Hypertherm Edge Pro Ti Instruction Manual

EDGE® Pro Ti

Shape Cutting Control

Instruction Manual

807660 – Revision 3

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ArcGlide, EDGE, HPR, HSD, Hypernet, Hypertherm, Phoenix, Powermax, and Sensor are trademarks of Hypertherm, Inc. and may be
registered in the United States and other countries.

© 2018 Hypertherm, Inc.

EDGE Pro Ti CNC

Instruction Manual

807660 – Revision 3

English

September 2018

Hypertherm, Inc.

Hanover, NH 03755 USA

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

Safety .........................................................................................................................................................xi

Recognize safety information .............................................................................................................................................................xi

Inspect equipment before using ........................................................................................................................................................xi

Follow safety instructions ....................................................................................................................................................................xi

Responsibility for safety ......................................................................................................................................................................xi

A plasma arc can damage frozen pipes .......................................................................................................................................... xi

Static electricity can damage printed circuit boards .................................................................................................................... xi

Grounding safety .................................................................................................................................................................................xii

Electrical hazards .................................................................................................................................................................................xii

Electric shock can kill .........................................................................................................................................................................xii

Cutting can cause fire or explosion ................................................................................................................................................ xiii

Fire prevention ............................................................................................................................................................................. xiii

Explosion prevention .................................................................................................................................................................. xiii

Machine motion can cause injury .................................................................................................................................................... xiii

Compressed gas equipment safety ...............................................................................................................................................xiv

Gas cylinders can explode if damaged .........................................................................................................................................xiv

Toxic fumes can cause injury or death ........................................................................................................................................... xiv

A plasma arc can cause injury and burns ......................................................................................................................................xv

Arc rays can burn eyes and skin ......................................................................................................................................................xv

Pacemaker and hearing aid operation ............................................................................................................................................xv

Noise can damage hearing ............................................................................................................................................................... xvi

Dry dust collection information ........................................................................................................................................................ xvi

Laser radiation ....................................................................................................................................................................................xvii

Additional safety information ........................................................................................................................................................... xvii

Product Stewardship ..........................................................................................................................xix

Introduction .......................................................................................................................................................................................... xix

National and local safety regulations ............................................................................................................................................. xix

Certification test marks ..................................................................................................................................................................... xix

Differences in national standards .................................................................................................................................................... xix

EDGE Pro Ti CNC Instruction Manual 807660 v

Contents

Safe installation and use of shape cutting equipment ............................................................................................................... xix

Procedures for periodic inspection and testing .......................................................................................................................... xix

Qualification of test personnel .......................................................................................................................................................... xx

Residual current devices (RCDs) .................................................................................................................................................... xx

Higher-level systems .......................................................................................................................................................................... xx

Environmental Stewardship ............................................................................................................. xxi

Introduction .......................................................................................................................................................................................... xxi

National and local environmental regulations ............................................................................................................................... xxi

The RoHS directive ............................................................................................................................................................................ xxi

Proper disposal of Hypertherm products ..................................................................................................................................... xxi

The WEEE Directive .......................................................................................................................................................................... xxi

The REACH regulation ...................................................................................................................................................................... xxi

Proper handling and safe use of chemicals ................................................................................................................................ xxii

Fumes emission and air quality ...................................................................................................................................................... xxii

Electromagnetic Compatibility (EMC) .........................................................................................xxiii

Introduction ........................................................................................................................................................................................ xxiii

Installation and use ........................................................................................................................................................................... xxiii

Assessment of area .......................................................................................................................................................................... xxiii

Methods of reducing emissions .................................................................................................................................................... xxiii

Mains supply .............................................................................................................................................................................. xxiii

Maintenance of cutting equipment ............................................................................................................................................... xxiii

Cutting cables ................................................................................................................................................................................... xxiii

Equipotential bonding .............................................................................................................................................................. xxiii

Screening and shielding ................................................................................................................................................................. xxiv

Warranty ................................................................................................................................................ xxv

Attention .............................................................................................................................................................................................. xxv

General ................................................................................................................................................................................................ xxv

Patent indemnity ................................................................................................................................................................................ xxv

Limitation of liability ........................................................................................................................................................................... xxv

National and local codes ................................................................................................................................................................. xxv

Liability cap ........................................................................................................................................................................................ xxvi

Insurance ............................................................................................................................................................................................ xxvi

Transfer of rights ............................................................................................................................................................................... xxvi

Waterjet product warranty coverage ........................................................................................................................................... xxvi

Product ....................................................................................................................................................................................... xxvi

Parts coverage .......................................................................................................................................................................... xxvi

Specifications ........................................................................................................................................ 27

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

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

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

vi EDGE Pro Ti CNC Instruction Manual 807660

Contents

Plasma system ............................................................................................................................................................................ 29

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

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

Torch height control (THC) ..................................................................................................................................................... 29

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

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

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

Overview .............................................................................................................................................................................................. 30

Features of the EDGE Pro Ti CNC ............................................................................................................................................... 31

Touchscreen ............................................................................................................................................................................... 31

Operator console ....................................................................................................................................................................... 31

Rear panel ................................................................................................................................................................................... 32

System specifications ....................................................................................................................................................................... 33

EDGE Pro Ti axis and I/O configuration ....................................................................................................................................... 35

Specifications for the Sensor Ti lifter ............................................................................................................................................ 36

Installation .............................................................................................................................................. 37

Upon receipt ....................................................................................................................................................................................... 37

Claims ........................................................................................................................................................................................... 37

Installation requirements .................................................................................................................................................................. 37

Gantry sizing for EDGE Pro Ti motors .................................................................................................................................. 37

Placement of system components ......................................................................................................................................... 38

Mounting the CNC ............................................................................................................................................................................ 39

Mounting hole patterns on the bottom of the CNC ........................................................................................................... 40

Mounting the THC ............................................................................................................................................................................. 41

Sensor™ Ti THC ......................................................................................................................................................................... 41

ArcGlide THC ............................................................................................................................................................................. 42

Configuration diagrams .................................................................................................................................................................... 49

X and Y axis configuration ............................................................................................................................................................... 51

The operator console ........................................................................................................................................................................ 51

Front panel I/O ........................................................................................................................................................................... 52

AC power ............................................................................................................................................................................................ 53

Power input ................................................................................................................................................................................. 53

Power cable ................................................................................................................................................................................ 53

Chassis grounding .................................................................................................................................................................... 54

Interface ports .................................................................................................................................................................................... 55

Hypernet

LAN interface .............................................................................................................................................................................. 55

USB interface ............................................................................................................................................................................. 55

Serial ports .................................................................................................................................................................................. 55

System connections .......................................................................................................................................................................... 56

®

interface ................................................................................................................................................................... 55

EDGE Pro Ti CNC Instruction Manual 807660 vii

Contents

Cable shield grounds .................................................................................................................................................................56

Emergency stop (E-stop) connection ............................................................................................................................................57

Safety audit ..................................................................................................................................................................................57

Sample E-stop circuit ................................................................................................................................................................58

EDGE Pro Ti safety circuit ........................................................................................................................................................59

E-stop test circuit .......................................................................................................................................................................60

E-stop cable .................................................................................................................................................................................62

Motor connection ...............................................................................................................................................................................63

Axis configuration .......................................................................................................................................................................64

Motor (031143) ..........................................................................................................................................................................65

Regeneration circuit ...........................................................................................................................................................66

Motor cable ..........................................................................................................................................................................66

Encoder connection ...........................................................................................................................................................................68

Encoder cable .............................................................................................................................................................................69

I/O connection ....................................................................................................................................................................................71

I/O cable .......................................................................................................................................................................................72

Configuring I/O ...........................................................................................................................................................................73

Shared inputs ......................................................................................................................................................................73

Input modes .........................................................................................................................................................................74

I/O circuits ............................................................................................................................................................................74

I/O Setup screen ........................................................................................................................................................................76

Plasma connection .............................................................................................................................................................................77

Plasma connection for Powermax plasma systems ............................................................................................................78

Plasma connection for generic plasma systems .................................................................................................................80

Plasma interface assembly (228256) ....................................................................................................................................82

Plasma connection to HSD130 plasma systems ................................................................................................................85

Lifter interface ......................................................................................................................................................................................87

Lifter interface cable ..................................................................................................................................................................88

24 VDC auxiliary power connector ................................................................................................................................................89

Hypernet and LAN cable ..................................................................................................................................................................89

Operation ................................................................................................................................................ 91

Operating the CNC ...........................................................................................................................................................................91

Touch screen LCD .....................................................................................................................................................................91

Screen navigation .......................................................................................................................................................................91

Help ...............................................................................................................................................................................................92

View additional manuals ............................................................................................................................................................93

Show bookmarks ........................................................................................................................................................................94

Automated operations .......................................................................................................................................................................94

Align Wizard ................................................................................................................................................................................94

CutPro Wizard .............................................................................................................................................................................95

viii EDGE Pro Ti CNC Instruction Manual 807660

Contents

Updating Phoenix software ............................................................................................................................................................. 95

Updating the software .............................................................................................................................................................. 95

Updating the Help ..................................................................................................................................................................... 95

Updating the cut charts ............................................................................................................................................................ 95

Maintenance and Diagnostics .......................................................................................................... 97

Introduction ......................................................................................................................................................................................... 97

Care and handling of the touchscreen ......................................................................................................................................... 97

Touchscreens, drops of water, and unintended motion ................................................................................................... 98

THC Slide Maintenance ................................................................................................................................................................... 98

Cleaning ....................................................................................................................................................................................... 98

Lubrication ................................................................................................................................................................................... 98

Diagnostic tests ................................................................................................................................................................................. 99

Machine interface tests ............................................................................................................................................................ 99

LAN and Hypernet tests ......................................................................................................................................................... 100

Serial test ...................................................................................................................................................................................101

USB test ....................................................................................................................................................................................102

E-stop test .................................................................................................................................................................................103

I/O test .......................................................................................................................................................................................105

Plasma and lifter tests ............................................................................................................................................................. 108

Operator panel test ................................................................................................................................................................. 109

Troubleshooting ...............................................................................................................................................................................110

Introduction ...............................................................................................................................................................................110

Common situations ................................................................................................................................................................. 111

Power up ............................................................................................................................................................................ 111

Display ................................................................................................................................................................................111

LED ......................................................................................................................................................................................111

Input failure ........................................................................................................................................................................ 112

Output failure ....................................................................................................................................................................112

Hypernet ............................................................................................................................................................................112

LAN connection ................................................................................................................................................................112

The regeneration circuit remains on for more than 25% of a single cut ............................................................. 112

Motion issues ....................................................................................................................................................................113

Serial communication issues ......................................................................................................................................... 113

The CNC is not recognizing a device in a USB port ............................................................................................... 113

Cut quality or plasma performance issues .................................................................................................................113

The CNC feels excessively warm .................................................................................................................................113

Loading files ...................................................................................................................................................................... 114

Wireless troubleshooting .......................................................................................................................................................114

Component locations and information ........................................................................................................................................115

Operator control panel board (141058) ....................................................................................................................................116

EDGE Pro Ti CNC Instruction Manual 807660 ix

Contents

Motherboard (141110) .................................................................................................................................................................. 118

Power distribution board (141153) ............................................................................................................................................ 119

4-axis MCC board (141191) ....................................................................................................................................................... 121

Utility and serial isolation board (141307) ................................................................................................................................ 124

Plasma interface board (141267) ............................................................................................................................................... 126

Relay I/O board (141278) ............................................................................................................................................................ 128

4-axis DC servo board (141281) ................................................................................................................................................ 135

Servo amplifier (228360) ...................................................................................................................................................... 139

Surge board (141287) ................................................................................................................................................................... 140

Plasma interface assembly (228256) ......................................................................................................................................... 141

EDGE Pro Ti Parts List ......................................................................................................................143

EDGE Pro Ti CNC parts ................................................................................................................................................................ 143

Sensor Ti THC parts .......................................................................................................................................................................143

Interface assembly kits ................................................................................................................................................................... 143

Safety circuit kits ............................................................................................................................................................................. 144

Diagnostic kits .................................................................................................................................................................................. 144

Cables ................................................................................................................................................................................................ 144

Cable connector kits ....................................................................................................................................................................... 146

PCB kits ............................................................................................................................................................................................. 146

Additional kits ................................................................................................................................................................................... 148

Wiring Diagrams .................................................................................................................................149

Wiring diagram symbols ................................................................................................................................................................ 150

EDGE Pro Ti system wiring ........................................................................................................................................................... 153

Motherboard ..................................................................................................................................................................................... 154

Power distribution board ............................................................................................................................................................... 155

Operator panel board ..................................................................................................................................................................... 156

Operator panel components ......................................................................................................................................................... 157

Utility and serial board .................................................................................................................................................................... 158

MCC board ....................................................................................................................................................................................... 159

I/O board ........................................................................................................................................................................................... 160

6-Axis servo board .......................................................................................................................................................................... 161

Surge board ...................................................................................................................................................................................... 162

ATX power supply ........................................................................................................................................................................... 163

60 VDC power supply .................................................................................................................................................................... 164

x EDGE Pro Ti CNC Instruction Manual 807660

Safety

RECOGNIZE SAFETY INFORMATION

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

FOLLOW SAFETY INSTRUCTIONS

Carefully read all safety messages in this manual and safety labels
on your machine.

• Keep the safety labels on your machine in good condition.
Replace missing or damaged labels immediately.

• Learn how to operate the machine and how to use the controls
properly. Do not let anyone operate it without instruction.

• Keep your machine in proper working condition. Unauthorized
modifications to the machine may affect safety and machine
service life.

RESPONSIBILITY FOR SAFETY

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

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

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

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

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

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

DANGER WARNING CAUTION

American National Standards Institute (ANSI) guidelines are used for
safety signal words and symbols. The signal word DANGER or
WARNING is used with a safety symbol. DANGER identifies the most
serious hazards.

• DANGER and WARNING safety labels are located on your machine
near specific hazards.

• DANGER safety messages precede related instructions in the
manual that will result in serious injury or death if not followed
correctly.

• WARNING safety messages precede related instructions in this
manual that may result in injury or death if not followed correctly.

• CAUTION safety messages precede related instructions in this
manual that may result in minor injury or damage to equipment if not
followed correctly.

INSPECT EQUIPMENT BEFORE USING

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

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

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

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

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

A PLASMA ARC CAN DAMAGE FROZEN PIPES

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

STATIC ELECTRICITY CAN DAMAGE PRINTED CIRCUIT BOARDS

Use proper precautions when handling printed circuit boards:

• Store printed circuit boards in anti-static containers.

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

Safety and compliance xi

Safety

GROUNDING SAFETY

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

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

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

ELECTRICAL HAZARDS

• Only trained and authorized personnel may open this equipment.

• If the equipment is permanently connected, turn it off, and lock
out/tag out power before the enclosure is opened.

• If power is supplied to the equipment with a cord, unplug the unit
before the enclosure is opened.

• Lockable disconnects or lockable plug covers must be provided by
others.

• Wait 5 minutes after removal of power before entering the enclosure
to allow stored energy to discharge.

ELECTRIC SHOCK CAN KILL

Input power

• Make sure to connect the power cord ground wire to the ground in
the disconnect box.

• If installation of the plasma system involves connecting the power
cord to the power supply, make sure to connect the power cord
ground wire properly.

• Place the power cord’s ground wire on the stud first, then place any
other ground wires on top of the power cord ground. Tighten the
retaining nut.

• Tighten all electrical connections to avoid excessive heating.

• If the equipment must have power when the enclosure is open for
servicing, arc flash explosion hazards may exist. Follow all local
requirements (NFPA 70E in the USA) for safe work practices and for
personal protective equipment when servicing energized equipment.

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

• Always follow these instructions for disconnecting power before
inspecting or changing torch consumable parts.

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

• Operating the plasma system completes an electrical circuit
between the torch and the workpiece. The workpiece and anything
touching the workpiece are part of the electrical circuit.

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

Electric shock prevention

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

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

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

• Insulate yourself from the work and ground using dry insulating
mats or covers big enough to prevent any physical contact with the
work or ground. If you must cut in or near a damp area, use
extreme caution.

• Provide a disconnect switch close to the power supply with
properly sized fuses. This switch allows the operator to turn off the
power supply quickly in an emergency situation.

• When using a water table, make sure that it is correctly connected
to an earth ground.

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

• Inspect the input power cord frequently for damage or cracking
of the cover. Replace a damaged power cord immediately.

Bare wiring can kill.

• Inspect and replace any worn or damaged torch leads.

• Do not pick up the workpiece, including the waste cutoff, while you
cut. Leave the workpiece in place or on the workbench with the
work lead attached during the cutting process.

• Before checking, cleaning, or changing torch parts, disconnect the
main power or unplug the power supply.

• Never bypass or shortcut the safety interlocks.

• Before removing any power supply or system enclosure cover,
disconnect electrical input power. Wait 5 minutes after
disconnecting the main power to allow capacitors to discharge.

• Never operate the plasma system unless the power supply covers
are in place. Exposed power supply connections present a severe
electrical hazard.

• When making input connections, attach a proper grounding
conductor first.

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

xii Safety and compliance

CUTTING CAN CAUSE FIRE OR EXPLOSION

Safety

Fire prevention

• Make sure the cutting area is safe before doing any cutting. Keep a
fire extinguisher nearby.

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

• Quench hot metal or allow it to cool before handling or before
letting it touch combustible materials.

• Never cut containers with potentially flammable materials inside –
they must be emptied and properly cleaned first.

• Ventilate potentially flammable atmospheres before cutting.

• When cutting with oxygen as the plasma gas, an exhaust ventilation
system is required.

Explosion prevention

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

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

• Do not cut containers that have held combustible materials.

Explosion Hazard

Hydrogen Detonation with Aluminum Cutting

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

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

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.

WARNING

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

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

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

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

MACHINE MOTION CAN CAUSE INJURY

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

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

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

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

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

Safety and compliance xiii

• Do not service or clean the machinery during operation.

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

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

Safety

COMPRESSED GAS EQUIPMENT SAFETY

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

• Use only correct gas cylinders, regulators, hoses, and fittings
designed for the specific application.

• Maintain all compressed gas equipment and associated parts in
good condition.

• Label and color-code all gas hoses to identify the type of gas in
each hose. Consult applicable national and local regulations.

TOXIC FUMES CAN CAUSE INJURY OR DEATH

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

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

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

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

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

It is the responsibility of the equipment and site owner to test the air
quality in the cutting area and to make sure that the air quality in the
workplace meets all local and national standards and regulations.

GAS CYLIND ERS 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.

xiv Safety and compliance

A PLASMA ARC CAN CAUSE INJURY AND BURNS

Eye protection Plasma arc rays produce intense visible and invisible

(ultraviolet and infrared) rays that can burn eyes and skin.

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

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

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

• Wear gauntlet gloves, safety shoes, and hat.

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

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

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

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

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

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

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

Safety

Instant-on torches

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

The plasma arc will cut quickly through gloves and skin.

• Keep away from the torch tip.

• Do not hold metal near the cutting path.

• Never point the torch toward yourself or others.

ARC RAYS CAN BURN EYES AND SKIN

Minimum protective

Arc current

Less than 40 A 5 5 8 9

41 A to 60 A 6 6 8 9

61 A to 80 A 8 8 8 9

81 A to 125 A 8 9 8 9

126 A to 150 A 8 9 8 10

151 A to 175 A 8 9 8 11

176 A to 250 A 8 9 8 12

251 A to 300 A 8 9 8 13

301 A to 400 A 9 12 9 13

401 A to 800 A101410N/A

shade number

(ANSIZ49.1:2012)

Suggested shade

number for comfort

(ANSI Z49.1:2012)

OSHA 29CFR

1910.133(a)(5)

Europe

EN168:2002

PACEMAKER AND HEARING AID OPERATION

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

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

Safety and compliance xv

To reduce magnetic field hazards:

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

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

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

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

Safety

NOISE CAN DAMAGE HEARING

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

Significant noise reduction can be obtained by adding simple
engineering controls to cutting tables such as barriers or curtains
positioned between the plasma arc and the workstation, and/or
locating the workstation away from the plasma arc. Implement
administrative controls in the workplace to restrict access and limit
operator exposure time, and screen off noisy areas and/or take
measures to reduce reverberation in cutting areas by putting up noise
absorbers.

DRY DUST COLLECTION INFORMATION

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

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

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

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

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

Note 1 – Unless a site-specific evaluation has been completed that
determines that none of the dust generated is combustible, then
NFPA standard 68 requires the use of explosion vents. Design the
explosion vent size and type to conform to the worst-case Kst value
as described in Annex F of NFPA standard 68. NFPA standard 68
does not specifically identify plasma cutting or other thermal cutting
processes as requiring deflagration venting systems, but it does
apply these new requirements to all dry dust collection systems.

Note 2 – Users should consult and comply with all applicable
national, state, and local regulations. Publications do not intend to
urge action that is not in compliance with all applicable regulations
and standards, and this manual may never be construed as doing so.

xvi Safety and compliance

Safety

LASER RADIATION

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

On products that use a laser pointer for alignment, one of the following laser radiation labels has been applied on the product near where the laser
beam exits the enclosure. The maximum output (mV), wavelength emitted (nM), and, if appropriate, pulse duration are also provided.

Additional laser safety instructions:

• Consult with an expert on local laser regulations. Laser safety
training may be required.

• Do not allow untrained persons to operate the laser. Lasers can be
dangerous in the hands of untrained users.

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

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

• Do not use the laser on reflective workpieces.

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

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

ADDITIONAL SAFETY INFORMATION

1. ANSI Standard Z49.1, Safety in Welding and Cutting, American
Welding Society, 550 LeJeune Road, P.O. Box 351020, Miami,
FL 33135

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

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

4. AWS F4.1, Recommended Safe Practices for the Preparation
for Welding and Cutting of Containers and Piping That Have
Held Hazardous Substances, American Welding Society, 550
LeJeune Road, P.O. Box 351040, Miami, FL 33135

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

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

• Use of adjustments or performance of procedures other than those
specified in this manual may result in hazardous laser radiation
exposure.

• Do not operate in explosive atmospheres, such as in the presence
of flammable liquids, gases, or dust.

• Use only laser parts and accessories that are recommended or
provided by the manufacturer for your model.

• Repairs and servicing must be performed by qualified personnel.

• Do not remove or deface the laser safety label.

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

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

8. NFPA Standard 51B, Cutting and Welding Processes, National
Fire Protection Association, 1 Batterymarch Park, Quincy, MA
02169-7471

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

10. OSHA, Safety and Health Standards, 29FR 1910 U.S.
Government Printing Office, Washington, D.C. 20402

11. AWS Safety and Health Fact Sheets, American Welding
Society, 550 LeJeune Road, P.O. Box 351040, Miami, FL
33135, www.aws.org/technical/facts/

Safety and compliance xvii

Safety

xviii 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 Documents Library on the Hypertherm web site at

www.hypertherm.com/docs

.

Differences in national standards

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

•Voltages

• Plug and cord ratings

• Language requirements

• Electromagnetic compatibility requirements

These differences in national or other standards may make it impossible
or impractical for all certification test marks to be placed on the same
version of a product. For example, the CSA versions of Hypertherm’s
products do not comply with European EMC requirements, and therefore
do not have a CE marking on the data plate.

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

•Australia

• New Zealand

• Countries in the European Union

• Russia

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

Safe installation and use of shape cutting equipment

IEC 60974-9, titled Arc Welding Equipment – Installation and use,
provides guidance in the safe installation and use of shape cutting
equipment and the safe performance of cutting operations. The
requirements of national and local regulations shall be taken into
consideration during installation, including, but not limited to, grounding
or protective earth connections, fuses, supply disconnecting device, and
type of supply circuit. Read these instructions before installing the
equipment. The first and most important step is the safety assessment of
the installation.

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

Procedures for periodic inspection and testing

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

Safety and Compliance xix

Product Stewardship

Hypertherm also removes some protective devices that would cause
false test results. Where required by local national regulations, a label
shall be attached to the equipment to indicate that it has passed the
tests prescribed by IEC 60974-4. The repair report shall indicate the
results of all tests unless an indication is made that a particular test has
not been performed.

Qualification of test personnel

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

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

Residual current devices (RCDs)

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

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

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

Higher-level systems

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

It is the responsibility of the end-use customer and the OEM to perform a
risk assessment for the higher-level system, and to provide protection
against hazardous moving parts. Unless the higher-level system is
certified when the OEM incorporates Hypertherm products into it, the
installation also may be subject to approval by local authorities. Seek
advice from legal counsel and local regulatory experts if you are uncertain
about compliance.

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

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

xx Safety and Compliance

Environmental Stewardship

Introduction

The Hypertherm Environmental Specification requires RoHS, WEEE and
REACH substance information to be provided by Hypertherm’s
suppliers.

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

National and local environmental regulations

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

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

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

The RoHS directive

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

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

Declarations of RoHS Conformity have been prepared for the current CE
versions of Hypertherm products that fall within the scope of the RoHS
Directive. These RoHS-compliant products also have a “RoHS mark”
near the “CE Marking” on the data plate. Parts 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, and there is no “RoHS mark” on their
data plates.

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.

• In other countries, check national and local laws.

• Consult with legal or other compliance experts when appropriate.

A variety of options for sustainable disposal of Hypertherm products are
available on our website at www.hypertherm.com/recycle

.

The WEEE Directive

The European Parliament and the Council of the European Union
authorized Directive 2012/19/EU or WEEE (Waste Electrical and
Electronic Equipment) Recast.

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 options for
Hypertherm systems can be found at www.hypertherm.com/recycle

The URL is printed on the symbol-only warning label for each CE version
Hypertherm plasma system since 2006. The CSA versions of products
manufactured by Hypertherm are either out of scope or exempt from
WEEE.

.

The REACH regulation

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

Safety and Compliance xxi

Environmental Stewardship

Proper handling and safe use of chemicals

Chemical Regulations in the USA, Europe, and other locations require
that Material Safety Data Sheets (MSDS) or Safety Data Sheets (SDS)
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 Documents Library on the Hypertherm web site at

www.hypertherm.com/docs

Safety Data Sheets” in the Category drop-down menu.

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.

. In the Documents Library, select “Material

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.

xxii Safety and Compliance

Electromagnetic Compatibility (EMC)

Introduction

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

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

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

Installation and use

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

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

Methods of reducing emissions

Mains supply

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

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

Maintenance of cutting equipment

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

Cutting cables

Assessment of area

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

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

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

b. Radio and television transmitters and receivers.

c. Computer and other control equipment.

d. Safety critical equipment, for example guarding of industrial

equipment.

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

pacemakers and hearing aids.

f. Equipment used for calibration or measurement.

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

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

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

out.

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

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

Equipotential bonding

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

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

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

Safety and compliance xxiii

Electromagnetic Compatibility (EMC)

Earthing of the workpiece

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

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

Screening and shielding

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

xxiv Safety and compliance

Warranty

Attention

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

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

General

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

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

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

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

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

Patent indemnity

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

Limitation of liability

In no event shall Hypertherm be liable to any person or entity for
any incidental, consequential direct, indirect, punitive or
exemplary damages (including but not limited to lost profits)
regardless of whether such liability is based on breach of
contract, tort, strict liability, breach of warranty, failure of
essential purpose, or otherwise, and even if advised of the
possibility of such damages. Hypertherm shall not be liable for
any losses to Distributor based on down time, lost production or
lost profits. It is the intention of the Distributor and Hypertherm
that this provision be construed by a court as being the
broadest limitation of liability consistent with applicable law.

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

National and local codes

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

Safety and compliance xxv

Warranty

Liability cap

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

Insurance

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

Transfer of rights

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

Waterjet product warranty coverage

Product Parts coverage

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

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

PowerDredge
abrasive removal
system

EcoSift abrasive
recycling system

Abrasive metering
devices

On/off valve air
actuators

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

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

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

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

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

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

filter and compliance with Hypertherm’s
water quality requirements

xxvi Safety and compliance

Section 1

Operator console

Cutting table

Control box

Drive amplifier

Oxyfuel cutting

system

EDGE Pro

CNC

THC

Plasma system

Products available from Hypertherm

Specifications

Main features of an automated cutting system

The diagram in Figure 1 illustrates the relationship between the components of an automated cutting system.
The following sections describe these components and their relationships more fully.

Figure 1 Components of an automated cutting system

EDGE Pro Ti CNC Instruction Manual 807660 27

Specifications

Operator console

Cutting table

Oxyfuel cutting

system

EDGE Pro TI

CNC

THC

Plasma system

Drive amplifier

Control box

Products available from

Hypertherm

Plasma system Cutting table Work piece Lifter

EDGE Pro Ti CNC Operator panel

Star ground

Rails

Gantry

Main features of an automated cutting system

The diagram in Figure 2 illustrates an automated cutting system that includes an EDGE Pro Ti CNC with the drive
amplifier located within the CNC and not on the cutting table.

Figure 2 Automated cutting system with an EDGE Pro Ti CNC

Figure 3 illustrates a typical cutting table with an EDGE Pro Ti CNC and other components that are described in the
following sections.

Figure 3 Illustration of a cutting table

28 EDGE Pro Ti CNC Instruction Manual 807660

Specifications

Main features of an automated cutting system

CNC

The computerized numerical control (CNC) reads part programs and communicates with the other components of the
shape cutting system. It controls which parts (shapes) are cut from the metal that is being cut. In addition, the
EDGE Pro Ti includes 4 drive amplifiers that control the motors for the X and Y axes.

Refer to the sections in this manual for more detailed information about the hardware features of the EDGE Pro Ti CNC.
Refer to the following Phoenix
EDGE Pro Ti CNC:

• Installation and Setup Manual (806410)

• Operator’s Manual (806400)

• Programmer’s Reference (806420)

®

software manuals for detailed information on the software that operates on the

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.

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 system

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

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

Control box

The control box (supplied by the table manufacturer) contains terminal blocks that route power and control signals to the
subsystems of the cutting system.

Drive system

The speed, smoothness, and accuracy of the cuts are determined by the combination of the CNC, encoders, servo drive
amplifiers, THC, gears, rails, servo motors, and how well they are integrated (tuned) by the table manufacturer. The table
manufacturer must select and install the motors that will be used with the EDGE Pro Ti CNC. 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 known as the standoff. This standoff is
usually defined by height or voltage.

®

If your system includes an ArcGlide
using it. If your THC is manufactured by another company, refer to the manual provided by the table manufacturer.

EDGE Pro Ti CNC Instruction Manual 807660 29

THC, refer to the user manual (806450) for more information about installing and

Specifications

2-Station operator console

Touchscreen

Overview

Operator console

The EDGE Pro Ti operator control panel can control two cutting stations. Additional control panels, not manufactured by
Hypertherm, may be installed by the table manufacturer to control oxyfuel, markers, ventilation systems, and other
devices. For more information about an optional control panel, refer to the manual provided by the table manufacturer.

Oxyfuel torch

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

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

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

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. For more information, see the appropriate HPR manual.

For other devices or processes, refer to the appropriate manual.

Overview

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

The EDGE Pro Ti CNC has up to 4 integrated servo drive amplifiers, a two-station operator console, a 15-inch
touchscreen, wireless communication, and the Phoenix application software.

EDGE Pro Ti features can be expanded with the addition of networking to download part programs or remote diagnostic
utilities.

Figure 4 Front view of the EDGE Pro Ti CNC

30 EDGE Pro Ti CNC Instruction Manual 807660

Specifications

2

3

4

5

1

Data transfer

2

Power switch

3

Program execution controls

4

Station controls

5

Manual motion controls

Features of the EDGE Pro Ti CNC

Features of the EDGE Pro Ti CNC

Touchscreen

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

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

See “Care and handling of the touchscreen” on page 99 for more information about how to care for the touchscreen.

Operator console

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

Figure 5 EDGE Pro Ti operator console

1

EDGE Pro Ti CNC Instruction Manual 807660 31

Specifications

1

987

6

5

4

3

2

1

Drive/encoder connectors

2

Wireless antennas

3

Plasma and lifter (Sensor Ti) connectors

4

I/O connectors

5

E-stop connector

6

24 V auxiliary power output

7

Serial ports

8

USB port

9

LAN port

10

Hypernet port

11

AC power input

10

11

Features of the EDGE Pro Ti CNC

Rear panel

The rear panel of the EDGE Pro Ti CNC has cable connectors for power, motion control, I/O, and communication ports.
These connectors are clearly labeled with their function.

Figure 6 Rear panel of the EDGE Pro Ti CNC

For more information about the electrical installation of the EDGE Pro Ti CNC, See Installation on page 37..

32 EDGE Pro Ti CNC Instruction Manual 807660

System specifications

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

Table 1 System specifications for the EDGE Pro Ti CNC

System features

Processor

Operating system Windows XPe

RAM ≥1GB

Ethernet port 1 RJ-45 Ethernet port

Hypernet port 1 Hypernet port for use with the ArcGlide THC

USB ports 2 USB 2.0 ports

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

Wireless communication Complies with 802.11G and 802.11N standards.

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

Hard drive SATA drive

Operator console 2-station standard (expandable by table manufacturer)

Intel

®

Processor

Specifications

System specifications

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

Regulatory compliance CE, CSA, GOST-R

Configuration

Number of I/O 12/12

I/O Type Positive logic input or dry contact and relay output

Axes available 2 – 4

Power

AC input Voltage: 100 VAC to 240 VAC

Current: single-phase, 10.0 A at 100 VAC/4.1 A at 240 VAC
Frequency: 50/60 Hz

DC output Encoder power: 5 VDC

E-stop power: 24 VDC
Axis 4 brake power: 24 VDC at 500 mA
Total field power available: Encoders = 5 V/0.5A, I/O = 1.5 A, E-stop = 500 mA, lifter brake = 0.5 A

Slow blow fuse (2) 250 V, 10A, 5 mm x 20 mm

DC available for I/O 24 V at 1.5 A

Servo output 700 watts continuous at 120 VAC input

700 continuous watts and 1,000 intermittent watts at 70% duty at 240 VAC input
DC brush or brushless motors with Hall sensor feedback

EDGE Pro Ti CNC Instruction Manual 807660 33

Specifications

System specifications

System features

Environmental

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

Humidity 95% maximum relative humidity

Ingress Protection IP2X

Protect the equipment from exposure to excessive moisture.

Altitude Operational up to 2000 m (6561 ft)

Environment Pollution degree Level II

Mechanical

Height 490.9 mm (19.33 in.)

Width 435 mm (17.13 in.)

Depth 377.2 mm (14.85 in.)

Weight 28.83 kg (63.55 lb)

34 EDGE Pro Ti CNC Instruction Manual 807660

Specifications

EDGE Pro Ti axis and I/O configuration

EDGE Pro Ti axis and I/O configuration

The EDGE Pro Ti interface offers 2 to 4 axes of motion control using internal motor drives with 12 inputs and 12 outputs.
This interface can be used to retrofit an existing system with the Edge Pro Ti interface.

The EDGE Pro Ti interface can be configured to supply encoder power at 5 VDC. For more information, See Ti I/O
circuits on page 75.

Table 2 EDGE Pro Ti part numbers

Part Number Number of Axes Number of I/O

090136 2 12/12

090137 3 12/12

090138 4 12/12

Figure 7 Rear panel of the EDGE Pro Ti CNC

EDGE Pro Ti CNC Instruction Manual 807660 35

Specifications

Table 3 Sensor Ti lifter part numbers

Part number

Description

228119 Sensor Ti lifter, motor, encoder, 4.53 k (10 lb) magnetic

breakaway

128277 35 mm (1-3/8 in.) torch mounting block

128278 44 mm (1-3/4 in.) torch mounting block

128279 50 mm (2 in.) torch mounting block

Specifications for the Sensor Ti lifter

Specifications for the Sensor Ti lifter

Compatible motors DC brush, 60 VDC, 1 A

Maximum power output 60 W

Standard lifter range Linear 152 mm (6 in.)

Accuracy 0.25 mm (0.01in.) or 0.5 V *

Measuring technology Arc voltage feedback and Ohmic contact sensing

Standard lifter dimensions 152 mm (6 in.) W x 80 mm (3.15 in.) D x 546 mm (21.5 in.) H*

Standard lifter weight 8.7 k (19 lb) *

Operating environment 0 to 50 C; 95% maximum relative humidity (non-condensing)

* With standard, supplied lifter mechanics

Figure 8 Sensor Ti lifter

36 EDGE Pro Ti CNC Instruction Manual 807660

Section 2

Installation

Upon receipt

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

•EDGE Pro Ti CNC

• Power cable (North America)

• EDGE Pro Ti CNC instruction manual

• Phoenix software instruction manuals

• Any other optional components that appear on your order form

• Inspect the system components for any physical damage that may have occurred during shipping.
If there is evidence of damage, refer to the following section, 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 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.

Gantry sizing for EDGE Pro Ti motors

There are many features of a cutting table that impact the performance of the complete system including:

• Size of the pinion gear

• Ratio of the gears

• Choice of direct-drive gearboxes or pulley sizing

• Gantry weight

EDGE Pro Ti CNC Instruction Manual 807660 37

Installation

Installation requirements

•Table size

•Design

The following information is intended to assist with determining the weight of a gantry on a table that is accelerated by the
EDGE Pro Ti motors (031143).

A theoretical table configuration using a single-side drive with rack and pinion mechanics is the basis for the calculations.
The pinion gear diameter is 50 mm (1.9 in.). Table 4 provides the suggested values for the weight of the gantry and
multiple gearbox ratios based on this hypothetical table.

Different table designs have different weight values. These values have been calculated with the torque equation, which
compares the maximum continuous torque of the motor to the theoretically calculated inertia of the cutting machine.

In the following table, the figure for maximum linear speed is based on the pinion diameter and gearbox ratio for a single
side drive using a 50 mm (1.9 in.) pinion gear. This figure does not include the limitations of table mechanics which can
significantly reduce this value. To determine the gantry weight for a dual gantry setup, increase the weight of the
single-side drive by 40%.

Table 4 G a ntr y siz i n g

Gear box ratio

10:1 54966/2164 131/288
15:1 36652/1443 197/433
20:1 27483/1082 263/579
25:1 21996/866 329/724

Properly sizing the machine to performance specifications requires mechanical engineering and motion engineering
expertise. Table manufacturers are responsible for the optimal sizing and performance characteristics of the complete
machine. The EDGE Pro Ti can be used in many different configurations but the final performance characteristics of the
machine depend on the total solution provided by the table manufacturer.

millimeter per minute/inch per minute

Maximum linear speed

Gantry weight (kg/lb)

Placement of system components

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

Mounting the CNC on page 39 for details.

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

grounding details.

WARNING!

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

38 EDGE Pro Ti CNC Instruction Manual 807660

Installation

435 mm

17.13 in.

491 mm

19.33 in.

Use M6 x 1 hardware for side mounting.

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

58 mm

2.29 in.

21 mm

0.82 in.

228.5 mm

9.00 in.

90 mm

3.50 in.

377.2 mm (14.85 in.)

36 mm

1.42 in.

Mounting the CNC

Mounting the CNC

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

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

Figure 9 Front and side views of the EDGE Pro Ti CNC

EDGE Pro Ti CNC Instruction Manual 807660 39

Installation

Use M6 x 1 hardware.

(10 places)

Maximum length inside

enclosure must not exceed

7.8 mm (0.31 in.)
305 mm

(12 in.)

127 mm

(5 in.)

356 mm

(14 in.)

203 mm

(8 in.)

89 mm

3.5 in.

114 mm

3.7 in.

58 mm

2.29 in.
148 mm

5.8 in.

97 mm

(3.8 in.)

Mounting the CNC

Mounting hole patterns on the bottom of the CNC

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

Figure 10 EDGE Pro Ti mounting hole pattern

40 EDGE Pro Ti CNC Instruction Manual 807660

Installation

142.75 mm (5.62 in.)

152.4 mm (6.00 in.)

88.9 mm
(3.50 in.)

88.9 mm
(3.50 in.)

88.9 mm
(3.50 in.)

24.5 mm (1 in.)

546.1 mm
(21.50 in.)

Ground stud —
connect to the star
ground on the
work table

Ø 0.265 in.
countersunk for cap
socket head screws

114.30 mm (4.50 in.)

Mounting the THC

Mounting the THC

Sensor™ Ti THC

The EDGE Pro Ti CNC supports one Sensor Ti THC. Mount the Sensor Ti lifter assembly (228119) on the cutting table to
take maximum advantage of the vertical travel range. Typically the bottom of the lifter should be between 15.24 and

20.32 cm (6 and 8 in.) above the cutting table.

Figure 11 Front and side views of the Sensor Ti

EDGE Pro Ti CNC Instruction Manual 807660 41

Installation

Mounting the THC

ArcGlide THC

The EDGE Pro Ti CNC supports a maximum of 4 ArcGlide THCs. Refer to the ArcGlide THC Instruction Manual
(806450) for complete information about installing this THC.

42 EDGE Pro Ti CNC Instruction Manual 807660

Installation

Mounting the THC

Recommended grounding and shielding

Introduction

This section describes practices for grounding and shielding a plasma cutting system to minimize its susceptibility to
electromagnetic interference (EMI) (also known as noise). It also describes the service ground, protective earth (PE)
ground, and DC power ground. The diagram at the end of this section shows these types of grounds in a plasma cutting
system.

Note: The grounding practices in this section have been used on many installations with excellent results, and
Hypertherm recommends that these practices be a routine part of the installation process. The actual methods
used to implement these practices may vary from system to system, but should remain as consistent as possible.
However, due to the variation in equipment and installations, these grounding practices may not succeed in every
case to eliminate EMI problems. Hypertherm recommends that you consult your local and national electrical codes
to make sure that the grounding and shielding practices that you use satisfy the requirements for your location.

Types of grounding

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

Protective earth (PE) ground is the grounding system inside the electrical equipment. The PE ground, which connects
to the service ground, provides electrical continuity between the equipment and the AC service.

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

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

EDGE Pro Ti CNC Instruction Manual 807660 43

Installation

Mounting the THC

Grounding practices

1. Unless noted, use cables with a minimum gauge of 13.3 mm2 (6 AWG) (047040) for the EMI ground
cables shown in the “Example grounding diagram” on page 47.

2. The cutting table is used for the common, or star, EMI ground point and should have threaded studs
welded to the table with a copper bus bar mounted on them. A separate bus bar should be mounted on
the gantry as close to each motor as possible. If there are motors at each end of the gantry, run a separate
EMI ground cable from the far motor to the gantry bus bar. The gantry bus bar should have a separate,
heavy EMI ground cable 21.2 mm
torch lifter and the RHF or combined ignition/gas connect console must each run separately to the table
ground bus.

3. Inadequate grounding not only exposes operators to dangerous voltages, but inadequate grounding also
increases the risk of equipment failure and unnecessary downtime. Ideally a ground should be zero ohms
resistance, but field experience indicates under 1 ohm resistance is satisfactory for most applications.
Hypertherm recommends that you consult your local and national electrical codes to make sure that the
grounding and shielding practices that you use satisfy the requirements for your location.

4. A ground rod (a PE ground) that meets all applicable local and national electric codes must be installed
within 6 m (20 ft) of the cutting table. The PE ground must be connected to the cutting table ground bus
bar using a minimum 13.3 mm

2

(4 AWG; 047031) to the table bus bar. The EMI ground cables for the

2

(6 AWG) green and yellow grounding cable (047121).

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

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

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

8. For a system with a remote high frequency (RHF) console or combined ignition/gas connect console, the
positive, negative, and pilot arc leads should be bundled together for as long a distance as possible. The
torch lead, work lead, and the pilot arc (nozzle) leads may be run parallel to other wires or cables only if
they are separated by at least 150 mm (6 inches). If possible, run power and signal cables in separate
cable tracks.

9. For a system with a RHF console or combined ignition/gas connect console, Hypertherm recommends
that you mount this console as close as possible to the torch. This console also must have a separate
ground cable that connects directly to the cutting table ground bus bar.

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

44 EDGE Pro Ti CNC Instruction Manual 807660

Installation

1 Gantry ground bus
2 Ground rod
3 Plasma system lead (+)
4 RHF console (if applicable, not on all systems)
5 CNC enclosure
6 Torch holder
7 Plasma system chassis

1 2 3

4

5 6 7

Mounting the THC

11. The metal braided shield on the torch lead must be connected firmly to the ignition/gas connect console

and to the torch. It is recommended to be electrically insulated from any metal and from any contact with
the floor or building. The torch lead can be run in a plastic cable tray or track, or covered with a plastic or
leather sheath.

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

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

13. If the gantry runs on rails that are not welded to the table, then each rail must be connected with a ground

cable from the end of the rail to the table. The rail ground cables connect directly to the table and do not
need to connect to the table ground bus bar.

14. If you are installing a voltage divider board, mount it as closely as possible to where the arc voltage is

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

15. All other signals (analog, digital, serial, and encoder) should run in twisted pairs inside a shielded cable.

Connectors on these cables should have a metal housing. The shield, not the drain, should be connected
to the metal housing of the connector at each end of the cable. Never run the shield or the drain through
the connector on any of the pins.

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

EDGE Pro Ti CNC Instruction Manual 807660 45

Installation

1 Cable to the cutting table ground bus
2 Ground cables from components on the

gantry

1 2

Mounting the THC

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

46 EDGE Pro Ti CNC Instruction Manual 807660

Example grounding diagram

Chassis and RFI ground

AC earth ground (PE)

1

2

3

4

5

6

7

8 9

10

11

12

13

1 Cutting table

2 Gantry

3 Plasma system
4 Table ground bus bar

5 Gantry ground bus bar

6 Torch height control lifter (ArcGlide, Sensor THC,

Sensor PHC, or other)

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

table ground bus bar.

8, 9 System-specific component such as metering

console, gas console, or selection console

10 CNC chassis

11 Torch height control module

(ArcGlide, Command THC)

12 System-specific component such as a cooler or

chiller

13 DC power ground

Installation

Mounting the THC

Note: This example is based on practices in North America. Other regions can have different local or national
electrical codes. Hypertherm recommends that you consult your local and national electrical codes to make sure

that the grounding and shielding practices that you use satisfy the requirements for your location.

EDGE Pro Ti CNC Instruction Manual 807660 47

Installation

Mounting the THC

48 EDGE Pro Ti CNC Instruction Manual 807660

Configuration diagrams

Lifter interface cable

Motor cable

Encoder cable

Encoder cable

Encoder cable

Encoder cable

Motor cable

Motor cable

Motor cable

Integrated Sensor Ti lifter with motor,
encoder and magnetic breakaway
(228119)

Torch mounting block

Ohmic contact wire, connect to torch shield

Motor (031143)

Motor (031143)

Motor

(031143)

EDGE Pro Ti CNC

Plasma interface cable for connection to
plasma interface assembly 228256

Plasma interface cable for connection to
plasma systems with a compatible, built-in
voltage divider

OR

E-stop cable

Figure 12 Example of a configuration with an EDGE PRO Ti CNC and an integrated Sensor Ti lifter

Installation

Configuration diagrams

EDGE Pro Ti CNC Instruction Manual 807660 49

Installation

Encoder cable

Encoder cable

Encoder cable

Motor cable

Motor cable

Motor cable

Motor (031143)

Motor (031143)

Motor (031143)

EDGE Pro Ti CNC

Hypernet cable to the Arc Glide THC. For complete
installation information, see the ArcGlide THC

Instruction Manual.

E-stop cable

Configuration diagrams

Figure 12 EDGE Pro Ti with an ArcGlide lifter

50 EDGE Pro Ti CNC Instruction Manual 807660

Installation

EDGE Pro Ti CNC

CNC control panel

X-

Y-

Y+

X+

Table origin and

Home position

(0,0)

X and Y axis configuration

X and Y axis configuration

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

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

Figure 13 Example of a shape cutting system configured with an EDGE Pro Ti CNC

The operator console

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

The operator console allows you to:

• Start and stop the cutting program.

• Switch to manual mode

• Manually jog the torch with the joystick

• Jog forward or backward on path

• Adjust the jog and cutting feed rates

• Activate or deactivate the 2 cutting stations

The device I/O for the operator console are assigned to Input and Output 129 and higher, as listed in Table 5.

EDGE Pro Ti CNC Instruction Manual 807660 51

Installation

The operator console

Front panel I/O

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

Table 5 Front panel I/O assignments

Function Input No. Output No.

Front Panel Start 129
Front Panel Stop 130
Front Panel Manual 131
Front Panel Forward On Path 132
Front Panel Backward On Path 133
Jog Up 134
Jog Down 135
Jog Left 136
Jog Right 137
Auto Select 1 138
Manual Select 1 139
Raise Torch 1 140
Lower Torch 1 141
Auto Select 2 142
Manual Select 2 143
Raise Torch 2 144
Lower Torch 2 145
Station Enable LED 1 129
Station Enable LED 2 130
Speed Pot 1 (Program Speed) Analog Input 1
Speed Pot 2 (Jog Speed) Analog Input 2
Divided and filtered arc voltage Analog Input 3
Scaled interior temperature Analog Input 4

Note: Loading a setup file from a different Hypertherm CNC will not affect these I/O assignments.

52 EDGE Pro Ti CNC Instruction Manual 807660

AC power

AC Power connector
Voltage range: 115 to 240 V, single phase
Fuse size: 250 V, 10 A, slow-blow, 5 mm x 20 mm

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

EDGE Pro Ti CNC

Power entry module:
2 Fuses: 250 V, 10 A, slow blow, 5 x 20 mm

EDGE Pro Ti CNC

Power entry module:
2 Fuses: 250 V, 10 A, slow blow, 5 x 20 mm

Customer-supplied
power 220 VAC

Customer-supplied
power 120 VAC

L1 – line

L2 – line

PE ground

L1 – line

L2 – neutral

PE ground

Power input

Figure 14 illustrates the power input connector on the rear of the EDGE Pro Ti CNC.

Figure 14 AC power input connector

Note: The AC power cable must be plugged into an AC branch circuit with a 20-A limit.

Power cable

Installation

AC power

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

For more electrical specifications, see “System specifications” on page 33. Figure 15 shows examples of how power
cables can be created.

Note: The fuse block holds two 250 V, 10 A, slow-blow, 5 mm x 20 mm fuses.

Figure 15 Input VAC wiring examples

EDGE Pro Ti CNC Instruction Manual 807660 53

Installation

To the star ground on the cutting table

AC power

Chassis grounding

The CNC must be properly grounded according to national and local electrical codes for safe operation. Use a number
6 AWG (16 mm
shown in Figure 16.

2

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

WAR NING!

ELECTRIC SHOCK CAN KILL

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

Figure 16 Ground cable on the CNC

54 EDGE Pro Ti CNC Instruction Manual 807660

Installation

Interface ports

Interface ports

Figure 17 illustrates the interface ports and their location on the rear of the EDGE Pro Ti CNC.

Figure 17 Interface ports

Hypernet® interface

The Hypernet interface allows the EDGE Pro Ti to connect to an ArcGlide THC and plasma system using the Hypernet
protocol over shielded, Ethernet Cat-5e cables. This configuration must include an industrial-grade Ethernet switch to
route communication from the EDGE Pro Ti to the other units in the system. Note that the EDGE Pro Ti does not support
both an ArcGlide and a Sensor Ti lifter in the same system. See EDGE Pro Ti Parts List for Hypernet cable lengths and
part numbers.

LAN interface

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

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

USB interface

The USB 2.0 port on the back of the CNC, like the one on the front panel, can be used to load programs or to connect a
USB keyboard or mouse.

Serial ports

The two serial RS-232/RS-422 ports on the back of the CNC are configurable ports and accept D-sub 9-pin
connectors. Transmission rate is up to 115K Baud. Both ports are preset for RS-422 as the default. For more information,
see “Utility and serial isolation board (141307)” on page 126.

EDGE Pro Ti CNC Instruction Manual 807660 55

Installation

Cable shield connection
for I/O 7 – 12

Cable shield connection
for I/O 1 – 6

Cable shield connection
for E-stop and 24 VDC
auxiliary power

Cable shield

connections for

motors and encoders

Connect the tab on the cable shield to the cable shield connection.

System connections

System connections

Cable shield grounds

To minimize electromagnetic and radio frequency interference (EMI/RFI), connect all interface cable shields to the
chassis using the following methods, as appropriate:

• The ground screw on the EDGE Pro Ti enclosure

• The dedicated ground pin on each plastic cable connector (CPC)

• The metal shell on the plasma and lifter cable D-sub connectors should be connected to the cable
shield

Figure 18 EDGE Pro Ti cable shield ground connections

56 EDGE Pro Ti CNC Instruction Manual 807660

Installation

E-stop connector

24 V auxiliary power output

Emergency stop (E-stop) connection

Emergency stop (E-stop) connection

The E-stop connector provides the interface for an E-stop button with a separate reset switch to meet local safety
regulations.

Safety audit

A safety audit must be conducted before the system is installed. All requirements for redundancy, monitoring, and
scheduled testing for safety circuits that result from the audit must be implemented.

Figure 19 Location of the EDGE Pro Ti E-stop connector

The table manufacturer must supply and install the E-stop logic functions, E-stop switch and reset switch to insure that
they are in complete compliance with national and local safety regulations and the configuration of the system.

Installation of the circuitry and switches can be done using safety relays or PLCs, as necessary. A safety PLC may be
preferred if advanced functionality or advanced machine and factory integration is required. The E-stop interface on the
rear of the EDGE Pro Ti enclosure has been tested with the following commercially available components:

• Safety relay (003239)

• Normally closed, dual pole, single throw E-stop switch (428025)

• Normally open, momentary reset switch (428026)

The E-stop interface must be satisfied to engage the motors. If the E-stop is not satisfied, the motors will not spin. Figure
20 on page 58 shows a possible design for an E-stop circuit, including the circuitry that exists within the EDGE Pro Ti
CNC and circuitry using an Allen Bradley safety relay.

Note:

• The safety relay is powered by 24 VDC from pins 1 and 10 of the E-stop connector on the CNC.

• The sensor circuit is wired for 2-channel E-stop monitoring with LS1 and LS2 monitor contacts in series.

• The start circuit is wired for manual, monitored activation.

• When the LED is illuminated, it indicates that the machine is disabled.

EDGE Pro Ti CNC Instruction Manual 807660 57

Installation

E-Stop enclosure

(Supplied by the table manufacturer)

Safety

relay

Reset switch

AC fused disconnect

AC

Disconnect

Connect tab to ground screw on the rear

panel of the CNC

Brown

Jumper

Green

Blue

Red

Violet
Black

Orange

White

E-stop switch

Normally closed

Normally open

Reset S34

24
23
13

14
A2

41

3

4

A1

S12

S52

S21

S22

S11

Jumper

42

E-stop cable

(page 62)

Connects to the E-stop CPC

(see Figure 21)

Lamp

X1

X2

2

2

1

1

1
2
3

7

6

5

4

10

9

8

12

11

15

14

13

Ye l l ow

Grey

CPC

Cable shield

Emergency stop (E-stop) connection

Sample E-stop circuit

Figure 20 illustrates an example of an E-stop that a table manufacturer might implement. The CPC for this circuit
connects to the E-stop connector on the rear enclosure of the CNC and to the built-in safety circuit within the EDGE Pro
Ti CNC, shown in Figure 21.

The E-stop in Figure 20 uses Hypertherm components; an E-stop switch (428025), safety relay (003239), and reset
switch (428026) and uses the EDGE Pro Ti E-stop cable to connect to the safety circuit within the CNC. Other
components require a different design.

Figure 20 Example of an E-stop circuit

58 EDGE Pro Ti CNC Instruction Manual 807660

EDGE Pro Ti safety circuit

Power distribution

board

(page 121)

250 V, 10 A slow

blow fuse

1 +24 V
2 E-Stop monitor 1A

3 E-Stop monitor 1B

7 24 V coil 1B

6 24 V coil 1A

5 E-Stop monitor 2B

4 E-Stop monitor 2A

10 Field ground

9 24 V coil 2B

8 24 V coil 2A

AC

DC

Power

good

Servo board

(page 137)

current control

and

Z axis brake

M1

M2

M3

M4

60 V enable

E-stop

12 Not connected

11 Not connected

15 Not connected

14 Not connected

13 Not connected

Power good bit

E-stop input bit

I/O board to CNC

motherboard

(page 120)

Surge and safety

relay board

(page 142)

EDGE Pro Ti CNC

Relay LS1 with

force-guided

contacts

Relay LS2 with

force-guided

contacts

Normally open

Normally open

Normally closed

Normally closed

J6

CPC

EMI ground screw. Connect the ring terminal
from the E-stop cable shield.

16 Cable shield

The EDGE Pro Ti CNC has a safety circuit that allows table manufacturers to implement E-stop or other safety measures
according the needs of their customers and their local and national safety regulations. Figure 21 illustrates this circuit.
Figure 20, illustrates an example of an E-stop design that might connect to the safety circuit within the EDGE Pro Ti
CNC through the E-stop connector on the rear panel of the CNC.

Figure 21 EDGE Pro Ti safety circuit

Installation

Emergency stop (E-stop) connection

EDGE Pro Ti CNC Instruction Manual 807660 59

Installation

CPC

1

3

7

5

9

12

11

15

13

2

6

4

10

8

14

16

AC fused

disconnect

AC

Disconnect

16

This E-stop test circuit connects to the E-stop circuit within the EDGE
Pro Ti. The CPC for this test circuit connects to the E-stop connector on
the rear enclosure of the CNC.

Emergency stop (E-stop) connection

E-stop test circuit

WARNING!

This test circuit is designed for testing only and does not replace an approved E-stop implementation.

Use this test circuit with two jumpers to provide E-stop inputs that engage the motor drives.

Machinery is activated as soon as the jumpers are applied and can present a danger.

Figure 22 E-stop test circuit

60 EDGE Pro Ti CNC Instruction Manual 807660

Figure 23 EDGE Pro Ti safety circuit

Power distribution

board

(page 121)

250 V, 10 A
slow blow fuse

1 +24 V

2

E-Stop monitor 1A

3 E-Stop monitor 1B

7 24 V coil 1B

6 24 V coil 1A

5 E-Stop monitor 2B

4 E-Stop monitor 2A

10 Field ground

9

24 V coil 2B

8 24 V coil 2A

AC

DC

Power
good

Servo board

(page 137)

current control
and Z axis brake

60 V enable

E-stop

12 Not connected

11 Not connected

16 Cable shield

15 Not connected

14 Not connected

13 Not connected

Power good
bit

E-stop input bit

I/O board to CNC

motherboard

(page 120)

Surge and safety

relay board

(page 142)

EDGE Pro Ti CNC

Relay LS1 with

force-guided

contacts

Relay LS2 with

force-guided

contacts

Normally open

Normally open

Normally closed

Normally closed

J6

CPC

M1

M2

M3

M4

Installation

Emergency stop (E-stop) connection

EDGE Pro Ti CNC Instruction Manual 807660 61

Installation

Key plugs in 11 – 15

1

16

36

10

14

Emergency stop (E-stop) connection

E-stop cable

Figure 24 E-stop cable

Table 6 E-stop cable pinouts

Pin no. Wire color Signal

1 Brown +24 V field
2 Orange E-stop monitor 1A
3 Blue E-stop monitor 1B
4 Violet E-stop monitor 2A
5 Grey E-stop monitor 2B
6 White 24 V coil 1A
7 Green 24 V coil 1B
8 Yellow 24 V coil 2A
9 Red 24 V coil 1B
10 Black Field ground
11–16 Not connected

Use the following information to order E-stop cables.

Part Number Length

223365 3.05 m (10 ft)
223366 6.08 m (20 ft)
223367 7.62 m (25 ft)
223368 10.66 m (35 ft)
223369 15.25 m (50 ft)

To create a custom cable, order the connector kit (428046).

62 EDGE Pro Ti CNC Instruction Manual 807660

Installation

Axis 1

12

5

3

76

Axis 2

Axis 3

Axis 4 – lifter

Motor connector

Motor connection

Motor connection

Install the motor cables between the Axis 4 motor connector and the motor connector on the Sensor Ti and between the
Axis 3, Axis 2, and Axis 1 motor connectors on the rear of the EDGE Pro Ti and the motor connector on the remaining
axis motors (031143). For more information about the motor cable, see Motor cable on page 66.

Figure 25 Ti motor interfaces

Table 7 Pinouts for motor interfaces

Pin no. Axis 4 – Lifter Axis 3 (Dual gantry) Axis 2 (Y or X) Axis 1 (X or Y)
Motor

connectors

1 Motor/brake A Motor/brake A Motor/brake A Motor/brake A
2 Motor/brake B Motor/brake B Motor/brake B Motor/brake B
3 Motor/brake C Motor/brake C Motor/brake C Motor/brake C
4 Brake+ (24 VDC) Brake+ (dry contact) Brake+ (dry contact) Brake+ (dry contact)
5 Brake- (common) Brake- (dry contact) Brake- (dry contact) Brake- (dry contact)
6 Shield Shield Shield Shield
7 Shield Shield Shield Shield

Note:

J16 J15 J14 J13

• Select brushed or brushless mode for the motor on each axis using the DIP switch on the Ti servo board
(141281) inside the back door of the CNC. A single EDGE Pro Ti can have both brush and brushless
motors if switches are set properly. For more information, see Axis configuration on page 64.

• Axis 4 is the only axis that supports a lifter. It is the only axis that supplies the 24 VDC that is required to
disable a lifter’s electromechanical power-off brake.

• For optimum noise immunity, cable shields should be tied externally to the CNC enclosure.

EDGE Pro Ti CNC Instruction Manual 807660 63

Installation

Brushless

Brush

Axis 1

Axis 2

Axis 3

Axis 4 – lifter

Default settings on the DIP switch

Motor connection

Axis configuration

The EDGE Pro Ti supports DC brush and brushless motors. Use the DIP switch on the Ti servo board (141281) to select
the type of motor for each axis. Verify that the axis number and type on the rear of the enclosure matches the number of
the axis on the DIP switch.

Figure 26 Axis configuration switch

In Phoenix software, the Drive Type parameter on the Axes Setup screen must be set to Current mode. For more
information, see the Phoenix Software Installation and Setup Guide (806410).

Table 8 Default axis assignments

Axes Axes Assignment Default motor type

1 Transverse or rail Brushless
2 Transverse or rail Brushless
3 Dual gantry Brushless
4THC Brush

64 EDGE Pro Ti CNC Instruction Manual 807660

Motor (031143)

14 mm
(0.545 in.)

3.18 mm
(0.125 in.) key

Ø

12.7 mm (0.5 in.)

32 mm (1.259 in.)

Motor
connector

Encoder
connector

Ø 5.5 mm (0.217 in.) through, equally spaced on a

98.5 mm (3.875 in.) bolt circle

86 mm

(3.0 in.)

305 mm

12 in.

73 mm

(2.875 in.)

147 mm

(5.799 in)

24 mm (0.95 in.)

1.5 mm (0.059 in.)

The Ti motor is a brushless motor (NEMA 34) with the following specifications:

Figure 27 Motor

Installation

Motor connection

Table 9 Motor specifications

Encoder pulses/revolution 1x = 2000 pulses/revolution, 4x = 8000 pulses /revolution
Differential encoders 5 VDC
Voltage constant 16 V/krpm
Torque constant 0.18 N-m/A, (1.56 in.-lb/A)
CNC axis constant current 6 A
CNC axis peak current (2 seconds) 12 A
Effective CNC and motor torque constant 1.08 N-m (9.36 in.-lb)
Effective CNC and motor torque peak (2 seconds) 2.16 N-m (18.72 in.-lb)
CNC motor power bus 60 VDC
Approximate maximum speed 3500 RPM
Hall Effect sensors 120 degrees
Rotor inertia (J)

Weight 2.90 kg (6.39 lb)

Table 10 Motor power

Pin no. Description

1 Brushless motor A or Brush+
2 Brushless motor B or Brush­3 Brushless motor C
4 Brake+ (24 VDC, 250 mA)
5Brake­6 Cable shield
7 Cable shield

1.60 kg-cm

2

(0.00142 lb-in.-sec2)

EDGE Pro Ti CNC Instruction Manual 807660 65

Installation

Motor cable to
axes 1, 2, and 3

Motor cable to
axis 4

Diameter = 11.6mm (0.458 in.)
Bend radius = 150 mm (6.0 in.)

Connect to motor connector ground stud

1

7

Motor connection

Regeneration circuit

When rapid deceleration of a motor brake creates additional, excessive voltage on the 60 VDC bus, the regeneration
circuit turns on a 10 Ohm resistor to divert the excess braking energy and lower the voltage. When the bus voltage
decreases, the resistor turns off.

When the resistor circuit turns on or off, the circuit sends an input signal to Phoenix software to report the change in
status. This signal is fixed as Input 14 in Phoenix software.

Users can monitor the regeneration circuit in the Watch Window on the Main screen in Phoenix software by turning on
the Regen Active status in the Watch Window setup. The oscilloscope function also allows users to monitor the
operation of the regeneration circuit. For more information on setting up the Watch Window or using the oscilloscope
function, refer to the Phoenix Software Operator’s Manual (806400).

The regeneration circuit should not be active for more than 25% of a single cut. See “Troubleshooting” on page 112 for
more information.

Motor cable

Figure 28 Motor cable from the CNC to the axes

Figure 29 Motor cable

66 EDGE Pro Ti CNC Instruction Manual 807660

Table 11 Pinouts for the motor cable

Pin no. Wire color Signal

1 Red Phase A
2 Black Phase B
3 Red Phase C
4 Red Brake+
5 Black Brake­6 Red Not connected
7 Black Chassis
8 Drain wire Shield

Use the following information to order motor cables.

Part Number Length

223052 1.52 m (5 ft)
223051 3.05 m (10 ft)
223347 6.08 m (20 ft)
123972 7.62 m (25 ft)
123973 10.06 m (33 ft)
223348 10.66 m (35 ft)
123974 10.97 m (36 ft)
123902 15.25 m (50 ft)

Installation

Motor connection

To create a custom cable, order the connector kit (428045).

EDGE Pro Ti CNC Instruction Manual 807660 67

Installation

Axis 1

13

4

8

1214

11

7

Axis 2

Axis 3

Axis 4 –
Lifter

Encoder connector

Encoder connection

Encoder connection

Install the encoder cables between the Axis 4 encoder connector and the encoder connector on the Sensor Ti and
between the Axis 3, Axis 2, and Axis 1 motor connectors on the rear of the EDGE Pro Ti and the motor connector on the
remaining axis motors (031143). For more information about the encoder cable, see Encoder cable on page 69.

Figure 30 EDGE Pro Ti encoder interfaces

Table 12 Pinouts for encoder interfaces

Pin no. Axis 4 – Lifter Axis 3 (Dual gantry) Axis 2 (Y or X) Axis 1 (X or Y)

J12 J11 J10 J9

1 (Red) +5 V +5 V +5 V +5 V
2 (Black) Ground Ground Ground Ground
3 (White) Axis 4A Axis 3A Axis 2A Axis 1A
4 (Black) Axis 4A\ Axis 3A\ Axis 2A\ Axis 1A\
5 (Green) Axis 4B Axis 3B Axis 2B Axis 1B
6 (Black) Axis 4B\ Axis 3B\ Axis 2B\ Axis 1B\
7 (Blue) Axis 4Z Axis 3Z Axis 2Z Axis 1Z
8 (Black) Axis 4Z\ Axis 3Z\ Axis 2Z\ Axis 1Z\
9 (Yellow) +V Encoder/Hall out

(Maximum 6 V at 30 mA)
10 (Black) Ground Ground Ground Ground
11 (Brown) Encoder/Hall A Encoder/Hall A Encoder/Hall A Encoder/Hall A
12 (Orange) Encoder/Hall B Encoder/Hall B Encoder/Hall B Encoder/Hall B
13 (White) Encoder/Hall C Encoder/Hall C Encoder/Hall C Encoder/Hall C
14 (Red) Shield Shield Shield Shield

+V Encoder/Hall out
(Maximum 6 V at 30 mA)

+V Encoder/Hall out
(Maximum 6 V at 30 mA)

+V Encoder/Hall out
(Maximum 6 V at 30 mA)

Note:

• Only 5 V encoders are supported.

• Hall sensors are used with brushless motors only.

• For optimum noise immunity, cable shields should be connected externally to the CNC enclosure.

68 EDGE Pro Ti CNC Instruction Manual 807660

Encoder cable

Encoder cable to
axes 1, 2, and 3

Encoder cable to
axis 4, lifter

Diameter = 9.753 mm (0.384 in.)

Bend radius = 150 mm (6.0 in.)

Connect to motor connector ground stud

1

14

Figure 31 Encoder cable to axes

Figure 32 Encoder cable

Installation

Encoder connection

Table 13 Pinouts for encoder cable

Pin no. Twisted pair colors Signal

1
2

3
4

5
6

7
8

9
10

11
12

13
14

Red
Black

White
Black

Green
Black

Blue
Black

Yellow
Black

Brown
Orange

White
Drain wire

Encoder +5 VDC
Encoder ground

Channel A
Channel A-

Channel B
Channel B-

Index
Index-

6 V Hall
Hall ground

Hall U
Hall V

Hall W
Shield

EDGE Pro Ti CNC Instruction Manual 807660 69

Installation

Encoder connection

Use the following information to order the encoder cable.

Part Number Length Part Number Length

223050 1.6 m (5 ft) 123970 10.06 m (33 ft)
223049 3.2 m (10 ft) 223342 10.66 m (35 ft)
223341 6.08 m (20 ft) 123971 10.97 m (36 ft)
123969 7.62 m (25 ft) 123899 15.25 m (50 ft)

To create a custom cable, order the connector kit (428045).

70 EDGE Pro Ti CNC Instruction Manual 807660

I/O connection

12

36

710

11 14

15 16

Install the I/O cables in the I/O connectors on the rear of the CNC.

Figure 33 EDGE Pro Ti I/O interface

Installation

I/O connection

Table 14 Pinouts for I/O interface

Pin no.

1 Output 1 common Output 4 common Output 7 common Output 10 common
2 Output 1 normally closed Output 4 normally closed Output 7 normally closed Output 10 normally closed
3 Output 1 normally open Output 4 normally open Output 7 normally open Output 10 normally open
4 Output 2 common Output 5 common Output 8 common Output 11 common
5 Output 2 normally closed Output 5 normally closed Output 8 normally closed Output 11 normally closed
6 Output 2 normally open Output 5 normally open Output 8 normally open Output 11 normally open
7 Output 3 common Output 6 common Output 9 common Output 12 common
8 Output 3 normally closed Output 6 normally closed Output 9 normally closed Output 12 normally closed
9 Output 3 normally open Output 6 normally open Output 9 normally open Output 12 normally open
10 Input 1 Input 4 Input 7 Input 10
11 Input 1 common Input 4 common Input 7 common Input 10 common
12 Input 2 Input 5 Input 8 Input 11 (shared with lifter

13 Input 2 common Input 5 common Input 8 common Input 11 common
14 Input 3 Input 6 Input 9 Input 12 (shared with lifter

15 Input 3 common Input 6 common Input 9 common Input 12 common
16 Shield Shield Shield Shield

Connector J9
I/O 1 – 3

Connector J10
I/O 4 – 6

Connector J11
I/O 7 – 9

Connector J12
I/O 10 – 12

Upper Limit input)

Lower Limit input)

EDGE Pro Ti CNC Instruction Manual 807660 71

Installation

Connect to I/O ground
connector

Diameter = 7.213 mm (0.284 in.)

Bend radius = 150 mm (6 in.)

1

16

I/O connection

I/O cable

Figure 34 I/O cable

Table 15 Pinouts for I/O cable

Pin no. Wire color Signal

1 Black Output 1 common
2 White Output 1 normally closed
3 Red Output 1 normally open
4 Green Output 2 common
5 Orange Output 2 normally closed
6 Blue Output 2 normally open
7 White/Black Output 3 common
8 Red/Back Output 3 normally closed
9 Green/Black Output 3 normally open
10 Orange/Black Input 1
11 Blue/Black Input 1 common
12 Black/White Input 2
13 Red/White Input 2 common
14 Green/White Input 3
15 Blue/White Input 3 common
16 Not connected

Use the following information to order I/O cables.

Part Number Length

223349 3.05 m (10 ft)
223350 6.08 m (20 ft)
223351 10.66 m (35 ft)
223352 7.62 m (25 ft)
223353 15.25 m (50 ft)

To create a custom cable, order the connector kit (228126).

72 EDGE Pro Ti CNC Instruction Manual 807660

Installation

1

OFF

2

3

Default settings on the DIP switch

ON

12 3

On

Use lower limit
switch

Upper limit
switch

Dry contact
inputs (default)

Off

I/O 12
(default)

I/O 11
(default)

Sourced inputs

I/O connection

Configuring I/O

The EDGE Pro Ti I/O circuitry provides inputs through optoisolators and outputs through relays. Contacts for both
normally open and normally closed outputs are available.

Use the DIP switch on the Relay I/O board (141278) to configure I/O.

Figure 35 I/O configuration DIP switch

Shared inputs

General inputs 11 and 12 are shared with the limit switch inputs. However, the Sensor Ti lifter does not use limit switches
so position 1 and 2 must remain in the OFF (default) position. In this case, inputs 11 and 12 are available on the I/O
interface CPC connector as general purpose inputs.

If you are using a custom lifter with upper and lower limit switches, change position 1 and 2 to the ON position and select
sourced input mode (position 3 in the OFF position); this changes all general purpose I/O to sourced inputs. Wire the
limit switches to the lifter interface DB-9 connector.

Regardless of the type of lifter you install, do not wire to both the CPC inputs 11 and 12 and to the DB-9 lifter interface
connector inputs 11 and 12 simultaneously.

EDGE Pro Ti CNC Instruction Manual 807660 73

Installation

I/O connection

Input modes

Inputs have two different modes that are selected using the DIP switch on the Relay I/O board (141278). When DIP
switch position 3 is ON (the default position), inputs are in dry contact mode and normally open. In this situation, inputs
require an external switch (or relay contact) to ground to activate the inputs. The logic states are reversed between the
two input modes. When position 3 of this switch is OFF, the inputs are in the sourced input mode and an external voltage
source of between 12 V and 24 V is required to activate each input.

I/O circuits

Figure 36 shows the details of connecting the I/O to common circuitry. All outputs are relay contacts rated at a maximum
of 1 A, 250 VAC.

74 EDGE Pro Ti CNC Instruction Manual 807660

Figure 36 Ti I/O circuits

Internal Circuitry

Outputs

Inputs

Example Inputs

External circuitry

Example Outputs

External circuitry

Dry contact inputs

Note: Logic level reversal

Normal sourced inputs

Use external +12 V supply

Dry contact inputs

DIP Switch 1-C closed

Normal sourced inputs

DIP Switch 1-C open

Normal sourced inputs

DIP Switch 1-C open

Use external +12V supply and

normally closed contact

Use external +5 V supply and

normally open contact

Use external 24 VAC and normally

open contact

Normal sourced inputs

Use external +12 V supply

Resistor

Optoisolator

Optoisolator

Relay

Relay SPDT

Relay SPDT

Relay SPDT

Relay

Resistor

External grounds

24 VAC

Switch

12 V

24 V

External ground

12 V

External

ground

Ground

5 V

LED

common

normally closed

normally open

common

normally closed

common

normally closed

normally open

normally open

24 V Field

Ground

Ground

Open

Open

3900

3900

3900

3900

3900

3900

Note:

• To prevent damage, do not apply more than 24 VDC to any optoisolator input and verify the correct signal

polarity.

• Do not exceed the following voltage and amperage ratings through any relay output:

• For outputs 1-12 and Plasma Start: 30 VAC or VDC/1 A. The rating is the same for both AC or DC.

• For the brakes 1-4: 30 VDC/1 A or 30 VAC/0.5 A.

• For Hold Ignition: 30 VDC/10 mA, polarity is important.

Installation

I/O connection

EDGE Pro Ti CNC Instruction Manual 807660 75

Installation

I/O connection

I/O Setup screen

The I/O setup screen in Phoenix software defines inputs, outputs, and their logic state.

Figure 37 I/O setup screen in Phoenix software

76 EDGE Pro Ti CNC Instruction Manual 807660

Installation

All inputs and outputs are limited to 30 V/1 A. Circuits that require more
than 1 A must have an external relay.

1

15

Plasma connection

Plasma connection

The plasma interface on the rear of the CNC is a 15-pin D-sub connector for the cable that connects the EDGE Pro Ti to
the plasma interface board in the plasma system. The Plasma interface is designed for use with the Sensor Ti lifter only.
This interface requires:

• Arc Voltage, Start, Transfer, and Hold signals. See Table 16 for information on signal wiring.

• A voltage divider

Figure 38 Plasma interface

Table 16 Pinouts for the plasma interface

Pin number Signal Dry contact circuit

1 +12 VDC
2 Plasma Start Output (Cut Control) Normally open
10 Plasma Start Output (Cut Control; Output 13 in

Phoenix)

3 Hold Ignition Output +
11 Hold Ignition Output (Output 14 in Phoenix)

4 Transfer Input + (Cut Sense)
12 Transfer Input - (Cut Sense; Input 13 in Phoenix)

5Common
6Common
7Common
8Arc Voltage + (Work)
9 +12 VDC
13 Common
14 Common
15 Arc Voltage - (Electrode)

EDGE Pro Ti CNC Instruction Manual 807660 77

Installation

Plasma interface cable

Powermax plasma system with a

built-in voltage divider

Diameter = 6.934 mm (0.273 in.)

Bend radius = 150 mm (6 in.)

End B

End A

1

15

14

11

7

31

4

8
12

Plasma connection

Plasma connection for Powermax plasma systems

Install plasma interface cable between the plasma interface on the rear of the EDGE Pro Ti and the connector on the rear
of a Powermax plasma system with a built-in voltage divider.

Figure 39 Plasma interface cable to a Powermax system

Figure 40 Plasma interface cable for Powermax systems

78 EDGE Pro Ti CNC Instruction Manual 807660

Installation

Plasma connection

Table 17 Pinouts for plasma interface cable

End A signal Pin no. Wire color Pin no. End B signal

+12 V to Transfer + 1 to 4 Jumper, black
Start 2 Black 4 Start
Start 10 Red 3 Start
Transfer 12 Black 12 Transfer­Transfer 5 White 14 Ground
V-Div- 15 Black 5 V-Div­V-Div+ 8 Green 6 V-Div+
Ground Shell Drain wire 13 Shield

Use the following information to order this plasma interface cable.

Part Number Length

223354 3.05 m (10 ft)
223355 6.08 m (20 ft)
223048 7.62 m (25 ft)
223356 10.66 m (35 ft)
123896 15.25 m (50 ft)

EDGE Pro Ti CNC Instruction Manual 807660 79

Installation

Plasma interface
cable

Plasma interface assembly

(228256)

Diameter = 7.213 mm (0.284 in.)

Bend radius = 150 mm (6 in.)

1

15

Plasma connection

Plasma connection for generic plasma systems

To connect the plasma interface on the EDGE Pro Ti CNC to any plasma system that does not have a compatible voltage
divider, install the generic plasma interface cable between the plasma interface on the EDGE Pro Ti and the 15-pin
D-sub connector (P1) on the plasma interface assembly (228256) in the plasma system. Refer to Plasma interface
assembly (228256) on page 82 for information about the plasma interface assembly and how to install and wire it.

Figure 41 Generic plasma interface cable to the plasma interface assembly (228256)

Figure 42 Generic plasma interface cable

80 EDGE Pro Ti CNC Instruction Manual 807660

Table 18 Pinouts for the generic plasma interface cable

Pin number Signal Dry contact circuit

1 +12 VDC
2 Plasma Start Output (Cut Control) Normally open
10 Plasma Start Output (Cut Control; Output 13 in

Phoenix)

3 Hold Ignition Output +
11 Hold Ignition Output - (Output 14 in Phoenix)

4 Transfer Input + (Cut Sense)
12 Transfer Input - (Cut Sense; Input 13 in Phoenix)

5Common
6Common
7Common
8Arc Voltage + (Work)
9 +12 VDC
13 Common
14 Common
15 Arc Voltage - (Electrode)

Installation

Plasma connection

Use the following information to order this plasma interface cable.

Part Number Length

223358 3.05 m (10 ft)
223359 6.08 m (20 ft)
223360 7.62 m (25 ft)
223361 10.66 m (35 ft)
223362 15.25 m (50 ft)
223363 22.86 m (75 ft)

EDGE Pro Ti CNC Instruction Manual 807660 81

Installation

Plasma connection

Plasma interface assembly (228256)

The plasma interface assembly (228256) is installed in between the CNC and any plasma system that does not have a
built-in voltage divider.

The plasma interface board (141267) is part of the plasma interface assembly (228256). I/O and arc voltage signals are
transmitted through this interface board between the CNC and plasma system. Connect the wires that exit the assembly
to the appropriate connectors within the plasma system.

If your plasma system has instructions for mounting the plasma interface assembly, use those instructions. If you have no
instructions for mounting the assembly, install it as far as possible from the control board, preferably with sheet metal
between them.

WARNING!

HAZARDOUS VOLTAGE AND ENERGY

The plasma interface signals from plasma cutting equipment without an internal voltage
divider are directly connected to the plasma cutting circuit output. To prevent electrical
shock and energy hazards, wiring from the plasma cutting circuit of the plasma system to
the plasma interface (228256) must be enclosed or protected.

The wiring from the plasma cutting circuit to the plasma interface (228256) must be
enclosed or protected for safe operation. The plasma cutting circuit output ratings are
printed on the data plate and vary by manufacturer and model up to 500 VDC and 400 ADC.
Contact with metal live parts of this connection under normal operating and fault
conditions can result in death or burns.

To make connections between the plasma cutting circuit and the plasma interface assembly:

• Use qualified service personnel only.

• Turn OFF and disconnect all power.

• Mount the plasma interface assembly (228256) as close as possible to the entry point to the plasma
system. Permanent connection is recommended.

• Use jacketed cables and wire that are appropriate for your installation and your local and national
safety regulations.

Follow these steps:

1. Verify that the outer jacket of each interconnecting cable is protected from damage at the entry point to the plasma
system. A strain relief is recommended.

2. Verify that the outer diameter of the interconnecting cable fits the strain relief that is provided with the plasma
interface assembly:

• Plasma start, transfer grip: 2.895 mm – 6.350 mm (0.114 in. – 0.250 in.) diameter

• Plasma interface grip: 1.625 mm – 5.334 mm (0.064 in. – 0.210 in.) diameter

3. Strip back the outer jacket and individual conductor insulation as needed.

4. Insert the outer jacket cable through the strain relief and make connections.

5. Verify that the outer jacket is a min. of 2.54 cm (1 in.) inside the 228256 and tighten the strain relief(s).

6. Before operating the equipment, verify that the connections are correct and that all live parts are enclosed and that all
jacket/conductor insulation is protected against damage.

82 EDGE Pro Ti CNC Instruction Manual 807660

Figure 43 Mounting dimensions for the plasma interface assembly (228256)

129.8 mm (5.08 in.)

35.6 mm

1.40 in.

Slots for no. 6 or

M3 screws

32.8 mm
(1.29 in.)

140.2 mm (5.52 in.)

Connect to the star ground on the
work table

15-pin D-sub connector for the plasma interface cable to the CNC

To the star ground on the work table

Arc voltage signals to the electrode on the control board

I/O signals between the CNC and the control board

Installation

Plasma connection

Figure 44 Plasma interface assembly (228256)

EDGE Pro Ti CNC Instruction Manual 807660 83

Installation

1

3

2

5

4

2

1

4

3

5

Control board in the

plasma system

Work (+)

Electrode (-)

To the star ground on the work

table (+)

Arc voltage (-)

Plasma interface board

6

5

4

3

2

1

Start -

2

Start +

3

Hold +

4

Hold -

5

Transfer -

6

Transfer +

J3

J1

J2

P1

Plasma connection

Figure 45 provides a conceptual representation of how the plasma interface is wired to the control board in the plasma
system. Refer to Table 16 on page 77 for detailed information about signal types and ratings.

To make the electrical connections for these signals within your plasma system, refer to the manual for your plasma
system for more detailed information.

Figure 45 Wiring between the plasma interface and control boards

1

For more information about the board within this assembly, see “Plasma interface board (141267)” on page 128.

84 EDGE Pro Ti CNC Instruction Manual 807660

Installation

Diameter = 7.213 mm (0.284 in.)

Bend radius = 150 mm (6 in.)

1

15

Plasma connection

Plasma connection to HSD130 plasma systems

The plasma interface cable and plasma interface assembly for HSD130 plasma systems are packaged together as a kit.
The Field Service Bulletin (805690) for the kit provides instructions for installing the plasma interface assembly and
connecting the plasma interface cable.

Figure 46 Plasma interface cable to an HSD130 plasma system

Figure 47 HSD130 plasma interface cable

EDGE Pro Ti CNC Instruction Manual 807660 85

Installation

Plasma connection

Table 19 Pinouts for the HSD130 plasma interface cable

Pin number Signal Dry contact circuit

1 +12 VDC
2 Plasma Start Output (Cut Control) Normally open
10 Plasma Start Output (Cut Control; Output 13 in

Phoenix)

3 Hold Ignition Output +
11 Hold Ignition Output - (Output 14 in Phoenix)

4 Transfer Input + (Cut Sense)
12 Transfer Input - (Cut Sense; Input 13 in Phoenix)

5Common
6Common
7Common
8Arc Voltage + (Work)
9 +12 VDC
13 Common
14 Common
15 Arc Voltage - (Electrode)

Use the following information to order the HSD130 plasma interface cable.

Part Number Length

428019 3.05 m (10 ft)
428020 6.08 m (20 ft)
228247 7.62 m (25 ft)
428021 10.66 m (35 ft)
228248 15.25 m (50 ft)
228306 22.86 m (75 ft)

86 EDGE Pro Ti CNC Instruction Manual 807660

Installation

1

9

Lifter interface

Lifter interface

The lifter interface on the rear door of the EDGE Pro Ti is a 9-pin D-sub connector for the lifter interface cable that
connects the EDGE Pro Ti to the optional, integrated Sensor Ti. The lifter interface is designed for use with the Sensor Ti
lifter only and provides the proper height during cutting. This interface requires:

• Arc Voltage, Start, Transfer, and Hold signals. See Figure 45and Table 16for information on signal

wiring.

• A voltage divider

The connection between the EDGE Pro Ti CNC and the ArcGlide lifter uses a Hypernet cable, as shown in Figure 12 on
page 50 and as described in the ArcGlide THC Instruction Manual.

Install the lifter cable between the lifter interface on the EDGE Pro Ti and the Sensor Ti.

Figure 48 Lifter interface for the Sensor Ti

Note: Lower Limit, Upper Limit, and Breakaway switch inputs are sinking inputs to field common.

For THCs that are not manufactured by Hypertherm, the Upper Limit and Lower Limit switch inputs are shared with
general inputs 11 and 12. For more information, see Shared inputs on page 73.

EDGE Pro Ti CNC Instruction Manual 807660 87

Installation

Lifter interface

Table 20 Pinouts for the lifter interface

Pin
number

1 +12 VDC Black
2 Upper Limit switch (shared with input 11) White Normally
3 Field Common Red

6 Lower Limit switch (shared with input 12) Blue
3 Field Common Red

7 Breakaway switch Orange
3 Field Common Red

8 Field Common Yellow
4 Nozzle contact -12 V Green
9 Nozzle contact sense Violet
5 Nozzle contact common Brown

Signal Wire color Dry contact circuit

open

88 EDGE Pro Ti CNC Instruction Manual 807660

Installation

Lifter cable

Sensor Ti

Diameter = 6.197 mm (0.244 in.)

Bend radius = 150 mm (6 in.)

1

9

5

6

Lifter interface

Lifter interface cable

The lifter interface cable is a 9-pin D-sub cable that connects the lifter interface on the CNC to the Sensor Ti.

Figure 49 Lifter interface cable to the Sensor Ti

Figure 50 Lifter interface cable

EDGE Pro Ti CNC Instruction Manual 807660 89

Installation

Lifter interface

Table 21 Pinouts for lifter interface cable

Pin
number

1 +12 VDC Black
2 Upper Limit switch (shared with input 11) White Normally
3 Field Common Red

6 Lower Limit switch (shared with input 12) Blue
3 Field Common Red

7 Breakaway switch Orange
3 Field Common Red

8 Field Common Yellow
4 Nozzle contact -12 V Green
9 Nozzle contact sense Violet
5 Nozzle contact common Brown

Signal Wire color Dry contact circuit

open

Use the following information to order the lifter interface cable.

Part Number Length

223343 3.05 m (10 ft)
223344 6.08 m (20 ft)
223345 7.62 m (25 ft)
223346 10.66 m (35 ft)
123968 10.97 m (36 ft)
123897 15.25 m (50 ft)

90 EDGE Pro Ti CNC Instruction Manual 807660

Installation

Connector

(428047)

Cable and cable shield provided and terminated by customer

1

4

23

24 VDC auxiliary power connector

24 VDC auxiliary power connector

The cable for the 24 V auxiliary power cable must be assembled to suit the needs of the system. Use the following
information to order the connector for this cable then add the cable and cable shield.

Figure 51 24 VDC auxiliary power connector and cable

Part Number Description

428047 24 VDC auxiliary power cable connector

Hypernet and LAN cable

Figure 52 Hypernet and LAN cable

Use the following information to order the Hypernet or LAN cable.

Part Number Length Part Number Length

223381 0.3 m (1 ft) 223223 10.66 m (35 ft)
223382 0.6 m (2 ft) 223008 15.25 m (50 ft)
223380 1.5 m (5 ft) 223099 22.86 m (75 ft)
223212 3.2 m (10 ft) 223100 30.48 m (100 ft)
223222 6.08 m (20 ft) 223101 45.72 m (150 ft)
223119 7.62 m (25 ft) 223102 60.96 m (200 ft)

Note: In some cases, EMI noise can interfere with LAN communication. If this happens, install an EMI ferrite filter
on the LAN cable to suppress both differential and common-mode EMI. Use one of the following filters:

Hypertherm 209195

•

• Fair-Rite 0431164181

Figure 53 Ferrite filter installed on a Hypernet or LAN cable

EDGE Pro Ti CNC Instruction Manual 807660 91

Installation

Hypernet and LAN cable

92 EDGE Pro Ti CNC Instruction Manual 807660

Section 3

Operation

Operating the CNC

Phoenix software runs on the Hypertherm computer numerical controls (CNCs) and 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.

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.

Screen navigation

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

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

EDGE Pro Ti CNC Instruction Manual 807660 93

Operation

Operating the CNC

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.

Help

Choose the Help soft key to display information about each screen

94 EDGE Pro Ti CNC Instruction Manual 807660

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

Operation

Operating the CNC

The Show Bookmarks soft key opens the navigation pane.

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.

EDGE Pro Ti CNC Instruction Manual 807660 95

Operation

Automated operations

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.

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.

96 EDGE Pro Ti CNC Instruction Manual 807660

Operation

Updating Phoenix software

CutPro Wizard

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

Updating Phoenix software

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

• Phoenix software update (update.exe)

• Phoenix Help file (Help.exe)

• Cut charts (CutChart.exe)

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 Saving System Files in Diagnostics and Troubleshooting in the Phoenix Software Operator’s
Manual 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. 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. 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.

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.

EDGE Pro Ti CNC Instruction Manual 807660 97

Operation

Updating Phoenix software

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.

98 EDGE Pro Ti CNC Instruction Manual 807660

Section 4

Maintenance and Diagnostics

WARNING!

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before performing any maintenance.

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

See 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.

Care and handling of the touchscreen

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

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

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

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

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

EDGE Pro Ti CNC Instruction Manual 807660 99

Maintenance and Diagnostics

THC Slide Maintenance

Touchscreens, drops of water, and unintended motion

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

To prevent motion caused by drops of water on the touchscreen:

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

• If water could accidently hit the touchscreen, do not include the jog keys in the watch windows.

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

THC Slide Maintenance

The ball screw in the lifter should be cleaned and lubricated every 6 months.

Cleaning

The ball screw should be cleaned carefully by wiping away all used grease, dust and dirt with a clean, dry cloth. If
possible, move the nut several times over the complete travel distance of the slide so that as much old grease as possible
comes out of the nut.

Note:

• Do not use any detergents or other cleaning fluids, such as trichloroethylene, alcohol, or acetone.

• Do not remove or disassemble the ball screw or ball screw nut.

Lubrication

To lubricate the lifter screw, apply a thin layer of fresh grease over the entire surface of the screw.

After lubrication, the assembly should be operated through its stroke several times at low speeds and low loads to ensure
that all the contact surfaces of the nut, balls, and screw are covered with a film of grease.

100 EDGE Pro Ti CNC Instruction Manual 807660