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MicroEDGE Pro Shape Cutting Control
User Manual
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Hypertherm MicroEDGE Pro Shape Cutting Control User Manual

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®
MicroEDGE
Pro
HyPath Picopath SERCOS II SERCOS III
Shape cutting control
Instruction manual
807290 – Revision 2
MicroEDGE Pro
®
Shape cutting control
Instruction Manual
(P/N 807290)
Revision 2 – December, 2013
Hypertherm, Inc.
Hanover, NH USA
www.hypertherm.com
© Copyright 2013 Hypertherm, Inc.
All Rights Reserved
ArcGlide, EDGE, HPR, Hypertherm, MicroEDGE, Phoenix, and Sensor are trademarks of Hypertherm, Inc.
and may be registered in the United States and/or other countries
Hypertherm Inc.
Etna Road, P.O. Box 5010 Hanover, NH 03755 USA 603-643-3441 Tel (Main Office) 603-643-5352 Fax (All Departments) info@hypertherm.com (Main Office Email)
800-643-9878 Tel (Technical Service)
technical.service@hypertherm.com (Technical Service Email)
800-737-2978 Tel (Customer Service)
customer.service@hypertherm.com (Customer Service Email)
866-643-7711 Tel (Return Materials Authorization) 877-371-2876 Fax (Return Materials Authorization)
return.materials@hypertherm.com (RMA email)
Hypertherm Plasmatechnik GmbH
Technologiepark Hanau Rodenbacher Chaussee 6 D-63457 Hanau-Wolfgang, Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm (S) Pte Ltd.
82 Genting Lane Media Centre Annexe Block #A01-01 Singapore 349567, Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax
65 6841 2489 (Technical Service)
Hypertherm (Shanghai) Trading Co., Ltd.
Unit 301, South Building 495 ShangZhong Road Shanghai, 200231 PR China 86-21-60740003 Tel 86-21-60740393 Fax
Hypertherm Europe B.V.
Vaartveld 9 4704 SE Roosendaal, Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel (Marketing)
31 165 596900 Tel (Technical Service) 00 800 4973 7843 Tel (Technical Service)
Hypertherm Japan Ltd.
Level 9, Edobori Center Building 2-1-1 Edobori, Nishi-ku Osaka 550-0002 Japan 81 6 6225 1183 Tel 81 6 6225 1184 Fax
Hypertherm Brasil Ltda.
Rua Bras Cubas, 231 – Jardim Maia Guarulhos, SP - Brasil CEP 07115-030 55 11 2409 2636 Tel 55 11 2408 0462 Fax
Hypertherm México, S.A. de C.V.
Avenida Toluca No. 444, Anexo 1, Colonia Olivar de los Padres Delegación Álvaro Obregón México, D.F. C.P. 01780 52 55 5681 8109 Tel 52 55 5683 2127 Fax
Hypertherm Korea Branch
#3904 Centum Leaders Mark B/D, 1514 Woo-dong, Haeundae-gu, Busan Korea, 612-889 82 51 747 0358 Tel 82 51 701 0358 Fax
12/2/13

CONTENTS

Contents ........................................................................................................................................................................................ i
Safety ........................................................................................................................................................................................ S-1
Recognize safety information ................................................................................................................................................................. S-2
Follow safety instructions ........................................................................................................................................................................ S-2
Electrical hazards ...................................................................................................................................................................................... S-2
Electric shock can kill ............................................................................................................................................................................... S-3
Cutting can cause fire or explosion ...................................................................................................................................................... S-4
Toxic fumes can cause injury or death ................................................................................................................................................. S-5
Static electricity can damage circuit boards ...................................................................................................................................... S-6
Compressed gas equipment safety ...................................................................................................................................................... S-6
Grounding safety....................................................................................................................................................................................... S-6
Gas cylinders can explode if damaged ................................................................................................................................................ S-6
A plasma arc can cause injury and burns ............................................................................................................................................ S-7
Arc rays can burn eyes and skin ............................................................................................................................................................ S-7
Noise can damage hearing ..................................................................................................................................................................... S-8
Pacemaker and hearingaid operation ................................................................................................................................................. S-8
A plasma arc can damage frozen pipes .............................................................................................................................................. S-8
Dry dust collection information .............................................................................................................................................................. S-9
Laser radiation .........................................................................................................................................................................................S-10
Additional safety information ................................................................................................................................................................S-11
Warning labels .........................................................................................................................................................................................S-11
Symbols and Marks ................................................................................................................................................................................S-13
Product Stewardship ......................................................................................................................................................... PS-1
Environmental Stewardship ............................................................................................................................................. ES-1
Electromagnetic Compatibility (EMC) ......................................................................................................................EMC-1
Warranty .................................................................................................................................................................................. W-1
Specifications ..........................................................................................................................................................................1-1
MicroEDGE Pro Instruction Manual 807290 i
Table of ConTenTs
Main features of an automated cutting system ...................................................................................................................................1-2
CNC ...................................................................................................................................................................................................1-3
Cutting table .....................................................................................................................................................................................1-3
Plasma arc cutting (PAC) system ................................................................................................................................................1-3
Control box .......................................................................................................................................................................................1-4
Drive system .....................................................................................................................................................................................1-4
Torch height control (THC) ...........................................................................................................................................................1-4
Oxyfuel torch ....................................................................................................................................................................................1-4
Marker ................................................................................................................................................................................................1-4
Overview of MicroEDGE Pro ..................................................................................................................................................................1-5
Common features ............................................................................................................................................................................1-5
System options ................................................................................................................................................................................1-5
Rear panel .........................................................................................................................................................................................1-6
System specifications ...............................................................................................................................................................................1-7
Machine interface configurations ...........................................................................................................................................................1-8
HyPath configuration ......................................................................................................................................................................1-8
Picopath configuration ...................................................................................................................................................................1-9
SERCOS II configuration ...........................................................................................................................................................1-10
SERCOS III configuration ..........................................................................................................................................................1-11
Integrated Sensor THC ...............................................................................................................................................................1-12
Secondary enclosure requirements .................................................................................................................................................... 1-13
Interior temperature ......................................................................................................................................................................1-13
Air circulation ................................................................................................................................................................................. 1-13
AC input..........................................................................................................................................................................................1-13
Installation ................................................................................................................................................................................2-1
Upon receipt ...............................................................................................................................................................................................2-3
Claims ...........................................................................................................................................................................................................2-3
Installation requirements...........................................................................................................................................................................2-3
Placement of system components .........................................................................................................................................................2-3
Mounting the CNC ....................................................................................................................................................................................2-4
Mounting hole patterns on the bottom of the CNC ................................................................................................................2-4
X and Y axis configuration .......................................................................................................................................................................2-5
AC power .....................................................................................................................................................................................................2-6
Power cable ......................................................................................................................................................................................2-6
Chassis grounding .....................................................................................................................................................................................2-7
Interface ports .............................................................................................................................................................................................2-8
Hypernet interface ...........................................................................................................................................................................2-8
LAN interface ....................................................................................................................................................................................2-8
USB interface (5) ............................................................................................................................................................................2-8
ii MicroEDGE Pro Instruction Manual 807290
Table of ConTenTs
Serial ports (4) .................................................................................................................................................................................2-8
VGA Port 1 .......................................................................................................................................................................................2-8
Picopath connections ...............................................................................................................................................................................2-9
Picopath I/O connections ..............................................................................................................................................................2-9
Picopath I/O connector ..............................................................................................................................................................2-10
Picopath I/O circuit examples .................................................................................................................................................. 2-11
Picopath drive/encoder connectors ......................................................................................................................................... 2-12
Picopath pin-outs for servo drive connectors .................................................................................................................2-13
Encoder voltage options on the Picopath interface ........................................................................................................................ 2-14
Encoder jumper options ..............................................................................................................................................................2-14
HyPath connections ............................................................................................................................................................................... 2-17
HyPath I/O .....................................................................................................................................................................................2-17
HyPath inputs ................................................................................................................................................................................ 2-18
HyPath input circuit examples .............................................................................................................................................. 2-18
HyPath outputs .............................................................................................................................................................................2-20
HyPath output circuit examples ........................................................................................................................................... 2-20
HyPath I/O connectors ...............................................................................................................................................................2-23
HyPath I/O pin-outs ................................................................................................................................................................2-24
HyPath 4-axis servo connectors ............................................................................................................................................... 2-25
HyPath servo connector ........................................................................................................................................................ 2-25
Analog connections ................................................................................................................................................................................2-27
Sensor THC connector ............................................................................................................................................................... 2-27
Pin-outs for Integrated Sensor THC 1 and 2 connectors ............................................................................................. 2-27
THC cable specifications ........................................................................................................................................................... 2-28
Pin-outs for voltage divider board 3 (VDC3) connectors .............................................................................................. 2-28
Pin-out for the cable between J2 on VDC3 and THC 1 on the CNC ........................................................................ 2-28
Joystick and speedpot connector ............................................................................................................................................. 2-29
Pin-outs for joystick and speedpot connector .................................................................................................................2-29
Joystick and speedpot cable adapter for MicroEDGE CNC (223252) .......................................................................... 2-30
SERCOS II I/O configuration ...............................................................................................................................................................2-31
SERCOS III I/O configuration ..............................................................................................................................................................2-32
SERCOS III Cable ....................................................................................................................................................................... 2-32
Serial port configuration ........................................................................................................................................................................ 2-33
Serial ports 1 and 2 ..................................................................................................................................................................... 2-33
Serial ports 3 and 4 ..................................................................................................................................................................... 2-33
Remote on/off cable ............................................................................................................................................................................... 2-35
Wireless network card ........................................................................................................................................................................... 2-36
Preparing to install the antenna .................................................................................................................................................2-36
Installing the antenna ................................................................................................................................................................... 2-36
Checking the wireless network in Windows .......................................................................................................................... 2-37
Mapping a network drive ............................................................................................................................................................2-38
MicroEDGE Pro Instruction Manual 807290 iii
Table of ConTenTs
Adding a folder in Phoenix .........................................................................................................................................................2-39
Operation ..................................................................................................................................................................................3-1
Operating the CNC ...................................................................................................................................................................................3-2
Operator console ............................................................................................................................................................................3-2
Touch screen LCD ..........................................................................................................................................................................3-2
LCD display ......................................................................................................................................................................................3-2
Screen navigation ............................................................................................................................................................................3-3
Help ....................................................................................................................................................................................................3-4
View additional manuals ................................................................................................................................................................3-4
Show bookmarks .............................................................................................................................................................................3-5
Automated operations...............................................................................................................................................................................3-5
Align Wizard .....................................................................................................................................................................................3-5
CutPro Wizard .................................................................................................................................................................................3-6
Using Phoenix without a touch screen ..................................................................................................................................................3-6
PC keyboard .....................................................................................................................................................................................3-6
Updating Phoenix software ......................................................................................................................................................................3-7
Updating the software ....................................................................................................................................................................3-7
Updating the Help ...........................................................................................................................................................................3-7
Updating the cut charts .................................................................................................................................................................3-8
Maintenance and Diagnostics ............................................................................................................................................4-1
Introduction .................................................................................................................................................................................................4-3
Diagnostic tests..........................................................................................................................................................................................4-4
Serial test ..........................................................................................................................................................................................4-6
USB test ............................................................................................................................................................................................4-7
I/O test ...............................................................................................................................................................................................4-8
Axis test ..........................................................................................................................................................................................4-10
THC test ......................................................................................................................................................................................... 4-11
LAN and Hypernet tests .............................................................................................................................................................4-12
Joystick and speedpot test .........................................................................................................................................................4-13
Troubleshooting.......................................................................................................................................................................................4-14
Introduction .................................................................................................................................................................................... 4-14
MicroEDGE Pro troubleshooting tables ..................................................................................................................................4-15
Power up ................................................................................................................................................................................... 4-15
Display ....................................................................................................................................................................................... 4-15
Field power failure ................................................................................................................................................................... 4-15
Input failure ............................................................................................................................................................................... 4-16
Output failure ...........................................................................................................................................................................4-16
Hypernet .................................................................................................................................................................................... 4-17
LAN connection ....................................................................................................................................................................... 4-17
iv MicroEDGE Pro Instruction Manual 807290
Table of ConTenTs
Motion issues ........................................................................................................................................................................... 4-18
THC ............................................................................................................................................................................................ 4-20
Serial communication issues ................................................................................................................................................ 4-21
USB issues ............................................................................................................................................................................... 4-21
Cut quality ................................................................................................................................................................................. 4-21
CNC temperature ...................................................................................................................................................................4-22
CNC is slow ............................................................................................................................................................................. 4-22
Wireless troubleshooting ...................................................................................................................................................................... 4-23
Component locations and information ............................................................................................................................................... 4-24
HyPath 24 I/O board (141070) ................................................................................................................................................ 4-25
Motherboard (141110) ............................................................................................................................................................... 4-27
SERCOS II master board (141116) ........................................................................................................................................4-28
SERCOS III master board (141310) .......................................................................................................................................4-29
Picopath 4-axis servo board (141122) ................................................................................................................................... 4-30
Analog board (141125) .............................................................................................................................................................. 4-34
Power distribution board (141153) ......................................................................................................................................... 4-36
SERCOS II and SERCOS III serial isolation and utility board (141194/141307) ....................................................... 4-38
HyPath 4-axis servo board (141197) ...................................................................................................................................... 4-40
CPC analog breakout board (141210) ..................................................................................................................................4-42
HyPath and Picopath 4-axis MCC, utility, and serial isolation board (141222) ............................................................ 4-44
Picopath 2-axis servo board (141254) ................................................................................................................................... 4-47
Picopath 2-axis MCC, utility, and serial isolation board (141256) ...................................................................................4-50
Parts List ...................................................................................................................................................................................5-1
Common MicroEDGE Pro parts .............................................................................................................................................................5-2
Picopath MicroEDGE Pro parts .............................................................................................................................................................5-4
HyPath MicroEDGE Pro parts ................................................................................................................................................................5-5
SERCOS II and SERCOS III MicroEDGE Pro parts .........................................................................................................................5-6
Common test plugs ...................................................................................................................................................................................5-7
Picopath test plugs ....................................................................................................................................................................................5-8
HyPath test plugs.......................................................................................................................................................................................5-9
Cable connector kits .............................................................................................................................................................................. 5-10
Wiring Diagrams .....................................................................................................................................................................6-1
Introduction .................................................................................................................................................................................................6-1
Wiring diagram symbols ...........................................................................................................................................................................6-1
MicroEDGE Pro Instruction Manual 807290 v
Table of ConTenTs
vi MicroEDGE Pro Instruction Manual 807290

Safety

In this section:
Recognize safety information ................................................................................................................................................................. S-2
Follow safety instructions ........................................................................................................................................................................ S-2
Electrical hazards ...................................................................................................................................................................................... S-2
Electric shock can kill ...............................................................................................................................................................................S-3
Cutting can cause fire or explosion ...................................................................................................................................................... S-4
Toxic fumes can cause injury or death ................................................................................................................................................. S-5
Static electricity can damage circuit boards ...................................................................................................................................... S-6
Compressed gas equipment safety ...................................................................................................................................................... S-6
Grounding safety ...................................................................................................................................................................................... S-6
Gas cylinders can explode if damaged ................................................................................................................................................ S-6
A plasma arc can cause injury and burns ............................................................................................................................................ S-7
Arc rays can burn eyes and skin ............................................................................................................................................................ S-7
Noise can damage hearing ..................................................................................................................................................................... S-8
Pacemaker and hearingaid operation ................................................................................................................................................. S-8
A plasma arc can damage frozen pipes .............................................................................................................................................. S-8
Dry dust collection information .............................................................................................................................................................. S-9
Laser radiation ......................................................................................................................................................................................... S-10
Additional safety information ................................................................................................................................................................S-11
Warning labels .........................................................................................................................................................................................S-11
Symbols and Marks ................................................................................................................................................................................S-13
Hypertherm S-1
03/10
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

Read carefully 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.
DANGER WARNING CAUTION
Hypertherm uses American National Standards Institute guidelines for safety signal words and symbols. A 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.

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.
•   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.
•   The enclosure shall be closed and the proper earth 
ground continuity to the enclosure verified prior to operating the equipment after moving, opening, or servicing.
•   Always follow these instructions for disconnecting 
power before inspecting or changing torch consumable parts.
S-2 Hypertherm
03/10

ELECTRIC SHOCK CAN KILL

Safety
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.
•   Never touch the torch body, workpiece or the waterin 
awater table when the plasma system isoperating.
Electric shock prevention
All Hypertherm 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 work and ground using dry 
insulating mats or covers big enough to prevent any physical contact with the work or ground. If you must work 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, be sure that it is correctly 
connected to earth ground.
•   Install and ground this equipment according to the 
instruction manual and in accordance with national and local codes.
•   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 cable 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 proper 
grounding conductor first.
•   Each Hypertherm plasma system is designed to be 
used only with specific Hypertherm torches. Do not substitute other torches which could overheat and present a safety hazard.
Hypertherm S-3
03/10
Safety

CUTTING CAN CAUSE FIRE OR EXPLOSION

Fire prevention
•   Be sure the 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container.
•   Do not cut containers that have held combustible 
materials.
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
Hydrogen Detonation with
Aluminum Cutting
•   Do not cut aluminum underwater or with water 
touching the underside of the aluminum.
•   Cutting aluminum underwater or with the water 
touching the underside of the aluminum can result in an explosive condition that can detonate during plasma cutting operations.
WARNING
Explosion Hazard
Underwater Cutting with Fuel Gases
•   Do not cut under water with fuel gases containing 
hydrogen.
•   Cutting under water with fuel gases containing 
hydrogen can result in an explosive condition that candetonate during plasma cutting operations.
S-4 Hypertherm
03/10

TOXIC FUMES CAN CAUSE INJURY OR DEATH

Safety
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.
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.
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 upon 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 area where the equipment is used and to ensure that the air quality in the workplace meets all local and national standards andregulations.
•   Volume of material removed.
•   Duration of cutting or gouging.
•   Size, air volume, ventilation and filtration of the 
workarea.
•   Personal protective equipment.
•   Number of welding and cutting systems in operation.
•   Other site 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 site 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.
•   Assure 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ensure safe air quality.
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.
Hypertherm S-5
03/10
Safety

GROUNDING SAFETY

Work cable Attach the work cable securely to the
workpiece or the work table with good metal-to-metal contact. Do not connect it to the piece that will fall away when the cut is complete.
Work table Connect the work table to an earth ground, in accordance with appropriate national and local electrical codes.

STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS

Use proper precautions when handling printed circuit boards:
•   Store PC boards in anti-static containers.
•   Wear a grounded wrist strap when handling PCboards.
Input power
•   Be 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, be 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. Fasten the retaining nut tightly.
•   Tighten all electrical connections to avoid excessive 
heating.

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 codes.

GAS CYLINDERS CAN EXPLODE IF DAMAGED

Gas cylinders contain gas under high pressure. Ifdamaged, a cylinder can explode.
•   Handle and use compressed gas cylinders in 
accordance with applicable national and local codes.
•   Never use a cylinder that is not upright and secured 
inplace.
•   Keep the protective cap in place over 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.
S-6 Hypertherm
03/10

A PLASMA ARC CAN CAUSE INJURY AND BURNS

Safety
Instant-on torches
Plasma arc comes on immediately when the torch switch is activated.

ARC RAYS CAN BURN EYES AND SKIN

Eye protection Plasma arc rays produce intense
visible and invisible (ultraviolet and infrared) rays that can burneyes and skin.
•   Use eye protection in accordance with applicable 
national and local codes.
•   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.
•   Gauntlet gloves, safety shoes and hat.
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.
•   Flame-retardant clothing to cover all exposed areas.
•   Cuffless trousers to prevent entry of sparks and slag.
•   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.
Arc current
(amps)
Less than 40 A 5 5 8 9 41 to 60 A 6 6 8 9 61 to 80 A 8 8 8 9 81 to 125 A 8 9 8 9 126 to 150 A 8 9 8 10 151 to 175 A 8 9 8 11 176 to 250 A 8 9 8 12 251 to 300 A 8 9 8 13 301 to 400 A 9 12 9 13 401 to 800 A 10 14 10 N/A
Minimum protective
shade number
(ANSIZ49.1:2005)
Suggested shade
number for comfort
(ANSI Z49.1:2005)
OSHA 29CFR
1910.133(a)(5)
Europe
EN168:2002
Hypertherm S-7
03/10
Safety
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.

NOISE CAN DAMAGE HEARING

Cutting with a plasma arc can exceed acceptable noise levels as defined by local codes 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 installed site have verified personal hearing protection is not necessary per relevant international, regional, and local codes.
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, limit operator exposure time, screen off noisy working
To reduce magnetic field hazards:
•   Keep both the work cable and the torch lead to one 
side, away from your body.
•   Route the torch leads as close as possible to the 
workcable.
•   Do not wrap or drape the torch lead or work cable 
around your body.
•   Keep as far away from the power supply as possible.
areas and/or take measures to reduce reverberation inworking areas by putting up noise absorbers.
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 devices such as ear muffs or ear plugs with a noise reduction rating appropriate for the situation. Warn others in the area of possible noise hazards. In addition, ear protection can prevent hot splatter from entering the ear.

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.
S-8 Hypertherm
03/10

DRY DUST COLLECTION INFORMATION

Safety
At some sites, dry dust can represent a potential explosion hazard.
The U.S. National Fire Protection Association’s 2007 
edition of 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 68 has been “adopted by reference” in your local building codes.
Refer to NFPA68 for definitions and explanations of regulatory terms such as deflagration, AHJ, adopted by
reference, the Kst value, deflagration index, and other 
terms.
Note 1 – Hypertherm’s interpretation of these new 
requirements is that unless a site-specific evaluation has been completed to determine that all dust generated is not combustible, the 2007 edition of NFPA 68 requires the use of explosion vents designed
to the worst-case Kst value (see annex F) that could be 
generated from dust so that the explosion vent size and type can be designed. NFPA 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 of Hypertherm manuals should consult 
and comply with all applicable federal, state, and local laws and regulations. Hypertherm does not, by the publication of any Hypertherm manual, 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.
Hypertherm S-9
03/10
Safety

LASER RADIATION

Exposure to the laser output can result in serious eye injury. Avoid direct eye exposure.
For your convenience and safety, on Hypertherm products that use a laser, 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, the pulse duration is 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.
•   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.
S-10 Hypertherm
03/10

ADDITIONAL SAFETY INFORMATION

Safety
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
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, 470 Atlantic Avenue, Boston, MA 02210
9.   NFPA Standard 70–1978, National Electrical Code, National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210
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/

WARNING LABELS

This warning label is affixed to some power supplies. It is important that the operator and maintenance technician understand the intent of these warning symbols as described.
Read and follow these instructions, employer safety practices, and material safety data sheets. Refer to ANS Z49.1, “Safety in Welding, Cutting and Allied Processes” from American Welding Society
(http://www.aws.org) and OSHA Safety and Health Standards, 29 CFR 1910 (http://www. osha.gov).
WARNING
Plasma cutting can be injurious to operator and persons in the work area. Consult manual before operating. Failure to follow all these safety instructions can result in death.
1. Cutting sparks can cause explosion or fire.
1.1 Do not cut near flammables.
1.2 Have a fire extinguisher nearby and ready to use.
1.3 Do not use a drum or other closed container as a cutting table.
2. Plasma arc can injure and burn; point the nozzle away from yourself. Arc starts instantly when triggered.
2.1 Turn off power before disassembling torch.
2.2 Do not grip the workpiece near the cutting path.
2.3 Wear complete body protection.
3. Hazardous voltage. Risk of electric shock or burn.
3.1 Wear insulating gloves. Replace gloves when wet or damaged.
3.2 Protect from shock by insulating yourself from work and ground.
3.3 Disconnect power before servicing. Do not touch live parts.
4. Plasma fumes can be hazardous.
4.1 Do not inhale fumes.
4.2 Use forced ventilation or local exhaust to remove the fumes.
4.3 Do not operate in closed spaces. Remove fumes with ventilation.
5. Arc rays can burn eyes and injure skin.
5.1 Wear correct and appropriate protective equipment to protect head, eyes, ears, hands, and body. Button shirt collar. Protect ears from noise. Use welding helmet with the correct shade of filter.
6. Become trained.
equipment. Use torches specified in the manual. Keep non-qualified personnel and children away.
7. Do not remove, destroy, or cover this label.
Replace if it is missing, damaged, or worn (PN 110584 Rev C).
Only qualified personnel should operate this
AVERTISSEMENT
Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le non respect des ces instructions de sécurité peut entraîner la mort.
1. Les étincelles de coupage peuvent provoquer une explosion ou un incendie.
1.1 Ne pas couper près des matières inflammables.
1.2 Un extincteur doit être à proximité et prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.
2. L’arc plasma peut blesser et brûler; éloigner la buse de soi. Il s’allume instantanément quand on l’amorce;
2.1 Couper l’alimentation avant de démonter la torche.
2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.
2.3 Se protéger entièrement le corps.
3. Tension dangereuse. Risque de choc électrique ou de brûlure.
3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou endommagés.
3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.
3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.
4. Les fumées plasma peuvent être dangereuses.
4.1 Ne pas inhaler les fumées
4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.
4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.
5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.
5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance appropriée.
6. Suivre une formation. Seul le personnel qualifié a le droit de faire
fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le manual. Le personnel non qualifié et les enfants doivent se tenir à l’écart.
7. Ne pas enlever, détruire ni couvrir cette étiquette.
La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C).
Hypertherm S-11
03/10
SAFETY
WARNING LABELS
This warning label is affixed to some power supplies. It is important that the operator and maintenance technician understand the intent of these warning symbols as described. The numbered text corresponds to the numbered boxes on the label.
1. Cutting sparks can cause explosion orfire.
1.1 Do not cut near flammables.
1.2 Have a fire extinguisher nearby and ready to use.
1.3 Do not use a drum or other closed container as a cutting table.
2. Plasma arc can injure and burn; point the nozzle away from yourself. Arc starts instantly when triggered.
2.1 Turn off power before disassembling torch.
2.2 Do not grip the workpiece near the cutting path.
2.3 Wear complete body protection.
3. Hazardous voltage. Risk of electric shock or burn.
3.1 Wear insulating gloves. Replace gloves when wet or damaged.
3.2 Protect from shock by insulating yourself from work and ground.
3.3 Disconnect power before servicing. Donot touch live parts.
4. Plasma fumes can be hazardous.
4.1 Do not inhale fumes.
4.2 Use forced ventilation or local exhaust to remove the fumes.
4.3 Do not operate in closed spaces. Remove fumes with ventilation.
5. Arc rays can burn eyes and injure skin.
5.1 Wear correct and appropriate protective equipment to protect head, eyes, ears, hands, and body. Button shirt collar. Protect ears from noise. Use welding helmet with the correct shade of filter.
6. Become trained. Only qualified personnel should operate this equipment. Use torches specified in the
manual. Keep non-qualified personnel 
and children away.
7. Do not remove, destroy, or cover this label. Replace if it is missing, damaged, or worn.
S-12 Hypertherm
03/10
English
Safety

Symbols and Marks

Your Hypertherm product may have one or more of the following markings on or near the data plate. Due to differences and conflicts in national regulations, not all marks are applied to every version of a product.
S mark
The S mark indicates that the power supply and torch are suitable for operations carried out in environments with increased hazard of electrical shock according to IEC 60974-1.
CSA mark
Hypertherm products with a CSA mark meet the United States and Canadian regulations for product safety. The products were evaluated, tested, and certified by CSA-International. Alternatively, the product may have a mark by one of the other Nationally Recognized Testing Laboratories (NRTL) accredited in both the United States and Canada, such as Underwriters Laboratories, Incorporated (UL) or TÜV.
CE mark
The CE marking signifies the manufacturer’s declaration of conformity to applicable European directives and standards. Only those versions of 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 Electromagnetic Compatibility (EMC) Directive. EMC filters needed to comply with the European EMC Directive are incorporated within versions of the product with a CE marking.
Eurasian Customs Union (CU) mark
CE versions of Hypertherm products that include an EAC mark of conformity meet the product safety and EMC requirements for export to Russia, Belarus, and Kazakhstan.
GOST-TR mark
CE versions of Hypertherm products that include a GOST-TR mark of conformity meet the product safety and EMC requirements for export to the Russian Federation.
C-Tick mark
CE versions of Hypertherm products with a C-Tick mark comply with the EMC regulations required for sale in Australia and New Zealand.
CCC mark
s
The China Compulsory Certification (CCC) mark indicates that the product has been tested and found compliant with product safety regulations required for sale in China.
UkrSEPRO mark
The CE versions of Hypertherm products that include a UkrSEPRO mark of conformity meet the product safety and EMC requirements for export to the Ukraine.
Serbian AAA mark
CE versions of Hypertherm products that include a AAA Serbian mark meet the product safety and EMC requirements for export to Serbia.
Hypertherm S-13
03/10

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.
are incorporated within versions of the power supply with a CE Marking.
Certificates of compliance for Hypertherm products are available fromthe Downloads Library on the Hypertherm web site at
https://www.hypertherm.com.
Differences in national standards
Nations may apply different performance, safety or other standards. National differences in standards include, but are not limited to:
• Voltages
• Plug and cord ratings
• Language requirements
• Electromagnetic compatibility requirements
These differences in national or other standards may make it impossible or impractical for all certification test marks to be placed on the same version of a product. For example,
the CSA versions of Hypertherm’s products do not comply 
with European EMC requirements, and therefore do not have a CE marking on the data plate.
Countries that require CE marking or have compulsory EMC regulations must use CE versions of Hypertherm products with the CE marking on the data plate. These include, but are not limited to:
• Australia
• New Zealand
• Countries in the European Union
• Russia
It is important that the product and its certification test mark be suitable for the end-use installation site. When Hypertherm products are shipped to one country for export to another country; the product must be configured and certified properly for the end-use site.
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
Product Stewardship PS-1
EnglishEnglish
PRODUCT sTewaRDshiP
PRODUCT STEWARDSHIP
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.
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 IEC60974-4. The repair report shall indicate the results of all tests unless an indication is made that a particular test has not been performed.
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.
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.
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.
PS-2 Product Stewardship
English
English
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.
PRODUCT sTewaRDshiP
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 end­use 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.
Product Stewardship PS-3
English
PRODUCT sTewaRDshiP
PS-4 Product Stewardship
English

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.
of Powermax series units shipped since 2006. Parts used in CSA versions of Powermax and other products manufactured by Hypertherm that are either out of scope or exempt from RoHS are continuously being converted to RoHS compliance in anticipation of future requirements.
Proper disposal of Hypertherm products
Hypertherm plasma cutting systems, like all electronic products, may contain materials or components, such as printed circuit boards, that cannot be discarded with ordinary waste. It is your responsibility to dispose of any Hypertherm product or component part in an environmentally acceptable manner according to national and localcodes.
•  In the United States, check all federal, state, and local 
laws.
•  In the European Union, check the EU directives, 
national, and local laws. For more information, visit www. hypertherm.com/weee.
•  In other countries, check national and local laws.
The European Environmental regulations are discussed later in TheWEEE Directive.
The RoHS directive
Hypertherm is committed to complying with all applicable laws and regulations, including the European Union Restriction of Hazardous Substances (RoHS) Directive that restricts the use of hazardous materials in electronics products. Hypertherm exceeds RoHS Directive compliance obligations on a global basis.
Hypertherm continues to work toward the reduction of RoHS materials in our products, which are subject to the RoHS Directive, except where it is widely recognized that there is no feasible alternative.
Declarations of RoHS Conformity have been prepared for the current CE versions of Powermax plasma cutting systems manufactured by Hypertherm. There is also a “RoHS mark” on the Powermax CE versions below the “CE Marking” on the data plate of CE versions
•  Consult with legal or other compliance experts when 
appropriate.
The WEEE directive
On January 27, 2003, the European Parliament and the Council of the European Union authorized Directive 2002/96/EC or WEEE (Waste Electrical and Electronic Equipment).
As required by the legislation, any Hypertherm product covered by the directive and sold in the EU after August 13, 2005 is marked with the WEEE symbol. This directive encourages and sets specific criteria for the collection, handling, and recycling of EEE waste. Consumer and business-to-business wastes are treated differently (all Hypertherm products are considered business-to­business). Disposal instructions for the CE versions of Powermax plasma systems can be found at www.hypertherm.com/weee.
Environmental Stewardship ES-1
English
EnvironmEntal stEwardship
The URL is printed on the symbol-only warning label for each of these CE version Powermax series units shipped since 2006. The CSA versions of Powermax and other products manufactured by Hypertherm are either out of scope or exempt from WEEE.
The REACH regulation
The REACH regulation (1907/2006), in force since June1, 2007, has an impact on chemicals available to the European market. The REACH regulation requirements for component manufacturers states that the component shall not contain more than 0.1% by weight of the Substances of Very High Concern (SVHC).
Component manufacturers and other downstream users, such as Hypertherm, are obligated to obtain assurances from its suppliers that all chemicals used in or on Hypertherm products will have a European Chemical Agency (ECHA) registration number. To provide chemical information as required by the REACH regulation, Hypertherm requires suppliers to provide REACH declarations and identify any known use of REACH SVHC. Any use of SVHC in amounts exceeding
0.1% w/w of the parts has been eliminated. The MSDS contains a full disclosure of all substances in the chemical and can be used to verify REACH SVHC compliance.
The lubricants, sealants, coolants, adhesives, solvents, coatings and other preparations or mixtures used by Hypertherm in, on, for, or with its shape cutting equipment are used in very small quantities (except the coolant) and are commercially available with multiple sources that can and will be replaced in the event of a supplier problem associated with REACH Registration or REACH Authorization (SVHCs).
Proper handling and safe use of chemicals
Chemical Regulations in the USA, Europe, and other locations require that Material Safety Data Sheets (MSDS) be made available for all chemicals. The list of chemicals is provided by Hypertherm. The MSDS are for chemicals provided with the product and other chemicals used in or on the product. MSDS can be downloaded from the Downloads Library on the Hypertherm web site at https://www.hypertherm.com. On the Search screen, insert MSDS in the document title and click on Search.
In the USA, OSHA does not require Material Safety Data Sheets for articles such as electrodes, swirl rings, retaining caps, nozzles, shields, deflectors and other solid parts of the torch.
Hypertherm does not manufacture or provide the materials that are cut and has no knowledge whether the fumes released from materials that are cut will pose a physical hazard or health risk. Please consult with your supplier or other technical advisor if you need guidance concerning the properties of the material you will cut using a Hypertherm product.
Fumes emission and air quality
Note: The following information on air quality is intended for general information only and should not be used as a substitute for reviewing and implementing applicable government regulations or legal standards in the country where the cutting equipment will be installed and operated.
In the USA, the National Institute for Occupational Safety and Health (NIOSH) Manual of Analytical Methods (NMAM) is a collection of methods for sampling and analyzing contaminants in workplace air. Methods published by others, such as OSHA, MSHA, EPA, ASTM, ISO or commercial suppliers of sampling and analytical equipment, may have advantages over NIOSH methods.
For example, ASTM Practice D 4185 is a standard practice for the collection, dissolution, and determination of trace metals in workplace atmospheres. The sensitivity, detection limit, and optimum working concentrations for 23 metals are listed in ASTMD4185. An industrial hygienist should be used to determine the optimum sampling protocol, considering analytical accuracy, cost, and optimum sample number. Hypertherm uses a third party industrial hygienist to perform and interpret air quality testing results taken by air sampling equipment positioned at operator stations in Hypertherm buildings where plasma cutting tables are installed and operated.
Where applicable, Hypertherm also uses a third party industrial hygienist to obtain air and water permits.
If you are not fully aware and up to date on all applicable government regulations and legal standards for the installation site, you should consult a local expert prior to purchasing, installing, and operating theequipment.
ES-2 Environmental Stewardship
English
English
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 workpiece. In other cases, it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases, electromagnetic disturbances must be reduced to the point where they are no longer troublesome.
Assessment of area
Before installing the equipment, the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:
a. Other supply cables, control cables, signaling and
telephone cables; above, below and adjacent to the cutting equipment.
b. Radio and television transmitters and receivers.
c. Computer and other control equipment.
d. Safety critical equipment, for example guarding
ofindustrial equipment.
e. Health of the people around, for example the use
ofpacemakers and hearing aids.
f. Equipment used for calibration or measurement.
g. Immunity of other equipment in the environment. User
shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures.
h. Time of day that cutting or other activities are to be
carried out.
The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of reducing emissions
Mains supply
Cutting equipment must be connected to the mains
supply according to the manufacturer’s recommendations. 
If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply.
Compliance Information EMC-1
7/ 10
ELECTROMAGNETIC COMPATIBILITY
Consideration should be given to shielding the supply cable of permanently installed cutting equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting power source enclosure.
Maintenance of cutting equipment
The cutting equipment must be routinely maintained
according to the manufacturer’s recommendations. All 
access and service doors and covers should be closed and properly fastened when the cutting equipment is in operation. The cutting equipment should not be modified in any way, except as set forth in and in accordance with
the manufacturer’s written instructions. For example, 
the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the
manufacturer’s recommendations.
Cutting cables
The cutting cables should be kept as short as possible and should be positioned close together, running at or close to the floor level.
Earthing of the workpiece
Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its
size and position, for example, ship’s hull or building 
steel work, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitances selected according to national regulations.
Note: The cutting circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will in crease the risk of injury, for example, by allowing parallel cutting current return paths which may damage the earth circuits of other equipment. Further guidance is provided in IEC60974-9, Arc Welding Equip ment, Part 9: Installation and Use.
Screening and shielding
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.
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire plasma cutting installation may be considered for special applications.
EMC-2 Compliance Information
7/ 10

WARRANTY

Attention
Genuine Hypertherm parts are the factory­recommended 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, and with respect to torch lifter assemblies within a period of one (1) year from its date of delivery to you, and with respect to Automation products one (1) year from its date of delivery to you, with the exception of the EDGEProCNC, EDGEProTiCNC, MicroEDGEProCNC and ArcGlideTHC, which shall be within a period of two (2) years from the date of delivery to you, and (iii)with respect to HyIntensity fiber
laser components within a period of two (2) years from the date of its delivery to you, with the exception of laser heads and beam delivery cables, which shall be within a period of one (1) year from its date of delivery to you.
or otherwise damaged.
Hypertherm provides repair, replacement or adjustment of the Product as the sole and exclusive remedy, if and only if the warranty set forth herein properly is invoked and applies. Hypertherm, at its sole option, shall repair, replace, or adjust, free of charge, any defective Products covered by this warranty which
shall be returned with Hypertherm’s prior authorization 
(which shall not be unreasonably withheld), properly
packed, to Hypertherm’s place of business in Hanover, 
New Hampshire, or to an authorized Hypertherm repair facility, all costs, insurance and freight pre paid by the customer. Hypertherm shall not be liable for any repairs, replacement, or adjustments of Products covered by this warranty, except those made pursuant to this paragraph
and with Hypertherm’s prior written consent.
The warranty set forth above is exclusive and is in lieu of all other warranties, express, implied, statutory, or otherwise with respect to the Products or as to the results which may be obtained therefrom, and all implied warranties or conditions of quality or of merchantability or fitness for a particular purpose or against infringement. The foregoing shall constitute the sole and exclusive remedy for any breach by Hypertherm of its warranty.
Distributors/OEMs may offer different or additional warranties, but Distributors/OEMs are not authorized togive any additional warranty protection to you or make any representation to you purporting to be binding upon Hypertherm.
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,
Compliance Information W-1
9/10
WARRANTY
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.
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.
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.
W-2 Compliance Information
9/10
Section 1

SPECIFICATIONS

In this section:
Main features of an automated cutting system ...................................................................................................................................1-2
CNC ...................................................................................................................................................................................................1-3
Cutting table .....................................................................................................................................................................................1-3
Plasma arc cutting (PAC) system ................................................................................................................................................1-3
Control box .......................................................................................................................................................................................1-4
Drive system .....................................................................................................................................................................................1-4
Torch height control (THC) ...........................................................................................................................................................1-4
Oxyfuel torch ....................................................................................................................................................................................1-4
Marker ................................................................................................................................................................................................1-4
Overview of MicroEDGE Pro ..................................................................................................................................................................1-5
Common features ............................................................................................................................................................................1-5
System options ................................................................................................................................................................................1-5
Rear panel .........................................................................................................................................................................................1-6
System specifications ...............................................................................................................................................................................1-7
Machine interface configurations ...........................................................................................................................................................1-8
HyPath configuration ......................................................................................................................................................................1-8
Picopath configuration ...................................................................................................................................................................1-9
SERCOS II configuration ...........................................................................................................................................................1-10
SERCOS III configuration ..........................................................................................................................................................1-11
Integrated Sensor THC ...............................................................................................................................................................1-12
Secondary enclosure requirements .................................................................................................................................................... 1-13
Interior temperature ......................................................................................................................................................................1-13
Air circulation ................................................................................................................................................................................. 1-13
AC input..........................................................................................................................................................................................1-13
MicroEDGE Pro Instruction Manual 807290 1-1
SpecificationS

Main features of an automated cutting system

The following diagram illustrates the relationship between the components of an automated cutting system. The following sections describe these components and their relationships more fully.
Operator console
Cutting table and
drive system
Control box
Oxyfuel cutting
system
Products available from
Hypertherm
CNC
Components of an Automated Cutting System
THC
Plasma cutting
system
Torch Height
Controller
Display and
operator console
MicroEDGE Pro
Rail
Plasma arc
cutting (PAC)
system
Gantry
Rail
Cutting table
Shape cutting system configured with an MicroEDGE Pro CNC
1-2 MicroEDGE Pro Instruction Manual 807290
SpecificationS
CNC
The computerized numerical control (CNC) reads part programs and communicates with the other components of the shape cutting system. It controls what parts (shapes) are cut from the material.
Refer to the sections in this manual for more detailed information about the hardware features of the MicroEDGE Pro CNC. Refer to the following Phoenix® software manuals for detailed information on the software that operates on the MicroEDGE Pro CNC:
•  Installation and Setup Manual (806410)
•  Operator’s Manual (806400)
•  Programmer’s Reference (806240)

Cutting table

The cutting table is the frame that supports the plate of material from which parts are cut. A typical cutting table has two rails that run the length of the table on either side and form the track for the gantry. The gantry rides along these rails and spans the width of the table. A torch height controller (THC) is attached to the gantry and provides the vertical movement of the cutting torch.
The horizontal motion of the gantry and torch station, and the vertical motion of the torch on the THC provide the three
axes that are necessary for controlling the torch’s position on the plate. Additional equipment can be added to the 
cutting table to permit beveling and other types of cutting.
Hypertherm does not manufacture cutting tables. For more information on the cutting table in your system, refer to the manual that the table manufacturer supplied.

Plasma arc cutting (PAC) system

The cutting tool is the heart of any cutting system and may be a plasma, oxyfuel, laser, or waterjet system. The cutting system controls key parameters, such as the plasma gas and assist gases, and controls how they are mixed.
Your cutting system may include a Hypertherm plasma system. Refer to the appropriate manual for additional information. Electronic (PDF) versions of many Hypertherm manuals are available on the CNC.
If your plasma supply or cutting system is manufactured by another company, refer to the appropriate manual.
MicroEDGE Pro Instruction Manual 807290 1-3
SpecificationS

Control box

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

Drive system

The speed, smoothness, and accuracy of the cuts are determined by the combination of the CNC, encoders, drive amplifiers, THC, gears, rails, servo motors, and how well they are integrated (tuned) by the table manufacturer. The MicroEDGE Pro is typically used with drives and motors selected by the table manufacturer.
For more information on the drive system for your cutting system, refer to the manual supplied by the table manufacturer.

Torch height control (THC)

The THC controls the distance between the torch and the workpiece (plate), also know as the standoff. This standoff is usually defined by height or voltage.
If a Hypertherm THC has been configured as part of your system, consult one of the following manuals for more information about installing and using it:
•  Sensor™ PHC (806150)
•  Sensor™ THC (806400, 806410, and 806420)
•  Command® THC (802780)
•  ArcGlide® THC (806450)
If your THC is manufactured by another company, refer to the manual supplied by the table manufacturer.

Oxyfuel torch

Automated cutting systems can also be configured with oxyfuel torches by adding an oxygen height control (OHC). If the Hypertherm Sensor OHC is configured in your system, refer to the Sensor OHC manual (MANU-0044) for information about installation and operation. For other devices, refer to the appropriate manual.
Refer to the manual supplied by the table manufacturer for more information about an oxyfuel torch.

Marker

A marker can be any device or process that marks a plate rather than piercing or cutting it. If the Hypertherm ArcWriter is configured in your system, refer to the ArcWriter manual (802520) for information about installation and operation. Any HPR plasma system can also be used for marking. See the appropriate HPR manual for more information. For other devices or processes, refer to the appropriate manual.
1-4 MicroEDGE Pro Instruction Manual 807290
SpecificationS

Overview of MicroEDGE Pro

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

Common features

The HyPath, Picopath, and SERCOS II and SERCOS III models of the MicroEDGE Pro CNC are configured with the following types of communication ports:
•  Serial ( 2 RS-232 and 2 RS-422)
•  Ethernet (1)
•  Hypernet (1)
•  USB (5)
•  Networking for part program download or remote diagnostic utilities
•  Remote on/off interface
For more information about MicroEDGE Pro features, see System Specifications, in this section.

System options

MicroEDGE Pro features can be expanded with the addition of the following options that are available from Hypertherm or your system integrator:
•  LCD touchscreen monitor (with 1024 x 768 resolution and 4:3 aspect ratio) and 2 m (6 ft) cables for power, USB,
and VGA
•  Touchscreen extension cable of up to 50 m (160 ft) for keyboard, video, and mouse
•  Multiple drive axes
•  Sensor THC or ArcGlide THC interface
•  Analog joystick and speedpot interface
•  Wireless card for Ethernet LAN
Front View of the MicroEDGE Pro CNC (all models)
MicroEDGE Pro Instruction Manual 807290 1-5
SpecificationS

Rear panel

The rear panel of the CNC has cable connectors for power, motion control feedback, I/O, and communication ports. These connectors are clearly labeled with their function. There are four configurations available: HyPath, Picopath, SERCOS II, and SERCOS III.
For more information about the electrical installation of the MicroEDGE Pro CNC, see Section 3, Installation.
Note: The rear panel shown below is for reference only. The rear panel on individual CNC units depends on which
configuration is ordered.
AC
power
input
Drive/encoder ports
Serial
ports on the
mother board
(RS-232)
VGA
port
LAN
port
I/O port
USB
ports
Remote On/Off
Antenna ports
for optional
wireless I/O
Hypernet
port
ports on the
serial isolation
(RS-422 or
RS-232)
Optional joystick and
speedpot port
Serial
board
Optional
SensorTHC
ports (2)
Rear panel of the Picopath MicroEDGE Pro CNC
1-6 MicroEDGE Pro Instruction Manual 807290

System specifications

System Features
Processor Intel® Processor
Operating system Windows XPe
Software Phoenix version 9.7.1 or later
LAN ports 1 Ethernet port for general use
Hypernet Port 1 for communication with Hypernet-enabled systems
USB ports 5 USB 2.0 ports
SpecificationS
Serial ports
VGA port 1 standard 15-pin port for monitor
Onboard monitoring devices
Hard drive SATA drive
THC support 2 Sensor THCs or 4 ArcGlide THCs (over Hypernet or discrete connections)
Certification cCSAus, CE, GOST-TR, c-Tick, UkrSEPRO
Configuration HyPath Picopath SERCOS II SERCOS III
Number of I/O 24/24 12/12 512/512 512/512
I/O Type
Axes available 2-4 2-4 2-12 2-12
Power
AC Input
Slow blow fuse 2 amp, 250 VAC
4 (2 RS-232 and 2 isolated RS-232/RS-422 configurable ports) with D-sub 9-pin connectors
Hardware monitoring, including fan, CPU temperature, voltages, POST display
Input: positive logic Output: contact closure
•  Voltage: 100 VAC to 240 VAC
•  Current: 1.3 amps at 100 VAC / 0.6 amp at 240 VAC
•  Frequency: 50/60 Hz
Input and output: Negative logic
Fiber optic ring Ethernet
HyPath Picopath SERCOS II SERCOS III
DC available for I/O 24 V at 1.5 Amps 24 V at 1.5 Amps
Environmental
Temperature 0º C to 40º C (32º F to 104º F)
Humidity 50% relative humidity at 40º C, 90% relative humidity at 20º
Ingress Protection IP2X according to IEC 60529. Protect the equipment from exposure to excessive moisture.
Mechanical
Height 238 mm (9.38 in.)
Width 463 mm (18.22 in.)
Depth 332 mm (13.08 in.)
Weight 15.9 kg (35 lbs)
MicroEDGE Pro Instruction Manual 807290 1-7
SpecificationS

Machine interface configurations

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

HyPath configuration

The HyPath interface is available in multiple configurations. The basic system offers 2 to 4 axes with 24inputs and 24outputs. The following table lists configuration options.
Part
Number
090118 2 24/24 No Yes No 090119 3 24/24 No Yes No 090120 4 24/24 No Yes No 090121 2 24/24 2 Yes Yes 090122 3 24/24 2 Yes Yes 090123 4 24/24 2 Yes Yes
Number
ofAxes
Number
of I/O
Integrated
Sensor THC
Wireless Analog
Rear panel of 090123
1-8 MicroEDGE Pro Instruction Manual 807290
SpecificationS

Picopath configuration

The Picopath Interface offers 2 to 4 axes of motion control with 12 inputs and 12 outputs. This interface can be used to retrofit an existing system with a compatible Picopath interface.
The Picopath interface can be configured to supply encoder power at 5 VDC, 12 VDC, or to supply externally supplied (standalone) voltage encoders. See the circuit example in the Installation section that shows the Picopath I/O connections.
Part
Number
090124 2 12/12 No No No 090125 2 12/12 2 No Yes 090126 2 12/12 No Yes No 090127 2 12/12 2 Yes Yes 090128 3 12/12 No No No 090129 3 12/12 2 No Yes 090130 3 12/12 No Yes No 090131 3 12/12 2 Yes Yes 090132 4 12/12 No No No 090133 4 12/12 2 No Yes 090134 4 12/12 No Yes No 090135 4 12/12 2 Yes Yes
Number
ofAxes
Number
of I/O
Integrated
Sensor THC
Wireless Analog
Rear panel of 090135
MicroEDGE Pro Instruction Manual 807290 1-9
SpecificationS

SERCOS II configuration

SERCOS (SErial Real time COmmunication System) servo drive interface communicates with the drive amplifiers using a fiber optic ring. SERCOS II replaces the traditional +/- 10 VDC analog output motion control card (MCC) with a fiber optic driver card. This configuration allows you to expand your system and accommodate 12 axes and 512 I/O.
Notes:
•  Multiple THC connections are available, as a function of SERCOS II.
•  SERCOS II compatible (digital) drives must be used with this configuration.
•  All SERCOS II MicroEDGE Pro configurations offer 512 I/O and wireless networking.
Part
Number
090107 2 Yes 090108 3 Yes 090109 4 Yes 090110 5 Yes 090111 6 Yes 090112 7 Yes 090113 8 Yes 090114 9 Yes 090115 10 Yes 090116 11 Yes 090117 12 Yes
Number
ofAxes
Wireless
Rear panel for all SERCOS II models
1-10 MicroEDGE Pro Instruction Manual 807290
SpecificationS

SERCOS III configuration

SERCOS stands for SErial Real time COmmunication System servo drive interface. This approach to communication with the drive amplifiers uses Ethernet and replaces the traditional +/- 10 VDC analog output motion control card (MCC) with a driver card that manages SERCOS III, real-time transmissions and allows you to expand your system to accommodate up to 12 axes and 512 I/O.
Notes:
•  Multiple THC connections are available, as a function of SERCOS III.
•  SERCOS III compatible (digital) drives must be used with this configuration.
•  All SERCOS III MicroEDGE Pro configurations offer 512 I/O and wireless networking.
Part
Number
090172 2 Yes 090173 3 Yes 090174 4 Yes 090175 5 Yes 090176 6 Yes 090177 7 Yes 090178 8 Yes 090179 9 Yes 090180 10 Yes 090181 11 Yes 090182 12 Yes
Number ofAxes
Wireless
Rear panel for all SERCOS III models
MicroEDGE Pro Instruction Manual 807290 1-11
SpecificationS

Integrated Sensor THC

If your MicroEDGE Pro configuration includes the optional integrated Sensor THC, the CNC includes an analog input for the HyPath and Picopath configuration and the following printed circuit boards (PCBs):
•  Analog PCB (141125) for 1 to 2 Sensor THCs
•  Breakout PCB (141210) for 1 to 2 Sensor THCs, 1 joystick, and 1 to 2 speedpots
•  VDC3 PCB (141201) for 1 Sensor THC
For more information, see Installation.
Refer to the following Phoenix® software manuals for detailed information on the software that operates on the MicroEDGE Pro CNC:
•  Installation and Setup Manual (806410)
•  Operator’s Manual (806400)
•  Programmer’s Reference (806420)
THC1
THC2
1-12 MicroEDGE Pro Instruction Manual 807290
SpecificationS

Secondary enclosure requirements

If the MicroEDGE Pro CNC is installed in a secondary enclosure, the secondary enclosure must maintain the environmental specifications for operation that are listed in System specifications in this section. In particular, the temperature within the primary MicroEDGE Pro enclosure must not exceed 60° C (140° F).
The addition of auxiliary cooling may be required to insure that the internal temperature of the MicroEDGE Pro enclosure remains within the system specification.

Interior temperature

During operation, the temperature of the utility PCB (141194, 141222, 141256, 141307) within the enclosure must remain below 60° C (140° F).
The temperature of the utility PCB is reported on the Control Information screen in Phoenix software. The utility PCB temperature can also be displayed in the Watch Window. To add this temperature monitor to the Watch Window:
1. From the Main screen, choose Setups > Watch.
2. Select Temperature from the Lower Location dropdown list.
3. Choose OK.

Air circulation

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

AC input

The range for AC power entering the enclosure must be maintained within 50/60 Hz, 100 – 240 VAC.
MicroEDGE Pro Instruction Manual 807290 1-13
SpecificationS
1-14 MicroEDGE Pro Instruction Manual 807290
Section 2

INSTALLATION

In this section:
Upon receipt ...............................................................................................................................................................................................2-3
Claims ...........................................................................................................................................................................................................2-3
Installation requirements...........................................................................................................................................................................2-3
Placement of system components .........................................................................................................................................................2-3
Mounting the CNC ....................................................................................................................................................................................2-4
Mounting hole patterns on the bottom of the CNC ................................................................................................................2-4
X and Y axis configuration .......................................................................................................................................................................2-5
AC power .....................................................................................................................................................................................................2-6
Power cable ......................................................................................................................................................................................2-6
Chassis grounding .....................................................................................................................................................................................2-7
Interface ports .............................................................................................................................................................................................2-8
Hypernet interface ...........................................................................................................................................................................2-8
LAN interface ....................................................................................................................................................................................2-8
USB interface (5) ............................................................................................................................................................................2-8
Serial ports (4) .................................................................................................................................................................................2-8
VGA Port 1 .......................................................................................................................................................................................2-8
Picopath connections ...............................................................................................................................................................................2-9
Picopath I/O connections ..............................................................................................................................................................2-9
Picopath I/O connector ..............................................................................................................................................................2-10
Picopath I/O circuit examples .................................................................................................................................................. 2-11
Picopath drive/encoder connectors ......................................................................................................................................... 2-12
Encoder voltage options on the Picopath interface ........................................................................................................................ 2-14
Encoder jumper options ..............................................................................................................................................................2-14
HyPath connections ............................................................................................................................................................................... 2-17
HyPath I/O .....................................................................................................................................................................................2-17
HyPath inputs ................................................................................................................................................................................ 2-18
HyPath outputs .............................................................................................................................................................................2-20
HyPath I/O connectors ...............................................................................................................................................................2-23
HyPath 4-axis servo connectors ............................................................................................................................................... 2-25
MicroEDGE Pro Instruction Manual 807290 2-1
InstallatIon
Analog connections ................................................................................................................................................................................2-27
Sensor THC connector ............................................................................................................................................................... 2-27
THC cable specifications ........................................................................................................................................................... 2-28
Joystick and speedpot connector ............................................................................................................................................. 2-29
Joystick and speedpot cable adapter for MicroEDGE CNC (223252) .......................................................................... 2-30
SERCOS II I/O configuration ...............................................................................................................................................................2-31
SERCOS III I/O configuration ..............................................................................................................................................................2-32
SERCOS III Cable ....................................................................................................................................................................... 2-32
Serial port configuration ........................................................................................................................................................................ 2-33
Serial ports 1 and 2 ..................................................................................................................................................................... 2-33
Serial ports 3 and 4 ..................................................................................................................................................................... 2-33
Remote on/off cable ............................................................................................................................................................................... 2-35
Wireless network card ........................................................................................................................................................................... 2-36
Preparing to install the antenna .................................................................................................................................................2-36
Installing the antenna ................................................................................................................................................................... 2-36
Checking the wireless network in Windows .......................................................................................................................... 2-37
Mapping a network drive ............................................................................................................................................................2-38
Adding a folder in Phoenix .........................................................................................................................................................2-39
2-2 MicroEDGE Pro Instruction Manual 807290
InstallatIon

Upon receipt

1. Verify that all the system components on your order have been received. Contact your supplier if any items are missing.
•  MicroEDGE Pro CNC
•  AC power input cable (North America)
•  AC power input cable connector (all other regions)
•  Joystick and speedpot adapter cable for analog option
•  MicroEDGE Pro CNC instruction manual
•  Phoenix software instruction manuals (3)
2. Inspect the system components for any physical damage that may have occurred during shipping. If there is evidence of damage, refer to Claims. All communications regarding claims must include the model number and serial number located on the back of the CNC.

Claims

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

Installation requirements

All installation and service of electrical systems must conform to national and local electrical codes. This work should be performed only by qualified personnel.
Direct any technical questions to your authorized Hypertherm distributor or the nearest Hypertherm Technical Service Department (listed in the front of this manual).

Placement of system components

•  Place all system components in position prior to making electrical and interface connections.
•  Ground all system components to earth. See Recommended grounding and shielding practices in this section for
details.
•  Insure that the forced air ventilation opening is not blocked.
•  Do not restrict operator access to the AC power connector for connection and disconnection of the power cord.
The AC power connector is the primary means for disconnection of power to the equipment.
MicroEDGE Pro Instruction Manual 807290 2-3
InstallatIon

Mounting the CNC

Before you configure the MicroEDGE Pro CNC, mount all system components using the appropriate instructions.
Do not allow the system components to lie unsecured on top of cabinets or on the floor.
463 mm
(18.22 in)
238 mm
9.38 in
332 mm
(13.08 in)
Front and Side Views of the MicroEDGE Pro CNC

Mounting hole patterns on the bottom of the CNC

If you are upgrading from a MicroEDGE CNC to a MicroEDGE Pro, the mounting bolt patterns are the same on both systems.
483 mm
(19 in)
279 mm
(11 in)
.281 in. diameter for
1/4 in. or
6 mm bolts
MicroEDGE Pro mounting pattern
2-4 MicroEDGE Pro Instruction Manual 807290
InstallatIon

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 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.
X+
Y+
Y–
X–
Typical table origin and Home position (0,0)
Example of a shape cutting system configured with an MicroEDGE Pro CNC
MicroEDGE Pro Instruction Manual 807290 2-5
InstallatIon

AC power

Fuse size  –  2 Amp, 250 V slow-blow
Ground nut and lock AC Power connector

Power cable

An AC power cable is standard equipment for North America, and is shipped with the MicroEDGE Pro CNC. For other regions, the CNC is shipped with a power connector only to allow you to create a connector and cable combination that meet the requirements of local code and power connections.
To create a power cable, use the plug (108842) that ships with the MicroEDGE Pro CNC and connect a 3-wire cable for line, neutral, and ground signals according to local electrical codes. For more electrical specifications, see the Power section of the System Specifications table in the Specifications section. Also see the drawings below for examples.
washer
#10-32
Note: The fuse block is universal and holds 1 fuse to comply with local electrical codes
Customer-supplied power
(without neutral)
L1 – line
L2 – line
PE ground
MicroEDGE Pro CNC (as shipped)
Power entry
module
1 fuse: 2 amp,
5 x 20 mm or
0.25" x 1.25"
Customer-supplied power
(with neutral)
L1 – line
Neutral
PE ground
VAC input wiring examples
MicroEDGE Pro CNC (as shipped)
Power entry
module
1 fuse: 2 amp,
5 x 20 mm or
0.25" x 1.25"
2-6 MicroEDGE Pro Instruction Manual 807290
InstallatIon

Chassis grounding

The CNC must be properly grounded according to national and local electrical codes for safe operation. Use a number6 AWG (16 mm2) wire between the ground stud on the rear of the CNC to the cutting table as shown below.
WARNING
ELECTRICAL SHOCK CAN KILL
This ground connection must be wired to insure safe and reliable operation.
To the star ground on the cutting table
Ground cable on the CNC
MicroEDGE Pro Instruction Manual 807290 2-7
InstallatIon

Interface ports

Hypernet interface

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

LAN interface

The RJ-45 Ethernet interface allows the MicroEDGE Pro to connect to a local area network (LAN) for downloading parts and using Remote Help.
For more information on LAN setup, see the Phoenix Software Installation and Setup Manual.

USB interface (5)

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

Serial ports (4)

The MicroEDGE Pro has 4 serial ports that use D-sub 9-pin connectors.
Two RS-232 serial ports (COM 1 and COM 2) are located on the motherboard.
Two more serial ports (COM 3 and COM 4) are located on all versions of the serial isolation board:
•  141222 for 4-axis HyPath and Picopath
•  141256 for 2-axis Picopath
•  141194/141307 for SERCOSII and SERCOS III
Transmission rate is up to 115K Baud. Both ports are preset with RS-422 as the default but both can be configured 
for RS-232. For more information, see Serial port configuration in this section and in the Maintenance and Diagnostics section.

VGA Port 1

The VGA port allows connection of an video monitor (touchscreen, LCD, or CRT).
2-8 MicroEDGE Pro Instruction Manual 807290
InstallatIon

Picopath connections

Picopath I/O connections

I/O assignments are made in the Phoenix software on the Machine Setups > I/O screen. For more information, see the
Phoenix Software Installation and Setup Manual.
Rear view of the MicroEDGE Pro CNC with Picopath I/O configuration
Picopath I/O offers:
•  12 negative logic inputs rated at 24 VDC
•  12 negative logic outputs, rated at 24 VDC for up to 1 A loads
•  24 VDC field power supply on the Picopath PCB with a total usage of 1.5 A
MicroEDGE Pro Instruction Manual 807290 2-9
InstallatIon

Picopath I/O connector

Use the following information to create Picopath I/O cables.
The Picopath I/O mating connector is a 37-pin circular connector:
•  Cable connector AMP #208470-1
•  Sockets contacts: AMP 66101-3 (16–18 ga), AMP 66105-3 (20–24 ga)
•  Hypertherm kit: 228490
Pin no. Signal
1 Input 1 2 Input 2 3 Input 3 4 Input 4 6 Input 6 8 Input 8
9 Input 9 10 Input 10 11 Input 11 12 Input 12 13 N/C 14 +24 VDC 15 +24 VDC 16 N/C 17 24 V Common 18 24 V Common 19 N/C 20 N/C 21 Output 1 22 Output 2 23 Output 3 24 Output 4 25 Output 5 26 Output 6 27 Output 7 28 Output 8 29 Output 9 30 Output 10 31 Output 11 32 Output 12 33 I/O Shield 34 +24 VDC 35 +24 VDC 36 24 V Common 37 24 V Common
16
10
5
1
4
9
15
23
28
29
33
34
37
22
Picopath I/O connector J8
Z/W AXIS
DRV/ENC
Picopath I/O connector
X/Y AXIS
DRV/ENC
I/O
2-10 MicroEDGE Pro Instruction Manual 807290

Picopath I/O circuit examples

+5 VDC
+24 VDC
Input
Common
Shield
InstallatIon
Switch
(normally open)
37
Customer supplied cable
FET
+24 VDC
MicroEDGE Pro
Input
Common
Shield
37
Customer circuit
Input – CNC sinking
24 VDC coil
with diode
Customer supplied cable
MicroEDGE Pro
Customer circuit
Output, 24 VDC coil – CNC sinking
MicroEDGE Pro Instruction Manual 807290 2-11
InstallatIon

Picopath drive/encoder connectors

Picopath axis assignments are made in Phoenix software on the Machine Setups > Axis screen. For more information, see the Phoenix Software Installation and Setup Manual.
Use the following information to create Picopath drive/encoder cables.
The Picopath drive/encoder mating connector is a 37-pin, circular connector:
•  Cable connector: AMP #208472-1
•  Pin contacts AMP 66099-3 (16–18 ga), AMP 66103-3 (20–24 ga)
•  Cabling: Belden # 9504 or equivalent for encoder signals
•  Cabling: Belden # 9501 or equivalent for drive signals
•  Hypertherm kit: 228489
Notes:
•  Enable individual drives for each axis for proper operation.
•  Connect cable shields to the metal shell of the connector for optimum noise immunity and to keep signal commons
separate from the ground.
16
22
23
28
29
33
34
37
10
5
1
4
9
15
Picopath drive/encoder
connector J6 and J7
J6 Z/W AXIS DRV/ENC
Picopath drive/encoder connectors
J7 X/Y AXIS DRV/ENC
I/O
2-12 MicroEDGE Pro Instruction Manual 807290
Picopath pin-outs for servo drive connectors
Connector J6
Pin no. for
Z Axis
2 2 +5 VDC or +12 VDC sourced for encoder power 3 3 Encoder power common 4 1 Encoder power output (available if needed) 7 7 Encoder power shield 8 6 Encoder power common (available if needed)
9 5 Encoder channel A input 14 11 Encoder channel /A Input 15 10 Encoder channel B Input 21 17 Encoder channel /B Input 22 16 Encoder channel Z Input 28 23 Encoder channel /Z Input 13 12 Encoder shields 24 26 Drive enable in (relay contact closure) 25 27 Drive enable out (relay contact closure) 37 34 Drive power input (+12 VDC or +15 VDC) 33 29 Servo output (± 10 VDC) 32 30 Drive power common 36 35 Drive power input (–12 VDC or –15 VDC)
20 18 Servo output common
19 31 Drive/servo shield
Pin no. for
W Axis
Signal
InstallatIon
Connector J7
Pin no. for
X Axis
2 2 +5 VDC or +12 VDC sourced for encoder power
3 3 Encoder power common
4 1 Encoder power output (available if needed)
7 7 Encoder power shield
8 6 Encoder power common (available if needed)
9 5 Encoder channel A input 14 11 Encoder channel /A Input 15 10 Encoder channel B Input 21 17 Encoder channel /B Input 22 16 Encoder channel Z Input 28 23 Encoder channel /Z Input 13 12 Encoder Shields 24 26 Drive enable in (relay contact closure) 25 27 Drive enable out (relay contact closure) 37 34 Drive power input (+12 VDC or +15 VDC) 33 29 Servo output (± 10 VDC) 32 30 Drive power common 36 35 Drive power input (–12 VDC or –15 VDC) 20 18 Servo output common 19 31 Drive/servo shield
Pin no. for
Y Axis
Signal
Note: See the jumpers on the Picopath
4-axis backdoor interface board to select one of the following:
•  5 VDC sourced encoder power (default).
•  12 VDC sourced encoder power.
•  Customer supplied encoder and field
power.
For more information, see Maintenance and Diagnostics.
MicroEDGE Pro Instruction Manual 807290 2-13
InstallatIon

Encoder voltage options on the Picopath interface

The Picopath interface in the MicroEDGE Pro is similar to and compatible with the Picopath interface in an EDGE or MicroEDGE CNC except that the MicroEDGE Pro Picopath interface provides jumper settings that allow the user to select how the field power supply voltages are routed on the board.
The jumper is set to 5 VDC sourced encoder power in the factory and uses the MicroEDGE Pro internal field power supply to power the encoder, analog, and 24 I/O circuits.
The drive/encoder and I/O connections on the back of the Picopath interface provide voltages that you can use to
power an external encoder, provide analog power to a drive, or provide DC power for the cutting system’s I/O. 
Encoder power is frequently used in DC drive systems because the motors’ encoder is usually wired directly to the 
drive/encoder connector of the CNC. Most modern encoders use 5 VDC for power while older cutting systems use 12VDC for encoder power. The jumper blocks on the MicroEDGE Pro Picopath interface allow you to replace an older CNC with the MicroEDGE Pro CNC without having to replace encoders or to rewire the drive circuit of the cutting system.

Encoder jumper options

The encoder jumper blocks allow you to chose between 5 V encoders, 12 V encoders, or to supply external voltages to the MicroEDGE Pro. The jumper must be installed on one of these encoder jumper blocks.
5 V sourced encoders use the MicroEDGE Pro internal field power supply to provide 5 VDC on pin 2 of each drive/ encoder connector to power an external encoder. It also puts 5 VDC on the pull-up resistor for each encoder input signal. This voltage should match the signal voltage of the encoder channels.
12 V sourced encoders use the MicroEDGE Pro internal field power supply to provide 12 VDC on pin 2 of each drive/ encoder connector to power an external encoder. It also puts 12 VDC on the pull-up resistor for each encoder
input signal. This voltage should match the switching voltage of the motor’s encoder.
External encoder voltage provides the MicroEDGE Pro with field power to supply encoder power (5 VDC or 12 VDC), voltage on the pull-up resistor on the encoder channel, drive analog power (+/- 12 VDC), and I/O power (24 VDC) to the Picopath interface. This option is common when a MicroEDGE Pro CNC is replacing a CNC that did not have an internal field power supply (D80).
2-14 MicroEDGE Pro Instruction Manual 807290
J13
!
12 V encoder
power (out)
InstallatIon
J12
J12
5 V encoder
power (out)
+5Vf
J14
External encoder, drive
and I/O voltage
J3
Encoder jumper blocks on the Picopath interface
+Ve +Va -Va
+12Vf -12Vf +24Vf
1
3
5
J12 5 V encoder power (out) Default setting, shown with jumper
+24Vf
7
/AXISWDOG_HDR
/AXISWDOG
9
J13
J13
12 V
encoder
power (out)
J14
J14
External
encoder,
drive, and I/O
voltage
MicroEDGE Pro Instruction Manual 807290 2-15
+12Vf
Encoder power (in)
2
1
2
4
3
4
6
5
6
8
7
8
10
9
10
1
2
+ Drive power (in)
3
4
5
6
- Drive power (in)
Circuit layout of the jumper blocks
7
8
I/O power (in)
9
10
InstallatIon
The following illustration shows an encoder circuit in which the jumper setting puts voltage on Ve which supplies voltage to the pull-up resistor on the encoder channels. The Ve voltage should equal the voltage on the encoder channel.
Refer to the instruction manual for your encoder to verify the encoder channel voltage or contact your table supplier.
Ve
From drive/encoder connectors
Encod e r Chan ne l A
Encoder channel A
Encod e r Chan ne l /A
Encoder channel /A
1
2 7
8
Ve
1 2
Ve
1 2
+5Vf
4
3
+
6
-
1
+5Vf
Encod e r Chan ne l B
Encoder channel B
Encod e r Chan ne l // B
Encoder channel /B
3 6
Ve
1 2
4 5
11
13
1 2
Encoder circuit with jumper settings for voltage on encoder channels
10
+
8
-
2-16 MicroEDGE Pro Instruction Manual 807290
InstallatIon

HyPath connections

HyPath I/O

The HyPath I/O PCB provides 24 inputs and 24 outputs through four circular plastic connectors (CPCs), each containing 6 inputs and 6 outputs.
HyPath I/O assignments are made in Phoenix software, on the I/O Setup screen. For more information, see the Phoenix Software Installation and Setup Manual.
View of the MicroEDGE Pro CNC with HyPath 24 I/O, 4-axis servo configuration and 2 Sensor THCs
MicroEDGE Pro Instruction Manual 807290 2-17
InstallatIon

HyPath inputs

•  Use positive logic that requires a positive voltage to activate the input.
•  Are opto-coupled and have a range of +4.7 V minimum to +32 V maximum. Internal series resistor = 4.7 K Ohm.
•  +24 VDC field power supply on the HyPath and 4-axis servo PCB with a total external usage of 1.5 A.
HyPath input circuit examples
•  Connection to a limit switch, a push-button switch, a home switch, a station select switch (toggle switch), a relay contact, or an emergency-stop button
+5 VDC +24 VDC
4.7 k
MicroEDGE Pro
Input
Common
Shield
37
Customer supplied cable
Customer-supplied, normally open switch
•  Connection to a opto-isolator, typically found in a THC and a plasma supply.
+5 VDC +24 VDC
4.7 k
Input
Common
Shield
37
Customer supplied cable
Customer circuit
VDC
MicroEDGE Pro
Customer circuit
Customer-supplied opto-isolator switch
2-18 MicroEDGE Pro Instruction Manual 807290
•  Typical connection to a PNP-style proximity sensor input (PNP)
+5 VDC +24 VDC
InstallatIon
4.7 k
MicroEDGE Pro
Customer supplied proximity switch – PNP sourced
Input
Common
Shield
37
Control
circuit
Customer supplied cable
Customer circuit
MicroEDGE Pro Instruction Manual 807290 2-19
InstallatIon

HyPath outputs

•  Use relay contact closure (003179). The relay outputs are normally open contacts. Outputs can be set to normally
closed by setting the output logic in the I/O screen in the Phoenix software.
•  5 V to 32 V switching voltage; 5 A continuous-resistive load; 2 A continuous-inductive load.
HyPath output circuit examples
Connection to a relay coil (1a, 1b, and 1c). Notice that the commons are connected together and a diode (supplied by the customer) is used between DC coil connections.
1a.
+24 VDC
1b.
Relay
003179
Relay
003179
MicroEDGE Pro
+24 VDC
Output A Output B Common
Output A Output B Common
Shield
Shield
VAC
AC coil
37
Customer supplied cable
Customer circuit
AC coil – supplied by customer
24 VDC coil, with
diode
37
Customer supplied cable
MicroEDGE Pro
Customer circuit
24 VDC coil – CNC sourced
2-20 MicroEDGE Pro Instruction Manual 807290
1c.
InstallatIon
+24 VDC
Output A Output B
Relay
003179
MicroEDGE Pro
Common
Shield
37
Customer supplied cable
24 VDC coil – CNC sourced
Connection to a relay coil (2a and 2b). The field voltage is supplied by the customer.
24 VDC coil,
with diode
Customer circuit
2a.
+24 VDC
VAC
AC relay
Customer circuit
Relay
003179
Output A
Output B Common
MicroEDGE Pro
Shield
37
Customer supplied cable
AC relay – supplied by customer
MicroEDGE Pro Instruction Manual 807290 2-21
InstallatIon
2b.
+24 VDC
Output A
Output B
Relay
003179
MicroEDGE Pro
Common
Shield
37
Customer supplied cable
Opto-relay – supplied by customer
3. Typical connection to an opto-isolator. The input is typical for a THC or PAC System.
VDC
Opto-relay
Customer circuit
+24 VDC
VDC
Opto-relay
Customer circuit
Relay
003179
Output A Output B Common
MicroEDGE Pro
Shield
37
Customer supplied cable
Opto-relay – CNC sourced
2-22 MicroEDGE Pro Instruction Manual 807290
InstallatIon

HyPath I/O connectors

Notes:
•  Isolate all external commons from the chassis ground.
•  If external voltage is used to activate I/O, connect the external source’s common to the internal +24 V common.
•  HyPath systems have the I/O for each connector printed above the connectors.
Use the following information to create HyPath I/O cables.
The HyPath I/O mating connector is a 37-pin, circular connector:
•  Cable connector: AMP 206305-1
•  Pin contacts: AMP 66098 (16–18 AWG), AMP 66331 (20–24 AWG)
•  Hypertherm kit: 228492
The following pages provide additional specifications and pinout information for the HyPath interface boards.
34
29
23
16
10
5
1
HyPath I/O connector
37
33
28
22
15 9
4
J6 I/O 7-12 J7 I/O 1-6
J5 I/O 13-18J4 I/O 19-24
HyPath I/O connectors
Location of the I/O connectors
MicroEDGE Pro Instruction Manual 807290 2-23
InstallatIon
HyPath I/O pin-outs
Connector J7 – I/O 1 to 6
Pin no. Inputs Pin no. Outputs
1 +24 VDC Source 19 +24 VDC Source
2 Input 1 20 Output 1A
3 Common 21 Output 1B
4 +24 VDC Source 22 +24 V Field
5 Input 2 23 Output 2A
6 Common 24 Output 2B
7 +24 VDC Source 25 +24 V Field
8 Input 3 26 Output 3A
9 Common 27 Output 3B
10 +24 VDC Source 28 +24 V Field
11 Input 4 29 Output 4A
12 Common 30 Output 4B
13 +24 VDC Source 31 +24 V Field
14 Input 5 32 Output 5A
15 Common 33 Output 5B
16 +24 VDC Source 34 +24 V Field
17 Input 6 35 Output 6A
18 Common 36 Output 6B
37 Shield
Connector J6 – I/O 7 to 12
Pin no. Inputs Pin no. Outputs
1 +24 VDC Source 19 +24 VDC Source
2 Input 7 20 Output 7A
3 Common 21 Output 7B
4 +24 VDC Source 22 +24 V Field
5 Input 8 23 Output 8A
6 Common 24 Output 8B
7 +24 VDC Source 25 +24 V Field
8 Input 9 26 Output 9A
9 Common 27 Output 9B
10 +24 VDC Source 28 +24 V Field
11 Input 10 29 Output 10A
12 Common 30 Output 10B
13 +24 VDC Source 31 +24 V Field
14 Input 11 32 Output 11A
15 Common 33 Output 11B
16 +24 VDC Source 34 +24 V Field
17 Input 12 35 Output 12A
18 Common 36 Output 12B
37 Shield
Connector J5 – I/O 13 to 18
Pin no. Inputs Pin no. Outputs
1 +24 VDC Source 19 +24 VDC Source
2 Input 13 20 Output 13A
3 Common 21 Output 13B
4 +24 VDC Source 22 +24 V Field
5 Input 14 23 Output 14A
6 Common 24 Output 14B
7 +24 VDC Source 25 +24 V Field
8 Input 15 26 Output 15A
9 Common 27 Output 15B
10 +24 VDC Source 28 +24 V Field
11 Input 16 29 Output 16A
12 Common 30 Output 16B
13 +24 VDC Source 31 +24 V Field
14 Input 17 32 Output 17A
15 Common 33 Output 17B
16 +24 VDC Source 34 +24 V Field
17 Input 18 35 Output 18A
18 Common 36 Output 18B
37 Shield
Connector J4 – I/O 19 to 24
Pin no. Inputs Pin no. Outputs
1 +24 VDC Source 19 +24 VDC Source
2 Input 19 20 Output 19A
3 Common 21 Output 19B
4 +24 VDC Source 22 +24 V Field
5 Input 20 23 Output 20A
6 Common 24 Output 20B
7 +24 VDC Source 25 +24 V Field
8 Input 21 26 Output 21A
9 Common 27 Output 21B
10 +24 VDC Source 28 +24 V Field
11 Input 22 29 Output 22A
12 Common 30 Output 22B
13 +24 VDC Source 31 +24 V Field
14 Input 23 32 Output 23A
15 Common 33 Output 23B
16 +24 VDC Source 34 +24 V Field
17 Input 24 35 Output 24A
18 Common 36 Output 24B
37 Shield
2-24 MicroEDGE Pro Instruction Manual 807290
InstallatIon

HyPath 4-axis servo connectors

The HyPath 4-axis servo PCB provides the drive and encoder connections for up to 4 independent servo axes. The board provides two circular connectors. Each connector provides connections for two independent servo axes.
Axis assignments are made in Phoenix software on the Axes screen. For more information, see the Phoenix Software Installation and Setup Manual.
HyPath servo connector
Use the following information to create HyPath servo cables.
The HyPath servo connector is a 37-pin, circular connector:
•  Cable connector: AMP 206150-1
•  Socket contacts: AMP 164164 (16–18 AWG), AMP 164163 (20–24 AWG)
•  Hypertherm kit: 228491
J3 Axes 1-2
J4 Axes 3-4
Location of the 4-axis servo connectors
HyPath servo
connectors
MicroEDGE Pro Instruction Manual 807290 2-25
InstallatIon
Drive/Encoder pin-outs
Notes:
•  Z Channel is the marker pulse channel which is 1 pulse/revolution.
•  Not all axes may be available. Verify how many axes are available on your CNC in the
Diagnostics > Control Information screen in Phoenix software.
HyPath servo connectors J3, J4
22
15
28
33
37
34
29
23
16
9
4
10
5
1
Connector J3 (Axes 1 and 2)
Pin no.
for Axis 1
Pin no.
for Axis 2
Signal
1 20 Axis shield 2 21 Encoder +5 V out 3 22 Encoder common 4 23 Encoder +12 V out 5 24 Encoder common 6 25 Encoder +24 V out 7 26 Encoder common 8 27 Encoder Axis A
9 28 Encoder Axis A\ 10 29 Encoder Axis B 11 30 Encoder Axis B\ 12 31 Encoder Axis Z 13 32 Encoder Axis Z\ 14 33 Axis enable A 15 34 Axis enable B 16 35 Axis servo output 17 36 Analog common 18 37 Axis shield 19 Shield
Connector J4 (Axes 3 and 4)
Pin no.
for Axis 3
Pin no.
for Axis 4
Signal
1 20 Axis shield 2 21 Encoder +5 V out 3 22 Encoder common 4 23 Encoder +12 V out 5 24 Encoder common 6 25 Encoder +24 V out 7 26 Encoder common 8 27 Encoder Axis A
9 28 Encoder Axis A\ 10 29 Encoder Axis B 11 30 Encoder Axis B\ 12 31 Encoder Axis Z 13 32 Encoder Axis Z\ 14 33 Axis enable A 15 34 Axis enable B 16 35 Axis servo output 17 36 Analog common 18 37 Axis shield 19 Shield
The following illustration shows the axis-enable relay contacts for each axis on the 4-axis servo board.
A
Customer
4
B
3
1
CNC
2
Relay SPST
HyPath 4-axis servo – axis enable output relay contacts
2-26 MicroEDGE Pro Instruction Manual 807290
InstallatIon

Analog connections

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

Sensor THC connector

In configurations with integrated Sensor THCs, the MicroEDGE Pro has dedicated connectors for THC 1, and THC 2.
Notes:
•  Analog inputs for the speed pots are rated at 0 to +10 VDC.
•  Connect cable shields to the external PE studs for optimum noise
immunity.
•  The Series 1 PCI analog card is named PCI-AIC Rev X on the CNC
3
7
11 12 13 14
15
Information Diagnostic screen in the Phoenix software
THC connector:
•  Cable connector: AMP 206708-1
•  Pin contacts: AMP 65105-3
1
4
7
•  Cabling: Belden # 9540 or equivalent for encoder signals
•  Hypertherm kit: 228495
1 2
4
7
Pin-outs for Integrated Sensor THC 1 and 2 connectors
Pin no. CNC I/O configuration Signal
1 Common Common 2 Input + Nozzle Contact Sense + ( relay contact ) 3 Input - Nozzle Contact Sense - ( relay contact ) 4 Output + Nozzle Contact Enable + ( relay contact ) 5 Output - Nozzle Contact Enable - ( relay contact ) 6 Analog input + THC + 7 Analog input - THC ­8 Output + Hold Ignition ( relay contact ) 9 Output - Hold Ignition ( relay contact )
Connector ground Shield
2
1
4
6
5
8
9
10
Joystick and speedpot interface
16
2
3
5 6
8
5
8
9
3
6
9
THC 1 interface
THC 2 interface
MicroEDGE Pro Instruction Manual 807290 2-27
InstallatIon

THC cable specifications

The following tables provide the pin-out details for the connectors on the Sensor THC amplifier, the MicroEDGE Pro CNC, and the voltage divider board (VDC3). Use these tables to manufacture the cables that connect these devices in your configuration.
Pin-outs for voltage divider board 3 (VDC3) connectors
J1 Power connector on VDC3
Pin no. Signal
1 120 VAC line 2 120 VAC neutral
J3 Field connector on VDC3 (black terminal strip)
Pin no. Signal
1 EMI Ground 2 Electrode (connection to negative connection inside plasma system) 3 Work (connection to the positive connection inside the plasma system) 4 No connection 6 Ohmic contact wire connection
Pin-out for the cable between J2 on VDC3 and THC 1 on the CNC
J2 I/O Connector on VDC3 THC1 Connector on the CNC
Pin no. Signal Pin no. Outputs
1 24 VDC common (out) 1 24 VDC Common (in) 2 +24 VDC (out) 2 Nozzle Contact Sense + 3 Nozzle contact sense (output) 3 Nozzle Contact Sense ­4 Nozzle contact enable (input) 4 Nozzle Contact Enable + 5 24 VDC common (out) 5 Nozzle Contact Enable ­6 + Analog out 6 + Analog in 7 - Analog out 7 - Analog in 8 Chassis ground (cable shield)
8 Hold + 9 Hold -
J1
J2
J3
Voltage divider board (141201)
2-28 MicroEDGE Pro Instruction Manual 807290

Joystick and speedpot connector

•  Cable connector: AMP 206037-1
•  Pin contacts AMP 65105-3
•  Cabling: Belden # 8308 or equivalent for encoder signals
•  Hypertherm kit: 228837
Pin-outs for joystick and speedpot connector
Pin no. Signal
1 Joystick up
2 Joystick down
3 Joystick left
4 Joystick right
5 Common
6 10 V reference
7 Speed pot 1+
8 Speed pot 1-
9 Common
10 10 V reference
11 Speed pot 2+
12 Speed pot 2-
13 Common
14 Common
15 Common
16 Common
InstallatIon
MicroEDGE Pro Instruction Manual 807290 2-29
InstallatIon

Joystick and speedpot cable adapter for MicroEDGE CNC (223252)

If the MicroEDGE Pro CNC is replacing a Hypertherm MicroEDGE CNC, an adapter cable is required to allow the cable for the MicroEDGE joystick and speedpot to connect to the MicroEDGE Pro.
Side A
Connect to the MicroEDGE joystick and
speedpot cable
1 3
2
64
5
7 9
8
Side A Pin no. Wire color Signal Side B Pin no.*
1 Black Joystick up 1
2 White Joystick down 2
3 Red Joystick left 3
4 Green Joystick right 4
5 Brown Common 5
6 Blue Speed pot 1+ 7
7 Orange Speed pot 1- 8
8 Yellow Speed pot 2+ 11
9 Purple Speed pot 2- 12
Side B
Connect to the MicroEDGE Pro joystick and
speedpot connector
2 1
4
12
3
7
8
11
5
*On Side B, there are no connections on pins 6,10 and 13 to 16.
2-30 MicroEDGE Pro Instruction Manual 807290
InstallatIon

SERCOS II I/O configuration

The MicroEDGE Pro SERCOS II I/O configuration conforms to the SERCOS II standard. The full details of this specification cannot be addressed in this manual. For complete of SERCOS technology and specifications, refer to: http://www.sercos.com.
Rear view of the SERCOS II MicroEDGE Pro CNC
MicroEDGE Pro Instruction Manual 807290 2-31
InstallatIon

SERCOS III I/O configuration

The MicroEDGE Pro SERCOS III I/O configuration conforms to the SERCOS III standard. The full details of this specification cannot be addressed in this manual. Refer to the Phoenix Software V9 Series Installation and Setup Guide (806410) for instructions about how to set up your EDGE Pro SERCOS III CNC. For complete information about SERCOS technology and specifications, refer to: http://www.sercos.com.
Port 1
Port 2
Rear view of the SERCOS III MicroEDGE Pro CNC

SERCOS III Cable

A shielded Cat-5e Ethernet cable connects the SERCOS III I/O interface on the rear of the CNC enclosure to the drive amplifier cabinet. A minimum of one cable is required for this connection to create a single SERCOS III line that connects Port 1 (P1) on the CNC and all the SERCOS III drives in the drive amplifier cabinet.
To create a SERCOS III ring that will provide communication redundancy and security, connect a second cable between Port 2 (P2) on the CNC and the drive amplifier cabinet.
Part number Length Part number Length
223212 3.0 m (10 ft) 223099 23.0 m (75 ft) 223222 6.0 m (20 ft) 223100 30.5 m (100 ft) 223119 7.5 m (25 ft) 223101 45.5 m (150 ft) 223223 10.5 m (35 ft) 223102 61.0 m (200 ft) 223008 15.0 m (50 ft)
2-32 MicroEDGE Pro Instruction Manual 807290
InstallatIon

Serial port configuration

The serial ports in the MicroEDGE Pro are designed to operate with a standard 9-pin serial port connector. The following list provides specifications for these ports. For more information, see the Phoenix Software Installation and Setup manual.
Serial isolation specifications (see Machine Setups > Ports In Phoenix software)
Channel Type Optically isolated RS-422 or RS-232
Information Code ASCII
Baud Rate User-selectable up to 115.2K baud
Number of Start Bits 1
Number or Stop Bits 1
Word Length User-selectable 7 or 8 bits
Parity User-selectable none, even or odd
Data Synchronization XON (Control-Q) / XOFF (Ctrl/S)
Time Out User-selectable in one-second increments
Transmit Delay User-selectable in 0.01-second increments
Rear Panel Connector IBM-PC/AT compatible 9-pin D-type female

Serial ports 1 and 2

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

Serial ports 3 and 4

Both serial ports on the following boards are shipped in the RS-422 wiring configuration:
•  HyPath and Picopath 4-axis MCC, utility, and serial isolation board (141222)
•  Picopath 2-axis MCC, utility, and serial isolation board (141256)
•  SERCOS II and SERCOS III utility and serial isolation board
(141194/141307)
To change either port to an RS-232 configuration, you must find the jumper for the appropriate port and move the jumper from the RS-422 position to the RS-232 position. These positions are clearly marked on the board.
Configure the port for RS-232 operation before connecting RS-232 compatible devices.
Serial port
3
Serial port
4
RS-422
RS-232
Jumpers in
RS-422 position
RS-422
RS-232RS-232
MicroEDGE Pro Instruction Manual 807290 2-33
InstallatIon
CNC RS-422 DB-9 Pin-out
Pin no. Signal Name Description
1 Shield Chassis ground 2 TxD- Transmit data - to external device 3 RxD- Receive data - from external device 4 TxD+ Transmit data + to external device 5 Common Ground 6 No connection 7 RxD+ Receive data + from external device 8 No connection 9 No connection
CNC RS-232 DB-9 Pin-out (reference only)
Pin
Signal Name Description
no.
1 Shield Chassis ground
2 TxD Transmit data to external device
3 RxD Receive data from external device
4 No connection
5 Common Ground
6 No connection
7 No connection
8 No connection
9 No connection
2-34 MicroEDGE Pro Instruction Manual 807290
InstallatIon

Remote on/off cable

Hypertherm does not supply a cable that connects to the remote on/off connector on the following boards:
•  141222 for 4-axis HyPath and Picopath
•  141256 for 2-axis Picopath
•  141194/141307 for SERCOSII and SERCOS III
However, Hypertherm provides the cable connector which shipped with the system in the remote on/off port, as shown in the following illustrations. You can use this connector to terminate a custom-built cable of the appropriate length.
Picopath and HyPath SERCOS II and SERCOS III
Location of the remote on/off connector on the MicroEDGEPro
To build the remote on/off cable, remove the connector from the port and attach purchased wires, a switch, and an LED. Use the circuit diagram below for details.
1
Remote on/off +
2
Remote on/off -
Customer supplied wiring, switch
and LED
On/Off
3
Common
LED
4
+12 V
5
Shield
Circuit diagram for the remote on/off cable
MicroEDGE Pro Instruction Manual 807290 2-35
InstallatIon

Wireless network card

The MicroEDGE Pro supports an optional wireless network card for part downloads, Remote Help, and other network tasks. The wireless network card is installed in PCI slot 2 on the motherboard. Two antennas extend from the card on the back of the MicroEDGE Pro. Unfold and adjust the antennas to a 45 degree angle.
When the MicroEDGE Pro is installed within a secondary enclosure, the antennas may be extended up to 3 m (10 ft) from the wireless network card. When using the 3 m antenna extension cables (223251), only 2.4 GHz frequency can be used at the router or access point.

Preparing to install the antenna

Follow these guidelines before mounting the antennas on a secondary CNC enclosure:
•  The antennas must exit to room air, preferably without metallic obstructions blocking signal transmission (such as equipment cabinets, circuit breaker panels, transformers, etc).
•  Antennas should not be located near the floor.
•  Use a plastic protective barrier if necessary to prevent accidental bumping of antenna orientation.
•  When mounting the antennas on a secondary CNC enclosure, you will need to drill two holes to accommodate the
threaded, bulkhead-mount antenna connectors. Be sure the connectors make contact with the metal on the en­closure, or use a lock washer to penetrate any coating on the enclosure. Metal-to-metal contact ensures that the antennas are grounded to the chassis.
•  The antenna connections are not waterproof.

Installing the antenna

Before you begin the antenna installation:
•  Make sure not to twist or kink the extension cables.
•  The extension cables should reside entirely inside the enclosure. Only the antenna itself should be on the outside of
the enclosure.
•  Route the cable away from noise generating sources such as power supplies, motor amplifiers, and AC circuits.
•  Use a service loop of at least 10 cm (4 in) diameter to coil excess coaxial antenna cable.
2-36 MicroEDGE Pro Instruction Manual 807290
InstallatIon
1. After selecting a suitable antenna mounting location, drill two 6.35 mm (.25 in) holes into the secondary CNC enclosure as shown below (drawing not to scale). Remove any burrs inside and outside.
6.35 mm (.25 in) diameter
36 mm (1.4 in)
2. Thread each bulkhead-mount antenna base through a hole and secure with a lock washer and nut. Be sure the antenna base makes contact with unpainted metal on the enclosure to ensure proper grounding.
3. Connect the antennas to the bases and point them skyward.
4. Connect the cables to the coaxial connectors on the wireless network card. Be sure to avoid twisting or kinking the cables. The entire extension cable should be within the CNC enclosure. Only the antennas are mounted on the outside of the enclosure.
5. Restore AC power to the CNC.

Checking the wireless network in Windows

The MicroEDGE Pro comes from the factory with the wireless network card drivers installed. To check the wireless network in Windows:
1. Turn on the MicroEDGE Pro.
2. Choose Setups>Password and enter the Special Setups password.
3. Choose System>Network Tools. The Network Connections dialog opens showing all network connections.
MicroEDGE Pro Instruction Manual 807290 2-37
InstallatIon

Mapping a network drive

Phoenix requires a network drive to be defined in Windows. After you define the network drive, you can add it as a folder in Phoenix.
Before you begin, connect a USB keyboard to the MicroEDGE Pro.
1. Press Alt+F4 to exit the Phoenix software.
2. Choose Start Menu>Windows Explorer>Tools>Map Network Drive.
3. Choose a drive letter, then the folder. Make note of the folder path. When you connect to the folder in Phoenix, you will need to enter the folder path.
4. Choose Reconnect at Logon.
5. Choose Finish to save the mapped network drive.
2-38 MicroEDGE Pro Instruction Manual 807290
InstallatIon

Adding a folder in Phoenix

Note: The Add Folders feature must be enabled in the Special Setups screen before you can perform these steps.
1. Restart the Phoenix software.
2. From the Main Screen, choose the Files soft key.
3. Double-click the blue message to add a folder.
4. In the dialog, choose Mapped Drive.
5. Enter a Drive Name. This is the name that appears in the Load Files list.
6. Enter the actual path to the drive, not a drive letter. The drive path is formatted \\servername\foldername.
7. Choose OK.  
MicroEDGE Pro Instruction Manual 807290 2-39
InstallatIon
2-40 MicroEDGE Pro Instruction Manual 807290
Section 3

OPERATION

In this section:
Operating the CNC ...................................................................................................................................................................................3-2
Operator console ............................................................................................................................................................................3-2
Touch screen LCD ..........................................................................................................................................................................3-2
LCD display ......................................................................................................................................................................................3-2
Screen navigation ............................................................................................................................................................................3-3
Help ....................................................................................................................................................................................................3-4
View additional manuals ................................................................................................................................................................3-4
Show bookmarks .............................................................................................................................................................................3-5
Automated operations...............................................................................................................................................................................3-5
Align Wizard .....................................................................................................................................................................................3-5
CutPro Wizard .................................................................................................................................................................................3-6
Using Phoenix without a touch screen ..................................................................................................................................................3-6
PC keyboard .....................................................................................................................................................................................3-6
Updating Phoenix software ......................................................................................................................................................................3-7
Updating the software ....................................................................................................................................................................3-7
Updating the Help ...........................................................................................................................................................................3-7
Updating the cut charts .................................................................................................................................................................3-8
MicroEDGE Pro Instruction Manual 807290 3-1
OperatiOn

Operating the CNC

Phoenix software runs on the Hypertherm computer numerical controls (CNCs) including the EDGE® Pro and MicroEDGE® Pro. Phoenix supports either a touch screen or LCD display with a USB-connected keyboard and mouse for entering information and navigating the software. For more information, see the Phoenix Software Operator’s Manual.
For more information about the components of your cutting system that are supplied by your table manufacturer, refer to the manuals supplied by the manufacturer

Operator console

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

Touch screen LCD

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

LCD display

The MicroEDGE Pro can support an LCD display and requires 1024 x 768 resolution with a 4:3 aspect ratio.
3-2 MicroEDGE Pro Instruction Manual 807290
OperatiOn

Screen navigation

The keys located at the bottom of the screen in the software are called soft keys. The soft keys correspond to function
keys on a PC keyboard. OK and Cancel soft keys let you save or cancel changes that you make in a screen. 
Refer to the Phoenix Software Operator’s Manual for more details.
Note: The features shown on each screen vary depending on the user level (Beginner, Intermediate, or Advanced) and
the features enabled on the Special Setups and Station Configuration screens. This manual assumes the CNC is in Advanced Mode and shows all features with an example machine configuration.
Phoenix Main screen
MicroEDGE Pro Instruction Manual 807290 3-3
OperatiOn

Help

Choose the Help soft key to display information about each screen.
Choose the OK soft key to exit the Help screen and return to the control screen.
The Show Bookmarks soft key opens the navigation pane. On a keyboard, press Ctrl+F to use full text search.

View additional manuals

The Help screen may also display buttons for other types of information, for example:
•  Manuals for the Hypertherm equipment installed with your CNC, such as plasma systems or torch height controls.
•  Manuals for equipment provided by your table manufacturer.
Choose any of these buttons to view this additional information.
3-4 MicroEDGE Pro Instruction Manual 807290
OperatiOn

Show bookmarks

Choose the Show Bookmarks soft key on the Help screen to view the list of Help topics. Click on a topic in the list to view it.
Note: If you are operating the MicroEDGE Pro with a keyboard, use the Page Up/Page Down keys to scroll through
the document on screen.

Automated operations

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

Align Wizard

The Align Wizard automates several tasks including aligning a nest on a plate, adjusting for a skewed plate, and positioning the torch at the program start location.
To start the Align Wizard, choose Shape Library on the Main screen, then choose Shape Wizard, Shape Options, Align. The Align Wizard may launch automatically. If not, choose the Align Wizard soft key.
For more information, see Align Wizard in the Arranging Parts chapter of the Phoenix Software Operator’s Manual.
MicroEDGE Pro Instruction Manual 807290 3-5
OperatiOn

CutPro Wizard

The CutPro Wizard automates common cutting tasks including loading a part or nest, selecting the cutting process, aligning the part or nest on the plate, and starting the program.
The CutPro Wizard may launch automatically when you start the CNC. If not, choose the CutPro Wizard soft key on the Main screen to start the wizard. For more information on the CutPro wizard see the Cutting Parts chapter.

Using Phoenix without a touch screen

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

PC keyboard

Hypertherm CNCs can support a USB, PC keyboard. You can use a keyboard to perform functions and data entry in the Phoenix software.
A label (210047) is included with the MicroEDGE Pro to modify a PC keyboard to use with Phoenix software, as shown in the following illustration.
3-6 MicroEDGE Pro Instruction Manual 807290
OperatiOn

Updating Phoenix software

Hypertherm provides regular updates to the Phoenix software. You can download the most current software from the website www.hypertherm.com. Choose Products > Controls for Automation > Software to open the Phoenix Software Update Downloads page. On this page you can download:
•  Phoenix software update (update.exe)
•  Phoenix Help file (Help.exe)
•  Cut charts (CutChart.exe)
Follow the instructions on the web page to download the updates in your language.
Before you update the Phoenix software, follow these guidelines:
•  Back up your system files: On the Main screen, choose Files > Save to Disk > Save System Files to Disk. See the
section Saving System Files in Chapter 11 Diagnostics and Troubleshooting for more information.
•  Copy the files that you download from Hypertherm.com to the root folder of a USB memory stick.
•  Be prepared to restart the CNC after you have updated the software.

Updating the software

1. At the CNC, plug the memory stick that contains the file update.exe into a USB port.
Note: Verify that update.exe resides in the root folder of the memory stick.
2. On the Main screen, choose Setups > Password. If you are not using a keyboard, double-tap the screen to display
an onscreen keyboard.
3. Enter updatesoftware (all lower case, one word) and choose Enter. The Phoenix software automatically reads the
memory stick and installs the new software.

Updating the Help

1. At the CNC, plug the memory stick that contains the file Help.exe into a USB port.
Note: Verify that Help.exe resides in the root folder of the memory stick.
2. On the Main screen, choose Setups >Password. If you are not using a keyboard, double-tap the screen to display
an onscreen keyboard.
3. Enter updatehelp (all lower case, one word) and choose Enter. The Phoenix software automatically reads the
memory stick and installs the new help file.
MicroEDGE Pro Instruction Manual 807290 3-7
OperatiOn

Updating the cut charts

Hypertherm provides cut charts in two different file types: .fac and .usr. The .fac files are the factory-default cut charts. These cut charts cannot be changed. The .usr cut charts contain any changes you have made to a cut chart and saved with the Save Process soft key.
The cut chart update file (CutChart.exe) contains both .fac and .usr cut chart files. The update automatically overwrites all of .usr cut charts. Before installing the update, back up your modified cut charts.
Hypertherm recommends saving modified cut charts as custom cut charts. When you create a custom cut chart, Phoenix creates a .usr file with a unique name. This prevents the custom cut charts from being overwritten by the .usr files in CutChart.exe. See the Phoenix Software Operator’s Manual for instructions.
To back up modified cut charts:
1. At the CNC, plug a memory stick into a USB port.
2. On the Main screen, choose one of the cut chart soft keys, such as Plasma 1 Cut Chart.
3. Choose the Save Cut Charts soft key. Phoenix copies all the cut charts associated with the Plasma 1 Torch Type onto the memory stick.
To update the cut charts:
1. At the CNC, plug the memory stick that contains the file CutChart.exe into a USB port. Note: Verify that CutChart.exe resides in the root folder of the memory stick.
2. On the Main screen, choose Process, and choose one of the cut chart soft keys such as Plasma 1 Cut Chart.
3. Choose the Load Cut Charts soft key, then choose Yes when prompted to load cut charts from the memory stick. Phoenix extracts the cut charts and copies them to the hard drive.
4. If you have modified cut charts to copy back onto the hard drive, you will need to exit Phoenix and use Windows® Explorer to copy your .usr files back onto the hard drive. The cut chart folder is c:\Phoenix\CutCharts.
3-8 MicroEDGE Pro Instruction Manual 807290
Section 4

MAINTENANCE AND DIAGNOSTICS

In this section:
Introduction .................................................................................................................................................................................................4-3
Diagnostic tests..........................................................................................................................................................................................4-4
Serial test ..........................................................................................................................................................................................4-6
USB test ............................................................................................................................................................................................4-7
I/O test ...............................................................................................................................................................................................4-8
Axis test ..........................................................................................................................................................................................4-10
THC test ......................................................................................................................................................................................... 4-11
LAN and Hypernet tests .............................................................................................................................................................4-12
Joystick and speedpot test .........................................................................................................................................................4-13
Troubleshooting.......................................................................................................................................................................................4-14
Introduction .................................................................................................................................................................................... 4-14
MicroEDGE Pro troubleshooting tables ..................................................................................................................................4-15
Power up ................................................................................................................................................................................... 4-15
Display ....................................................................................................................................................................................... 4-15
Field power failure ................................................................................................................................................................... 4-15
Input failure ............................................................................................................................................................................... 4-16
Output failure ...........................................................................................................................................................................4-16
Hypernet .................................................................................................................................................................................... 4-17
LAN connection ....................................................................................................................................................................... 4-17
Motion issues ........................................................................................................................................................................... 4-18
THC ............................................................................................................................................................................................ 4-20
Serial communication issues ................................................................................................................................................ 4-21
USB issues ............................................................................................................................................................................... 4-21
Cut quality ................................................................................................................................................................................. 4-21
CNC temperature ...................................................................................................................................................................4-22
CNC is slow ............................................................................................................................................................................. 4-22
Wireless troubleshooting ...................................................................................................................................................................... 4-23
MicroEDGE Pro Instruction Manual 807290 4-1
Maintenance and diagnostics
Component locations and information ............................................................................................................................................... 4-24
HyPath 24 I/O board (141070) ................................................................................................................................................ 4-25
Motherboard (141110) ............................................................................................................................................................... 4-27
SERCOS II master board (141116) ........................................................................................................................................4-28
SERCOS III master board (141310) .......................................................................................................................................4-29
Picopath 4-axis servo board (141122) ................................................................................................................................... 4-30
Analog board (141125) .............................................................................................................................................................. 4-34
Power distribution board (141153) ......................................................................................................................................... 4-36
SERCOS II and SERCOS III serial isolation and utility board (141194/141307) ....................................................... 4-38
HyPath 4-axis servo board (141197) ...................................................................................................................................... 4-40
CPC analog breakout board (141210) ..................................................................................................................................4-42
HyPath and Picopath 4-axis MCC, utility, and serial isolation board (141222) ............................................................ 4-44
Picopath 2-axis servo board (141254) ................................................................................................................................... 4-47
Picopath 2-axis MCC, utility, and serial isolation board (141256) ...................................................................................4-50
4-2 MicroEDGE Pro Instruction Manual 807290
Maintenance and diagnostics
DANGER
ELECTRIC SHOCK CAN KILL
Disconnect electrical power before performing any maintenance. See the Safety section in this manual for more safety precautions.

Introduction

Hypertherm assumes that the service personnel who perform troubleshooting testing are high-level electronic service technicians who have worked with high-voltage electro-mechanical systems. Knowledge 
of final isolation troubleshooting techniques is also assumed.
In addition to being technically qualified, maintenance personnel must perform all testing with safety in mind. For more information, refer to the Safety section for operating precautions and warning formats.
MicroEDGE Pro Instruction Manual 807290 4-3
Maintenance and diagnostics

Diagnostic tests

Note: Test kits are required to perform the following diagnostic tests.
Machine interface tests
If you are using a MicroEDGE Pro CNC, you can perform diagnostic tests with the following connectors and Phoenix software to test the interface ports on the CNC (228831):
•  Serial interface RS-232 on the motherboard
•  Serial interface RS-422 on the serial isolation board
•  Ethernet and Hypernet
•  USB
Note: This is the only kit needed for SERCOS II and SERCOS III systems and it is included in the HyPath and Picopath kits.
The HyPath version of the MicroEDGE Pro CNC offers the following, additional testers (228832):
•  I/O (2)
•  Axes
•  THC
•  Joystick and speedpot
The Picopath version of the MicroEDGE Pro CNC offers the following, additional testers (228833):
•  I/O (2)
•  Axes
•  THC
•  Joystick and speedpot
Machine interface test screen
4-4 MicroEDGE Pro Instruction Manual 807290
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