC automatically parks and unparks the axes to cut the rotating stock.
When the CNC runs a pipe program, the CNC parks the Transverse axis and moves the
Pipe axis (Transverse 2).
When the CNC runs a tube program, the CNC moves the Transverse axis and parks the
Pipe axis. When the CNC cuts the radius of the tube, however, it moves the Transverse,
Pipe, and Sensor THC axes together in coordinated motion around the tube corner radius.
The direction of the pipe axis rotation depends on the linear direction of the cuts and is always
opposite the travel direction of the Transverse axis. If Transverse is designated as X and right
direction is +X, then:
To cut in the +X, positive Transverse direction, the Pipe axis rotates counterclockwise.
To cut in the -X, negative Transverse direction, Transverse 2 rotates clockwise.
Regardless of how Transverse and Transverse 2 are assigned to X or Y, Transverse 2 always rotates
about the Rail axis.
When the CNC parks the Transverse axis (torch), the CNC uses the Rail and Transverse 2 axes to
perform positioning. In this drawing, the pipe is represented by the gray cylinder that rotates about
the Y axis. The pipe rotates either clockwise or counterclockwise and the gantry moves along the
rails so that the fixed Transverse axis (the torch) can cut the shape.
20 810790 Application Note EDGE Connect
Cutting speeds
The CNC recalculates the cutting, traverse, and trial speeds for the rotating Transverse 2 axis when
you load a part program with one of the following codes:
G96 Xxx. The Xxx value (or Yxx if Transverse is Y) is the diameter of the pipe. The CNC
saves this value in the Phoenix.ini file as pipe circumference and adjusts pipe rotational
speed using the pipe diameter and the program speed. The CNC retains the diameter value
until you load a new part program with a different value.
G00 Pxx Txx Sxx Rxx. The CNC uses the radius (R) value to set the corner radius of the 4
corners on the tube.
G01 Pxx Fxx Txx Sxx Rxx. The CNC uses the speed value (F) to set the rotational speed of
the tube in revolutions per minute (RPM).
Cutting speeds for tubes with very small corner radii may be limited even
more by the CNC. See Tube cutting on page 29 for more information on
program codes and examples.
Transverse 2 setup for stock rotation
Pipe and tube cutting on EDGE Connect CNCs
This section summarizes the selections you make on the Transverse 2 axis screen. See Dual
Transverse Setup and Operation Application Note (807610) for more information on setting up the
Dual Transverse axis.
The CNC requires that 10 axes be enabled so that the following selections can be activated in the
Machine Setups screen:
Tilt Rotator Installed = Yes
Dual Tilt Rotator Installed = Yes
Dual Transverse = Yes
1. Activate the axes on the Setups > Password > Machine Setups screen.
2. Choose Password and enter NRT.
3. Choose Setups > Machine Setups > Axes 6 - 12 > Tra nsver se 2.
4. Choose Yes for Rotating Transverse, and enter the encoder counts per revolution.
5. Choose No for Use Software Travel Limits.
EDGE Connect Application Note 810790 21
Pipe and tube cutting on EDGE Connect CNCs
Hardware overtravel switch and homing for Transverse 2
The Transverse 2 axis requires that you select Home to Overtravel Switch in Machine Setups >
Transverse 2 screen. To use an overtravel switch on Transverse 2, wire the overtravel switch to the
Rotate 2 Home input. Set the following options on the Transverse 2 screen:
Option Setting
Use Hardware Overtravels Yes
Home To Overtravel Switch
Absolute Home Position 0
Home Offset Distance 0
Axis I/O point
Transverse -X/-Y overtravel
Transverse 2 Rotate2Home
Disabling Auto Torch Spacing
Using Transverse 2 to rotate stock requires that you disable Auto Torch Spacing on the CNC.
Instead, you can use Go To Home Position on the Home Axes screen to send the Transverse
(torch) axis to a position over the pipe axis.
Check the following settings to disable Auto Torch setting:
1. Choose Setups > Machine Setups.
2. Set Auto Torch Spacing to No.
See Homing the axes on page 24 for more information.
22 810790 Application Note EDGE Connect
Pipe and tube cutting on EDGE Connect CNCs
3. Choose Setups > Special Setups.
4. In the Status/Feature list, choose Not Allowed for Torch Spacing.
5. Choose Main screen > Setups.
6. In the Status/Program Code list, choose Disabled for Auto Torch Spacing Override.
About park inputs
Once a pipe or tube program is loaded, the CNC controls the parking and unparking of Transverse
and Transverse 2 axes. After you load a pipe program, the CNC parks the Transverse axis and
unparks Transverse 2. Before you can perform any manual motion with the Transverse axis, such as
any of the options on the Manual screen or jogging using the joystick, you must park Transverse 2
and unpark Transverse. The CNC gives you control of parking and unparking only after you have
canceled the pipe or tube part program.
Many pipe and tube cutting systems include dedicated switches on the operator console to control
parking of the Transverse and Transverse 2 axes. In Hypertherm CNCs, the inputs for parking the
axes are called Park Dual Head 1 and Park Dual Head 2. Assign Park Dual Head 1 to Transverse
and Park Dual Head 2 to Transverse
The following park M codes are not required with pipe and tube part programs. The parking is
handled automatically for parts with G96 Pipe Diameter or Tube Corner Radius part program codes.
M86 Unpark Head 1 - Unpark Transverse
M87 Park Head 1 - Park Transverse
M88 Unpark Head 2 - Unpark Transverse 2
M89 Park Head 2 - Part Transverse 2
2.
EDGE Connect Application Note 810790 23
Pipe and tube cutting on EDGE Connect CNCs
Operation
Pipe and tube cutting operations generally follow this order:
1. Set the Plate Size in the Cutting screen.
If Transverse is the X axis, enter the pipe circumference for X and enter the pipe length for Y. If
Transverse is the Y axis, enter the pipe length for X and the pipe circumference for Y.
If these dimensions aren’t accurate, the CNC may show the Part Larger
than Plate warning message. To determine the pipe circumference,
measure the pipe diameter and multiply by pi (3.14). Increase this value by
approximately10% to prevent any warning messages.
2. Load a part program:
A pipe program includes the G96 Xxx where value equals the pipe diameter.
A tube program includes the G00 Pxx Txx Sxx Rxx (Xxx or Yxx) code with the rotational angle,
and top, side, and tube corner radius dimensions, and optional rail travel distance (Xxx or
Yxx).
3. Home the cutting system (Manual > Home Axes).
4. Position the torch axis over the center of the stock using a Go To Home position.
On the Home Axes screen, enter a distance from the home position of the Transverse axis to
the center of the pipe axis. The Rail axis position of the Go To Home position should be the
point along the rail to begin all pipe or tube programs.
5. Switch both park inputs off. The part program takes control of the parking and unparking of the
axes.
6. Run the part program.
Homing the axes
Be sure to load the pipe- or tube-cutting program before homing the cutting system. The part
program contains the codes and dimensions that the CNC uses to set the speed for homing. You
want the part program to match the size of the stock you have loaded in the machine. Otherwise, the
machine may move too fast or slow in relation to the stock you have loaded.
Transverse 2 homes in the opposite direction of the Transverse axis. If Transverse homes in the
negative direction, Transverse 2 homes in the positive direction.
1. Choose the Manual screen using one of these methods:
Press Manual Options on the operator’s console of the CNC.
Press the Manual soft key (located in the center of the jog keys).
Press F11 on the keyboard.
2. Choose Home Axes.
24 810790 Application Note EDGE Connect
3. Choose either the Transverse soft key or the All soft key.
Transverse and Transverse 2 home at the same time.
The CNC displays the status message Fast Homing.
Transverse moves toward its overtravel switch.
Transverse 2 rotates toward its overtravel switch but in the opposite direction of Transverse.
Motion for each axis stops when the axes engage their overtravel switches. This position
equals absolute home.
The CNC changes the status message to Slow homing.
Set the Home Offset Distance to 0 (zero) for Transverse 2 to eliminate any travel distance
inaccuracies that could occur if the pipe diameter was not correctly set before homing.
Centering the torch over the stock
Pipe and tube part programs start with the torch centered over the stock. In most chuck-based
systems, the center of the stock does not shift even when cutting different pipe diameters or
different tube widths. The following steps describe a method for programming this position into the
CNC so that you can move the torch to the center point before each job.
Pipe and tube cutting on EDGE Connect CNCs
1. Locate a reference point on the gantry. This point could be the Transverse axis home position or
another mechanical reference on the gantry.
2. Measure the distance between the reference point and the center of the chuck.
3. Set this value as a Go To Home position in the Home Axes screen:
a. Choose Manual > Home Axes.
b. Choose a Go To Home Position soft key from 1 to 12.
c. Either enter the coordinates of the position on the gantry that represents the center of the
pipe or tube stock or choose Use Current Position if the torch is already at the correct
location.
EDGE Connect Application Note 810790 25
Pipe and tube cutting on EDGE Connect CNCs
Running a part program
Before pressing Start to run the part program, check the following:
The current part program has a G96 code with a diameter value that equals the diameter of
the loaded pipe stock, or a G00 or G01 code with the dimensions of the tube stock.
The cutting system has been homed.
The torch has been positioned over the center of the stock.
Park inputs are off.
The CNC shows parts and machine movement in two dimensions. Because cutting rotational stock
is three dimensional process, it may not always be represented on the screen as you would expect.
For example, the geometry for a pipe cut-off would look like this in the preview window.
26 810790 Application Note EDGE Connect
Restarting a part program
Sometimes, after you begin cutting a part on rotating stock, the stock can shift in the chuck. Follow
these steps to recover from this condition:
1. Stop and cancel the part program using one of these methods:
Press the emergency stop. This cancels the part program and requires that you re-home the
cutting system.
Press Program Stop (red) pushbutton on the operator console.
F10 if you are using a keyboard, then press Cancel on the screen.
2. Take corrective action to reseat the stock.
3. With the original part program loaded, home the cutting system, then reposition the torch at the
center of the stock using the Go To Home position.
4. On the Main screen, change Cut Mode to Trial . You may need to reduce the Trial Speed on the
Main screen to prevent the stock from rotating at maximum speed.
Pipe and tube cutting on EDGE Connect CNCs
5. Press the Program Start (green) pushbutton on the operator console, or F9 if you are using a
keyboard.
6. When the torch approaches the point where you stopped the program, press the Program Stop
(red) pushbutton.
7. Change Cut Mode to Plasma 1.
8. Press the Program Start (green) pushbutton to restart cutting at the point where the program
was interrupted.
Canceling a program
In some cases, if you cancel the part program, the Transverse axis remains parked and Transverse 2
remains active. Do the following routine to restart motion in the Transverse axis:
1. Turn on and off Park Head 1 input.
2. Turn on Park Head 2 input.
3. Jog the Transverse axis to move the torch.
EDGE Connect Application Note 810790 27
Pipe and tube cutting on EDGE Connect CNCs
Pipe Cutting Program examples
The CNC supports two common pipe cutting applications:
Feature cutting – The torch axis is parked and the pipe and rail axes move together to cut a
feature (for example, a circular hole) into the pipe.
Pipe cut-off – The torch axis is parked and the pipe rotates while the torch cuts through it.
In both applications, the CNC determines the cutting speed based on the diameter of the pipe and
requires the torch to be positioned above the center of the pipe.
Cutting a feature into a pipe
This program assumes the X axis is the Transverse axis and the Y axis is the Rail axis, and that the
torch has been positioned over the center of the pipe.
Code Description
G20 Select English units.
G91 Use incremental mode.
Set a pipe diameter of 9.5 inches.
G96 X9.50
M36 T1 Select process Plasma 1.
M37 T1 Select Station 1.
G41 Enable left kerf compensation.
M07 Turn on Cut Control.
G02 X0 Y0 I0.707 J-0.707 Cut a circle 2 inches in diameter.
M08 Turn Cut Control off.
G40 Disable kerf compensation.
M19 Cancel all stations.
M02 End of program.
Replace X with Y if the Transverse 1 axis is
assigned to Y.
28 810790 Application Note EDGE Connect
Cutting off the end of a pipe
Top length
Side length
Corner radius
This program assumes the X axis is the Transverse axis and the Y axis is the Rail axis, and that the
torch has been positioned over the center of the pipe axis.
Code Function
G20 Select English units.
G91 Use incremental mode.
G96 X9.50 Set a pipe diameter of 9.5 inches.
M36 T1 Select process Plasma 1.
M37 T1 Select Station 1.
G41 Enable left kerf compensation.
M07 Turn on Cut Control.
Pipe and tube cutting on EDGE Connect CNCs
Tube cutting
When cutting square tube, the CNC creates Z-axis motion to lift the torch and cut each corner’s
radius as the stock rotates. Tube cutting requires the Sensor THC.
The CNC requires the following tube dimensions in the part program:
Corner radius
Top length
Side length
G01 X30 Y0
M08 Turn off Cut Control.
G40 Disable kerf compensation.
M19 Cancel all stations.
M02 End of program.
Linear cut that exceeds the circumference of the pipe
(29.83 inches)
EDGE Connect Application Note 810790 29
Pipe and tube cutting on EDGE Connect CNCs
Top (Txx)
Top (Txx )
Side (Sxx)
Side (Sxx)
Corner Radius (Rxx)
Torch cuts along top of stock.
Torch lifts to cut corner radius
as stock rotates.
The Top dimension changes each time the stock rotates.
The sides of the tube are cut using G01 commands with the axis and length of the cut. Before
cutting the corner radius, the Sensor THC arc voltage tracking must be disabled with the M50 code
(Torch height disable). Use either of the following codes in the part program to rotate the tube and
cut the corner:
G00 Pxx Fxx Txx Sxx Rxx Yxx or Xxx
G01 Pxx Fxx Txx Sxx Rxx Yxx or Xxx
Where:
P = Degrees of rotation, from -90 degrees to +90 degrees
F = Program speed override (Optional for G00 command; required for G01 where Fxx is
rotational speed (RPM).
T = Top length
S = Side length
R = Corner radius
Y or X = Optional rail offset distance
T is always the surface being cut. S is always the next surface to be cut. With the Sensor THC
disabled, the CNC makes the Z-axis moves needed to cut the corner radius and to avoid colliding
with the rotating tube.
In tube cutting, the transverse motion uses both Transverse and Transverse 2 axes. The Transverse
axis cuts on the flat sides of the stock with Transverse 2 parked, and then the Transverse axis parks
after a height offset, and Transverse 2 rotates so that the Transverse can cut the radius of the stock.
When the radius cut is complete, Transverse 2 parks and Transverse unparks to cut the next flat side
of the stock. The CNC controls the unparking and parking of the axes.
A tube program follows this sequence:
30 810790 Application Note EDGE Connect
Before starting the tube program, the torch must be positioned over the center of the stock.
An M50 code before the G00 Pxx Txx Sxx Rxx disables automatic voltage control on the
Sensor THC.
The Transverse axis is parked when the G00 Pxx Txx Sxx Rxx command is executed.
The Sensor THC makes a height offset that is controlled by the CNC, not by a code
embedded in the part program.
The CNC maintains the cut height around the radius cut.
An M51 reenables automatic voltage control on the Sensor THC. Transverse is parked and
Transverse 2 is unparked.
The values for T and S switch for the next G00 Pxx Txx Sxx Rxx command.
Torch height control for tube cutting
A correctly tuned THC axis is recommended to maintain the cut height when cutting the corner radii.
The THC has to accelerate quickly enough so that the torch can move to the offset distance as the
stock rotates. A slow response from the lifter, or a high following error, affects the cut quality in the
radius of the tube and can result in a torch collision.
The Z axis must be able to operate at a minimum of 400 in/min (10,160 mm/min).
The following error at maximum speed must be low to maintain an accurate cut height while
cutting a radius. You can observe the following error in the Watch Window, and run this test:
Pipe and tube cutting on EDGE Connect CNCs
Set THC Fast IHS Speed equal to Maximum Speed (temporarily).
Set THC Jog Speed to Fast IHS Speed in Manual Options screen.
Jog the lifter up and down the entire stoke and watch the following error.
THC acceleration also affects the response of lifter. The recommended setting for
acceleration is 100 mGs, but be sure to check the lifter mechanics and drive to make sure
both are capable of 100mG acceleration.
These considerations are affected by the maximum cut speed of the tube cutting system: the
slower the cut speeds, the lower the required responsiveness of the Z axis.
EDGE Connect Application Note 810790 31
Pipe and tube cutting on EDGE Connect CNCs
HPR tube cutting program examples
The following part program example assumes the torch is positioned above the center of the stock,
and that the 10 inch side of the tube is face up, ready to be cut first. All units are in inches.
Code Description Comments
G20 Select English units.
G91 Use incremental mode.
M36 T1 Select process Plasma1.
M37 T1 Select Station 1.
G41 Enable left kerf compensation.
M07 Turn on Cut Control.
G01 X3.5 Y0 Linear cut Start cut at tube center.
M50 Disable torch height control.
G00 P90 T6 S10 R1.5 Rotate tube 90º and cut tube radius.
M51 Enable torch height control.
G01 X3 Y0 Linear cut Cut side of tube.
M50 Disable torch height control.
G00 P90 T10 S6 R1.5 Rotate tube 90º and cut tube radius.
M51 Enable torch height control.
G01 X7 Y0 Linear cut Cut side of tube.
M50 Disable torch height control.
G00 P90 T6 S10 R1.5 Rotate tube 90º and cut tube radius.
M51 Enable torch height control.
G01 X3 Y0 Linear cut Cut side of tube.
M50 Disable torch height control.
G00 P90 T10 S6 R1.5 Rotate tube 90º and cut tube radius.
M51 Enable torch height control.
G01 X3.5 Y0 Linear cut
M08 Turn off Cut Control.
G40 Disable kerf compensation.
M19 Cancel all stations.
Finish cut on 10 inch side of
tube.
M02 End of program.
32 810790 Application Note EDGE Connect
Pipe and tube cutting on EDGE Connect CNCs
The following part program example assumes the torch is positioned above the center of the stock,
and shows the rail offset in the tube cutting command. In this program, the Rail axis is X. In addition,
this program shows G00 rotate commands that rotate the tube without making the radius cut. All
units are in inches.
The G00 rotational commands must appear in the part program after the
first occurrence of the G00 or G01 Pxx Fxx Txx Sxx Rxx command.
Code Description Comments
G20 Select English units.
G91 Use incremental mode.
M36 T1 Select process = Plasma 1
M37 T1 Select Station 1.
G00 X-3.306 Y-0. Rapid traverse
G59 V502 F35 Plasma 1 Torch Type = HPRXD Bevel
G59 V503 F1 Plasma 1 Material Type = Mild Steel
G59 V504 F80 Plasma 1 Current = 80 A
G59 V505 F2 Plasma 1 Plasma gas = O
G59 V506 F1 Plasma 1 Cutting Surface = above water
G59 V507 F29 Plasma 1 Material Thickness = 0.25 inches
G59 V600 F119. Plasma 1 Set Arc Voltage = 119 V
G59 V601 F0.3 Plasma 1 Pierce Time = 0.3 seconds
G59 V602 F200 Plasma 1 Pierce Height Factor = 200%
G59 V603 F0.08 Plasma 1 Cut Height = 0.08 inches
G59 V604 F200. Plasma 1 Transfer Height Factor = 200%
M07 Turn on Cut Control.
M51 Enable torch height control.
F110. Override cut speed to 110 in/min.
G01Y-1.5 Linear cut
M50 Disable torch height control.
G01 P-90.00 T4. S4. R0.5 X0.866
M51 Enable torch height control.
Rotate tube -90º, cut 0.5 inch radius, and move
0.866 along Rail axis.
, shield gas = air
2
Process section codes
(V5xx)
Torch height control
codes (V6xx)
G01X2.44Y-1.4087 Linear cut
G01Y-0.1826 Linear cut
G01X-2.44Y-1.4087 Linear cut
M50 Disable torch height control.
G01 P-90.00 T4. S4. R0.5 X-0.866
M51 Enable torch height control.
EDGE Connect Application Note 810790 33
Rotate tube -90º, cut 0.5 inch radius, and move
0.866 along Rail axis.
Pipe and tube cutting on EDGE Connect CNCs
Code Description Comments
G01Y-3. Linear cut
M50 Disable torch height control.
G01 P-90.00 T4. S4. R0.5 X0.8665
Rotate tube -90º, cut 0.5 inch radius, and move
0.866 along Rail axis.
M51 Enable torch height control.
G01X-0.0004Y0.0003 Linear cut
G01X2.44Y-1.4088 Linear cut
G01Y-0.1825 Linear cut
G01X-2.44Y-1.4087 Linear cut
G01X-0.0005Y-0.0003 Linear cut
M50 Disable torch height control.
G01 P-90.00 T4. S4. R0.5
X-0.8655
Rotate tube -90º, cut 0.5 inch radius, and move
0.866 along Rail axis.
M51 Enable torch height control.
G01Y-1.5 Linear cut
M08 Turn off Cut Control.
G59 V607 F1 Set Plasma 1 THC operating mode to Manual.
Change THC to
manual mode in
preparation for Z axis
move before tube
rotation.
G00 Z-5 Z-axis traverse.
M11 Turn on Marker Offset 1.
G00 P90. Rotational traverse. Rotate pipe 90º.
M12 Cancel Marker Offset 1.
G59 V607 F2 Set Plasma 1 THC operating mode to Automatic.
G00 X-0.5837 Y-0.4495 Rapid traverse
G43X0.068 Set kerf offset to 0.068.
G41 Enable left kerf compensation.
M07 Turn on Cut Control.
F110. Override cut speed to 110 in/min.
G03 X-0.3 Y-0.52 I-0.15 J-0.26
G03I0.7389J0.7389
Counterclockwise arc at XY endpoint and IJ
centerpoint (radius value).
M50 Disable torch height control.
Lift up the torch 5
inches.
Use marker offset to
execute an X/Y move
to position the torch
clear of the rotating
tube.
Change back to
Automatic THC mode.
34 810790 Application Note EDGE Connect
Pipe and tube cutting on EDGE Connect CNCs
Code Description Comments
G03 X0.248 Y-0.035 I0.27 J1.009
Counterclockwise arc at XY endpoint and IJ
centerpoint (radius value).
M08 Turn off Cut Control.
G40 Disable kerf compensation.
M51 Enable torch height control.
G59 V607 F1 Set Plasma 1 THC operating mode to Manual.
G00 Z-5 Z-axis traverse.
M11 Turn on Marker Offset 1.
G00 P180. Rotational traverse. Rotate pipe 180º.
M12 Cancel Marker Offset 1.
G59 V607 F2 Set Plasma 1 THC operating mode to Automatic.
G00 X0.057 Y0.547 Rapid traverse
G43X0.068 Set kerf offset to 0.068.
G41 Enable left kerf compensation.
M07 Turn on Cut Control.
F110. Override cut speed to 110 in/min.
G03 X-0.3 Y-0.52 I-0.15 J-0.26 Counterclockwise arc
Repeats sequence of
THC Manual mode, Z
axis move, marker
offset, tube rotation,
then return to
Automatic THC mode.
G03I0.7389J0.7389 Counterclockwise arc
M50 Disable torch height control.
G03 X0.248 Y-0.035 I0.27 J1.009 Counterclockwise arc
M08 Turn off Cut Control.
G40 Disable kerf compensation.
M51 Enable torch height control.
G59 V607 F1 Set Plasma 1 THC operating mode to Manual.
G00 Z-5 Z-axis traverse. Move up lifter 5 inches.
M11 Turn on Marker Offset 1.
G00 P90. Rotational traverse. Rotate pipe 90º.
M12 Cancel Marker Offset 1.
G59 V607 F2 Set Plasma 1 THC operating mode to Automatic.
G00 X-2.0172 Y0.893 Rapid traverse.
M07 Turn on Cut Control.
F110. Override cut speed to 110 in/min.
G00 X-2.0172 Y0.893 Rapid traverse
M07 Cut on
F110. Override cut speed to 110 in/min.
EDGE Connect Application Note 810790 35
Pipe and tube cutting on EDGE Connect CNCs
Code Description Comments
G01X-0.Y1.5 Linear cut
M50 Disable torch height control.
G01 P90.00 T4. S4. R0.5 Rotate tube -90º and cut 0.5 inch radius.
M51 Enable torch height control.
G01X-0.Y3. Linear cut
M50 Disable torch height control.
G01 P90.00 T4. S4. R0.5 Rotate tube -90º and cut 0.5 inch radius.
M51 Enable torch height control.
G01X-0.Y3. Linear cut
M50 Disable torch height control.
G01 P90.00 T4. S4. R0.5 Rotate tube -90º and cut 0.5 inch radius.
M51 Enable torch height control.
G01X-0.Y3. Linear cut
M50 Disable torch height control.
G01 P90.00 T4. S4. R0.5 Rotate tube -90º and cut 0.5 inch radius.
M51 Enable torch height control.
G01X-0.Y1.5 Linear cut
M08 Turn off Cut Control.
M19 Cancel all stations.
M02 End of program.
This sequence of
linear cuts is the tube
cut-off.
36 810790 Application Note EDGE Connect
Pipe and tube cutting on EDGE Connect CNCs
XPR tube cutting program example
The following part program example assumes the torch is positioned above the center of the stock,
and shows the rail offset in the tube cutting command. In this program, the Rail axis is X. In addition,
this program shows G00 rotate commands that rotate the tube without making the radius cut. All
units are in inches.
The G00 rotational commands must appear in the part program after the
first occurrence of the G00 or G01 Pxx Fxx Txx Sxx Rxx command.
Code Description Comments
G20 Select English units.
G91 Use incremental mode.
FA200
G93 X0.03 Adjust to bevel equations for consumable lengths.
(CutPro Wizard - Load Material:
Mild Steel; 8 inch x 16.283 inch;
0.5 inch)
M36 T1 Select process Plasma1.
M37 T1 Select Station 1.
G00 X0.42223 Y0.5625 Rapid traverse
(Seq 1 - Rect 5x4x.5) Comment - Part Seq
M51 Enable torch height control.
G59 V509 F11420 Select cut chart.
(130Amp O2/Air _True Hole_) Comment - Consumables
M29 Enable CBH / rotator. Follower on
M90 Align CBH.
M07 HS AVO163 CHT0.30825 Turn on Cut Control.
Smooth motion 200 ms for any angle or direction
change.
Material comments
Rotator to tangent
angle of the next cut
segment
Arc Voltage and Cut
Height override
F40. Override cut speed to 40 in/min.
G01Y-0.1875 Linear cut
G59 V603 F0.308 Plasma 1 Cut Height = 0.308 inches
G01A25.440 F20. Set Bevel Angle.
G01Y-0.3375 Linear cut
M28 Disable CBH / rotator. Follower off
G01Y-0.0375 Linear cut
M50 Disable torch height control.
G01X-0.375 Linear cut
EDGE Connect Application Note 810790 37
Start of mitered end
cut
Pipe and tube cutting on EDGE Connect CNCs
Code Description Comments
M29 Enable CBH / rotator. Follower on
Rotator to tangent
M90 Align CBH.
angle of next cut
segment
G01Y-0.1875 Linear cut
M51 Enable torch height control.
G01Y-0.81855 Linear cut
M50 Disable torch height control.
G01 P90.00 A0. F6.366 T4. S5.
R1. X-0.41203
Rotate tube 90° and cut corner.
M51 Enable torch height control.
F40. Override cut speed to 40 in/min.
G01X-1.24259Y-2.99988 Linear cut
M50 Disable torch height control.
G01 P90.00 A-23.11 F6.366 T5.
S4. R1. X-0.39826
Rotate tube 90° and cut corner.
M51 Enable torch height control.
F40. Override cut speed to 40 in/min.
G01Y-1.9836 Linear cut
M50 Disable torch height control.
G01 P90.00 A0. F6.366 T4. S5.
R1. X0.39826
Rotate tube 90° and cut corner.
M51 Enable torch height control.
F40. Override cut speed to 40 in/min.
G01X1.24259Y-2.99988 Linear cut
M50 Disable torch height control.
Set bevel angle A and
length motion X.
Set bevel angle A and
length motion X.
Set bevel angle A and
length motion X.
G01 P90.00 A25.44 F6.366 T5.
S4. R1. X0.41203
Rotate tube 90° and cut corner.
Set bevel angle A and
length motion X.
M51 Enable torch height control.
F40. Override cut speed to 40 in/min.
G01Y-0.00605 Linear cut
M50 Disable torch height control.
G01Y-0.5 Linear cut
G01Y-0.5 Linear cut
M28 Disable CBH / rotator. Follower off
G01Y-0.75 Linear cut
M08 Turn off Cut Control.
G01A0.000 F20. Cancel Set Bevel Angle
38 810790 Application Note EDGE Connect
Pipe and tube cutting on EDGE Connect CNCs
Code Description Comments
M51 Enable torch height control.
M38 T1 Deselect Station.
G04X0.5 Dwell
M36 T1 Select process Plasma1.
M37 T1 Select Station 1.
G01 P-180.00 F30. Rotate tube 180° and move position.
G00 X-3.09267 Y0.90153 Rapid traverse
M07 HS N2 Turn on Cut Control (Marking).
F250. Override cut speed to 250 in/min.
G01X-0.30304Y-0.30305 Linear cut
M50 H-0.02 Disable torch height control.
G01X-0.17678Y-0.17678 Linear cut
M08 RT Turn off Cut Control.
G00 X0.17678 Y0.47982 Rapid traverse
M07 N2 Turn on Cut Control (Marking).
M51 Enable torch height control.
F250. Override cut speed to 250 in/min..
G01X0.30304Y-0.30304 Linear cut
M50 H-0.02 Disable torch height control.
G01X0.17678Y-0.17678 Linear cut
M08 Turn off Cut Control.
M38 T1 Deselect Station Marking N
marking on
2
G04X0.5 Dwell
M36 T1 Select process Plasma1.
M37 T1 Select Station 1.
G00 X-3.13135 Y0.3803 Rapid traverse
G43X0.104 Set kerf offset to 0.104. Rapid traverse
G41 Enable left kerf compensation.
M07 O2S Turn on Cut Control. N
marking on
2
M50 Disable torch height control.
F48. Override cut speed to 48 in/min.
G03Y-0.427I0.J-0.2135 Arc cut
F80. Override cut speed to 80 in/min.
G03X-0.34099Y0.53106I0.J0.375 Arc cut
G03X0.34099Y-0.53106I0.34099J
-0.15606
Arc cut
M50H-0.035 Disable torch height control.
EDGE Connect Application Note 810790 39
Pipe and tube cutting on EDGE Connect CNCs
Code Description Comments
G03X0.23189Y0.08029I0.J0.375 Arc cut
M08 Turn off Cut Control.
G40 Disable kerf compensation.
M51 Enable torch height control.
G01 P180.00 F30. Rotate tube 180° and move position.
G00 X-2.84689 Y0.29471 Rapid traverse
G43X0.104 Set kerf offset to 0.104.
G41 Enable left kerf compensation.
M07 Turn on Cut Control.
F80. Override cut speed to 80 in/min.
G03X0.615I0.3075J0. Arc cut
G01Y1.001 Linear cut
M50 Disable torch height control.
G01 P-90.00 F12.732 T4. S5. R1. Rotate tube 90° and cut around corner.
Rectangle corner and
tube motion
M51 Enable torch height control. Feedrate RPM
F80. Override cut speed to 80 in/min.
G01Y3.002 Linear cut
M50 Disable torch height control.
G01 P-90.00 F12.732 T5. S4. R1. Rotate tube 90° and cut corner.
Rectangle corner and
tube motion
M51 Enable torch height control. Feedrate RPM
F80. Override cut speed to 80 in/min.
G01Y2.002 Linear cut
M50 Disable torch height control.
G01 P-90.00 F12.732 T4. S5. R1. Rotate tube 90° and cut corner.
Rectangle corner and
tube motion
M51 Enable torch height control. Feedrate RPM
F80. Override cut speed to 80 in/min.
G01Y3.002 Linear cut
M50 Disable torch height control.
G01 P-90.00 F12.732 T5. S4. R1. Rotate tube 90° and cut corner.
Rectangle corner and
tube motion
M51 Enable torch height control. Feedrate RPM
F80. Override cut speed to 80 in/min.
G01Y1.001 Linear cut
M08 Turn off Cut Control.
G40 Disable kerf compensation.
40 810790 Application Note EDGE Connect
Pipe and tube cutting on EDGE Connect CNCs
Code Description Comments
M51 Enable torch height control.
M19 Enable CBH rotator.
M02 End of program.
EDGE Connect Application Note 810790 41
Pipe and tube cutting on EDGE Connect CNCs
42 810790 Application Note EDGE Connect
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