Hypertherm Phoenix User Manual
Automation
Hypertherm Automation
5 Technology Drive, Suite 300
W. Lebanon, NH 03784 USA
Phone: 603-298-7970
Fax: 603-298-7977
HYPERTHERM SHAPE CUTTING CONTROL
OPERATOR AND INSTALLATION MANUAL
Software Version 8.0 for Touch Screen CNCs
July 2008
D
ISCLAIMER The information in this document is subject to change without notice and should not be
construed as a commitment by Hypertherm Automation. Hypertherm Automation
assumes no responsibility for any errors that appear.
T
RADEMARKS Hypertherm Automation is a wholly owned subsidiary of Hypertherm, Inc.
Command, HT 4400, HD3070 HyDefinition Plasma and HD4070 HyDefinition Plasma
are registered trademarks of Hypertherm, Inc.
FASTLaser is a trademark of Hypertherm, Inc.
EDGE, HyperCAD, HyperNet, HyperNest, Phoenix, and ShapeWizard are registered
trademarks of Hypertherm Automation.
Align, APC, CutPro, Gemini, HPR130, HPR260 HyPerformance Plasma, Mariner,
Nester, Remote Help, Sensor, and Voyager are trademarks of Hypertherm Automation.
HASP is a registered trademark of Aladdin Knowledge Systems Ltd.
Indramat is a trademark of Bosch Rexroth.
Pacific Scientific is a trademark of Danaher Motion.
Pentium and Celeron are registered trademarks of Intel Corporation.
Virus Scan is a registered trademark of McAfee Associates, Inc.
Microsoft, the Microsoft logo, and Windows are registered trademarks of Microsoft
Corporation.
NJWIN is a registered trademark of NJStar Software Corporation.
SERCOS Interface is a trademark of SERCOS North America.
Norton AntiVirus and Norton Ghost are trademarks of Symantec Corporation.
Other trademarks are the property of their respective holders.
C
OPYRIGHT 2008 by Hypertherm Automation. All rights Reserved
Printed in USA
ii
Contents
Safety ............................................................................................................................................ 1
Overview ...................................................................................................................................... 9
CutPro Wizard ........................................................................................................................ 9
Align Wizard ........................................................................................................................... 9
Remote Help ........................................................................................................................... 9
ShapeWizard ........................................................................................................................... 9
Teach/Trace ............................................................................................................................. 9
Shape Libraries ..................................................................................................................... 10
Program Upload and Download............................................................................................ 10
SoftMotion ............................................................................................................................ 10
Cutting Options ..................................................................................................................... 10
Programming Features .......................................................................................................... 11
Performance Features............................................................................................................ 12
Installation and Setup Features ............................................................................................. 12
Hardware Specifications ....................................................................................................... 13
Model Numbering System .................................................................................................... 13
Front Panel Layout ................................................................................................................ 14
PC Keyboard Layout ............................................................................................................. 17
Key and Menu Functions ...................................................................................................... 20
Numeric Keypad ................................................................................................................... 22
Help Screen ........................................................................................................................... 22
Main Screen .......................................................................................................................... 23
Shape Manager Screen .......................................................................................................... 26
Files ....................................................................................................................................... 28
Setups Screen ........................................................................................................................ 30
Change Consumable ............................................................................................................. 31
Remote Help .............................................................................................................................. 33
Install Shared View ............................................................................................................... 33
Use Remote Help .................................................................................................................. 34
Setups ......................................................................................................................................... 37
Cutting................................................................................................................................... 37
Process .................................................................................................................................. 43
Oxy Fuel................................................................................................................................ 44
Plasma ................................................................................................................................... 52
HD3070 Auto Gas Interface ................................................................................................. 56
HD4070 and HPR Overview ................................................................................................ 59
FineLine Overview ............................................................................................................... 65
Marker ................................................................................................................................... 71
Laser Overview ..................................................................................................................... 75
Laser Cut Chart Screen ......................................................................................................... 81
Water Jet ............................................................................................................................... 87
Watch .................................................................................................................................... 89
iii
Shape Manager.......................................................................................................................... 93
Shape Library ........................................................................................................................ 93
Text Editor ............................................................................................................................ 94
Shape Wizard ........................................................................................................................ 95
Teach Trace ........................................................................................................................... 97
Nester .................................................................................................................................. 102
Manual Nesting ................................................................................................................... 103
Nester Setup ........................................................................................................................ 105
Using Nester........................................................................................................................ 106
HyperNest – CNC Automatic Nesting Software ................................................................ 109
Automatic Nesting Setup .................................................................................................... 110
Using HyperNest – CNC .................................................................................................... 112
HyperCAD .......................................................................................................................... 119
HyperNEST......................................................................................................................... 121
Files........................................................................................................................................... 123
Load from
Disk ................................................................................................................... 123
Resume Last Part Features .................................................................................................. 125
Save to Disk ........................................................................................................................ 126
Download from Host ........................................................................................................... 129
Upload to Host .................................................................................................................... 131
Loading Invalid Files .......................................................................................................... 132
Library Shapes ........................................................................................................................ 135
Rectangle............................................................................................................................. 136
Circle ................................................................................................................................... 138
Triangle ............................................................................................................................... 140
L-Bracket ............................................................................................................................ 142
Trapezoid ............................................................................................................................ 144
Slant Rectangle ................................................................................................................... 146
Gambrel Rectangle .............................................................................................................. 148
Roofed Rectangle ................................................................................................................ 150
4-Sided Polygon .................................................................................................................. 152
5-Sided Polygon .................................................................................................................. 154
Oval ..................................................................................................................................... 156
Circle with Flat Side ........................................................................................................... 158
Circle Slice .......................................................................................................................... 160
Straight Slots ....................................................................................................................... 162
Angled Slots ........................................................................................................................ 164
Horizontal Rip ..................................................................................................................... 166
Vertical Rip ......................................................................................................................... 168
Flange .................................................................................................................................. 170
Circle with Rectangular Hole .............................................................................................. 172
Gusset .................................................................................................................................. 174
8-Sided ................................................................................................................................ 176
Rectangle with Convex Corners ......................................................................................... 178
Rectangle with Concave Corners ........................................................................................ 180
L-Bracket with Elbow Radii ............................................................................................... 182
iv
Slant L-Bracket with Elbow Radii ...................................................................................... 184
Flange Slice ......................................................................................................................... 188
Elbow .................................................................................................................................. 190
Flange Repair Ring ............................................................................................................. 192
Rectangle with Rectangular Hole ....................................................................................... 194
Rectangle with Circular Hole .............................................................................................. 196
Rectangle with Circular Hole and Convex Corners ............................................................ 198
Rectangle with Tab ............................................................................................................. 200
Rectangle with Convex Tab ................................................................................................ 202
Rectangle with Notch .......................................................................................................... 204
Concave Rectangle .............................................................................................................. 212
Triangle with Concave Side ................................................................................................ 214
Polygon with Concave Side ................................................................................................ 216
Slant Rectangle with Radius ............................................................................................... 218
Slant Rectangle with Circular Hole .................................................................................... 220
Slant Rectangle with Beveled Corners ............................................................................... 222
Cross ................................................................................................................................... 224
Cross with Circular Hole and Concave Inside Corners ...................................................... 226
4 Sided Convex Rectangle .................................................................................................. 228
4 Sided Concave Rectangle ................................................................................................ 230
Pipe Mount .......................................................................................................................... 232
Bolt Hole Circle .................................................................................................................. 234
Bolt Hole Flange ................................................................................................................. 236
Bolt Hole Rectangle ............................................................................................................ 238
Bolt Hole Rectangle with Convex Corners ......................................................................... 240
Bolt Hole Rectangle with Center Hole ............................................................................... 242
Bolt Hole Rectangle with Center Hole and Convex Corners ............................................. 244
Rounded L-Bracket ............................................................................................................. 246
Horseshoe ............................................................................................................................ 248
Convex Roof Trapezoid with Hole ..................................................................................... 250
Convex Roof Polygon with Hole ........................................................................................ 252
Convex Roof Polygon with Oval Hole and Concave Bottom ............................................ 254
Pulley Cover........................................................................................................................ 256
Paddle Blind ........................................................................................................................ 258
Water Pump Gasket ............................................................................................................ 260
Frame .................................................................................................................................. 262
Pulley .................................................................................................................................. 264
Sprocket .............................................................................................................................. 266
Text ..................................................................................................................................... 268
Test Pattern ......................................................................................................................... 270
Part Options ............................................................................................................................ 271
Repeat ................................................................................................................................. 273
Align ................................................................................................................................... 276
Align Wizard ....................................................................................................................... 276
Manual Part Alignment ....................................................................................................... 277
Automatic Plate Alignment (APA) ..................................................................................... 278
v
Cut Operations ........................................................................................................................ 283
CutPro Wizard .................................................................................................................... 283
Cutting in Manual Mode ..................................................................................................... 283
Multitasking ........................................................................................................................ 287
Pause......................................................................................................................................... 289
Change Consumable ........................................................................................................... 295
Manual ..................................................................................................................................... 297
Manual Options ................................................................................................................... 303
Home Axes.......................................................................................................................... 305
Diagnostics ............................................................................................................................... 307
Control Information ............................................................................................................ 307
I/O ....................................................................................................................................... 309
Analog Input Diagnostics ................................................................................................... 312
Serial Port............................................................................................................................ 313
Drives and Motors............................................................................................................... 315
SERCOS Drives and Motors .............................................................................................. 317
Error Messages.................................................................................................................... 320
Norton Ghost Utility ........................................................................................................... 325
Password Setups ...................................................................................................................... 329
Machine............................................................................................................................... 330
SERCOS ............................................................................................................................. 333
Speeds ................................................................................................................................. 336
CBH Speed Setups .............................................................................................................. 339
THC Speed Setups .............................................................................................................. 339
Torch Height Disable .......................................................................................................... 341
Ports .................................................................................................................................... 343
I/O ....................................................................................................................................... 348
Speed Pot and Joystick Overview ....................................................................................... 350
Axes – Transverse or Rail ................................................................................................... 364
Axes -- Dual Gantry ............................................................................................................ 369
Axes -- CBH ....................................................................................................................... 372
Axes -- Rotate ..................................................................................................................... 375
Axes -- Tilt .......................................................................................................................... 376
Axes -- Transverse 2 ........................................................................................................... 377
Station Configuration .......................................................................................................... 378
Special ................................................................................................................................. 385
System Tools – Windows XP ............................................................................................. 391
Phoenix Link............................................................................................................................ 399
Overview ............................................................................................................................. 399
Files ..................................................................................................................................... 400
Settings ................................................................................................................................ 402
Installation........................................................................................................................... 403
Software .............................................................................................................................. 403
Hardware ............................................................................................................................. 407
Operating Phoenix Link ...................................................................................................... 408
Common Errors ................................................................................................................... 408
vi
Error Messages.................................................................................................................... 409
Sensor THC ............................................................................................................................. 411
Overview ............................................................................................................................. 411
Cut Setups ........................................................................................................................... 412
Plasma Setups ..................................................................................................................... 413
Marker Setups ..................................................................................................................... 417
Process Watch ..................................................................................................................... 419
Main Cut Screen ................................................................................................................. 420
Sensor THC Setups ............................................................................................................. 421
Sensor THC Axis Setups .................................................................................................... 422
THC Speeds ........................................................................................................................ 424
THC I/O .............................................................................................................................. 425
Command THC ....................................................................................................................... 429
Main Cut Screen ................................................................................................................. 433
Diagnostics .......................................................................................................................... 435
Machine Interface ............................................................................................................... 435
Motion Overview ..................................................................................................................... 437
Closed Loop Servo Control ................................................................................................ 437
Encoders .............................................................................................................................. 438
Encoder Counts and Maximum Machine Speed ................................................................. 440
Motion Tuning Watch Windows ........................................................................................ 445
SERCOS Interface Overview ............................................................................................. 447
ASCII Codes ............................................................................................................................ 449
0BProgram Codes ........................................................................................................................ 451
1BEIA RS-274D ...................................................................................................................... 451
2B2BESSI .................................................................................................................................... 459
3B3BAdvanced Feature Codes ................................................................................................... 463
4BStation Selects ..................................................................................................................... 464
5BAutomatic Torch Spacing ................................................................................................... 465
6BSensor THC Part Program Support ..................................................................................... 468
7BSubparts............................................................................................................................... 469
8BMarker Font Generator ....................................................................................................... 471
9BSerial Messaging ................................................................................................................. 475
Automated Plasma Interface ................................................................................................. 485
HPR and HD4070 Interface ................................................................................................ 485
Cut Charts ........................................................................................................................... 486
Custom Cut Charts .............................................................................................................. 490
Change Consumable ........................................................................................................... 493
HD4070 Diagnostics ........................................................................................................... 494
HPR Diagnostics ................................................................................................................. 495
HD3070 Auto Gas Interface ............................................................................................... 504
FineLine Overview ............................................................................................................. 507
Serial Ports .............................................................................................................................. 515
Control RS-232C DB-9 Pinout ........................................................................................... 515
RS-232C Connections to Host PC with 9-pin D-type connector ........................................ 516
RS-232C Connections to Host PC with 25-pin D-type connector ...................................... 516
vii
Automatic DXF Import .......................................................................................................... 517
Overview ............................................................................................................................. 517
Load DXF Files................................................................................................................... 517
Raw DXF Files ................................................................................................................... 518
Prepared DXF Files............................................................................................................. 520
Networking .............................................................................................................................. 523
Network Operating System ................................................................................................. 523
Configuring the Network Interface Card ............................................................................ 523
Connecting the CNC to a Network ..................................................................................... 524
Mapping a Connection to a Network Share ........................................................................ 524
Connecting the CNC to a Workgroup ................................................................................. 527
Hardware Considerations .................................................................................................... 529
MicroEdge ............................................................................................................................... 535
Overview ............................................................................................................................. 535
Keyboard Layout ................................................................................................................ 536
System Requirements.......................................................................................................... 536
Machine Interface ............................................................................................................... 537
I/O Configuration ................................................................................................................ 538
I/O Interface ........................................................................................................................ 539
THC and Joystick Interface ................................................................................................ 544
Calibration........................................................................................................................... 548
Edge Ti ..................................................................................................................................... 549
Overview ............................................................................................................................. 549
Machine Interface ............................................................................................................... 550
I/O Configuration ................................................................................................................ 551
I/O Interface ........................................................................................................................ 552
Lifter Interface .................................................................................................................... 555
Plasma Interface .................................................................................................................. 556
External Interlock................................................................................................................ 557
Voyager III .............................................................................................................................. 561
Overview ............................................................................................................................. 561
Setups .................................................................................................................................. 563
Common Status Messages .................................................................................................. 564
Machine Interface ............................................................................................................... 565
SERCOS to Analog Conversion Card ................................................................................ 570
Mariner .................................................................................................................................... 573
Overview ............................................................................................................................. 573
Touch Screen ...................................................................................................................... 573
THC, Joystick and Speedpots ............................................................................................. 573
AC Input Pinout .................................................................................................................. 574
E-Stop ................................................................................................................................. 574
Diagram Location Din-02 ................................................................................................... 574
SERCOS Motion and I/O.................................................................................................... 574
viii
Safety
Product Listings
MicroEdge and Voyager III
Note: This product has been designed and manufactured in accordance with CE and UL Safety
Standards.
UL has successfully tested and listed these products in accordance with the applicable U.S. and
Canadian Safety Standards. File number E178333. Note: Suitable for pollution degree 2
environment only.
This appliance has been successfully tested and listed by CE under the following standards; EN
500081-2 1994, EN 61000-6-2 1999, and EN 55011:1998. Certificate number: Retlif R-3909N
Edge TI
Note: This product has been designed and manufactured in accordance with CE and UL Safety
Standards.
UL has successfully tested and listed these products in accordance with the applicable U.S. and
Canadian Safety Standards. File number E307226.
Additional markings:
1. Use minimum 75° C copper wire only.
2. Use copper conductors only.
3. Suitable for use on a circuit capable of delivering not more than 5000rms symmetrical
amperes, 230 volts maximum.
4. Solid state motor overload protection is not provided on this device.
5. Integral solid state short circuit protection does not provide branch circuit protection.
Branch circuit protection provided by integral LISTED branch circuit protection fuse.
This appliance has been successfully tested and listed by CE under the following standards; EN 5000812 1994, EN 61000-6-2 1999, and EN 55011:1998. Certificate number: Retlif R-3909N
Please contact Hypertherm Automation for further safety listing information.
1
2 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
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.
• WARNING safety messages precede related
instruc tions 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
damage to equipment if not followed correctly.
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.
CUTTING CAN CAUSE FIRE OR EXPLOSION
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
• When cutting aluminum underwater, or with the
water touching the underside of the aluminum, free
hydrogen gas may collect under the workpiece and
detonate during plasma cutting operations.
• Install an aeration manifold on the floor of the water
table to eliminate the possibility of hydrogen
detonation. Refer to the Appendix section of this
manual for aeration manifold details.
Safety 3
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.
ELECTRIC SHOCK CAN KILL
• 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.
Use proper precautions when handling printed
circuit boards.
STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS
• Store PC boards in anti-static containers.
• Wear a grounded wrist strap when handling
PC boards.
4 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.
TOXIC FUMES CAN CAUSE INJURY OR DEATH
The air quality level in any relevant workplace
depends on site-specific variables such as:
• Table design (wet, dry, underwater).
• Material composition, surface finish, and
composition of coatings.
• Volume of material removed.
• Duration of cutting or gouging.
• Size, air volume, ventilation and filtration of the
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.
Safety 5
Instant-On Torches
Plasma arc comes on immediately when the torch
switch is activated.
A PLASMA ARC CAN CAUSE INJURY AND BURNS
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.
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 or 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 arcʼs
ultraviolet and infrared rays.
Lens Shade
Arc Current AWS (USA) ISO 4850
Up to 100 A No. 8 No. 11
100-200 A No. 10 No. 11-12
200-400 A No. 12 No. 13
Over 400 A No. 14 No. 14
ARC RAYS CAN BURN EYES AND SKIN
Skin Protection Wear protective clothing to protect
against burns caused by ultraviolet light, sparks and
hot metal.
• Gauntlet gloves, safety shoes and hat.
• 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.
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 or
local electrical codes.
GROUNDING SAFETY
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.
6 Safety
ADDITIONAL SAFETY INFORMATION
1. ANSI Standard Z49.1,
Safety in Welding and Cutting,
American
Welding Society, 550 LeJeune Road
P.O. Box 351020, Miami, FL 33135
2. ANSI Standard Z49.2,
Fire Prevention in the Use of Cutting and
Welding Processes,
American National Standards Institute
1430 Broadway, New York, NY 10018
3. ANSI Standard Z87.1,
Safe Practices for Occupation and
Educational Eye and Face Protection,
American National
Standards Institute, 1430 Broadway, New York, NY 10018
4. AWS F4.1,
Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers and Piping That Have Held
Hazardous Substances,
American Welding Society
550 LeJeune Road, P.O. Box 351040, Miami, FL 33135
5. AWS F5.2,
Recommended Safe Practices for Plasma Arc
Cutting,
American Welding Society
550 LeJeune Road, P.O. Box 351040, Miami, FL 33135
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
• 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 or local codes.
GAS CYLINDERS CAN
EXPLODE IF DAMAGED
COMPRESSED GAS EQUIPMENT SAFETY
Gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode.
• Handle and use compressed gas cylinders in
accordance with applicable national or 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.
Prolonged exposure to noise from cutting or gouging
can damage hearing.
• Use approved ear protection when using plasma
system.
• Warn others nearby about the noise hazard.
NOISE CAN DAMAGE HEARING
Pacemaker and hearing aid operation can be affected
by magnetic fields from high currents.
Pacemaker and hearing aid wearers should consult a
doctor before going near any plasma arc cutting and
gouging operations.
To reduce magnetic field hazards:
• Keep both the work 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.
PACEMAKER AND HEARING
AID OPERATION
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.
Safety 7
WARNING LABEL
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 Keep flammables away from cutting.
1.2 Keep a fire extinguisher nearby, and have
a watchperson ready to use it.
1.3 Do not cut on any closed containers.
2. The plasma arc can cause injury and
burns.
2.1 Turn off power before disassembling torch.
2.2 Do not hold the material near cutting path.
2.3 Wear complete body protection.
3. Electric shock from torch or wiring can kill.
Protect yourself from electric shock.
3.1 Wear insulating gloves. Do not wear wet or
damaged gloves.
3.2 Insulate yourself from work and ground.
3.3 Disconnect input plug or power before
working on machine.
4. Breathing cutting fumes can be hazardous
to your health.
4.1 Keep your head out of the fumes.
4.2 Use forced ventilation or local exhaust to
remove the fumes.
4.3 Use ventilating fan to remove the fumes.
5. Arc rays can burn eyes and injure skin.
5.1 Wear hat and safety glasses. Use ear
protection and button shirt collar. Use
welding helmet with correct shade of filter.
Wear complete body protection.
6. Become trained and read the instructions
before working on the machine or cutting.
7. Do not remove or paint over (cover)
warning labels.
www.hypertherm.com/weee
110647 Rev. A
8 Safety
Overview
The following sections highlight the features of the Hypertherm Automation CNC and version
8.0 of the Phoenix® software.
CutPro Wizard
The CutPro™ wizard is an interactive tool that simplifies the steps of cutting a part. The CutPro
wizard helps you:
• Load a part program
• Select a cut process
• Align a plate and adjust for skew
• Set scrap clearance
• Select cut mode
• Start the cut directly from the wizard or by pressing the green Start button on the console
The wizard opens automatically from the Main screen after 10 seconds. Automatic activation
can be disabled on the Special password setup screen. However, the wizard is always
accessible by pressing the CutPro Wizard soft key on the Main screen.
Align Wizard
The Align™ wizard is an interactive tool that guides you through the process of aligning a plate
and adjusting for a skewed plate. This wizard can be accessed from the CutPro Wizard or from
the Align screen.
Remote Help
The Remote Help™ facility is an easy-to-use and reliable means of remotely connecting the
Hypertherm Automation CNC to up to 15 users for:
• Observing an operator at the machine
• Reviewing settings and software configurations
• Transferring setup files, part programs, software updates, etc.
• Performing HPR diagnostics
• Training users
ShapeWizard
The ShapeWizard
on the internal hard disk present in the control.
®
tool allows you to graphically create simple part programs and store them
Teach/Trace
9
Overview
If your system is configured with a tracing head, you can use the control to digitize almost any
pattern, store it on the internal hard disk, and further customize the program with ShapeWizard.
The control has both smart-arc and smart-line translators to provide you with optimum program
resolution.
Shape Libraries
Graphically select the desired shape from the parts library. Then you simply add the dimensions
you want, and the scaled part, with your entered dimensions, will be displayed. There is even a
Help Icon to step you through the data entry.
Program Upload and Download
Communication is an integral part of today’s fabricating shop. All part programs that have
been entered in the control can be uploaded to a remote computer or file server with an
integrated RS-232C/ RS-422 communications link. CAD generated programs can be
downloaded at baud rates of up to 115K baud and visually previewed on the color LCD display.
Visual representation of part programs, along with full alpha-numeric file name support, gives
you the flexibility to manage your data as you see fit. Use of the optional Network Card allows
us to bring the latest in communication technology for increased speed and productivity to your
shape cutting controller. Additionally, built-in Control monitoring features allow current
operational status to be displayed at the host Link screen.
SoftMotion
SoftMotion is a proprietary data buffer and interrupt structure that allows the control to generate
all of its motion control algorithms from the main Pentium® Processor. This architecture allows
SoftMotion to tightly couple the motion control and I/O logic to the operator interface.
Cutting Options
Flexibility in your cutting operation is the key to success. The control comes standard with the
following cutting functions to help you optimize material and plate usage. These functions
work on any program. After selecting one of these functions, the new part will be graphically
displayed.
Mirror function
The mirror function can be used to create a mirror image of the part along either the X or Yaxis.
Rotate function
The rotate function can be used to rotate the current part.
Scale function
The scale function can be used to increase or decrease the current part by a programmed ratio.
Repeat function
10
Overview
The repeat function duplicates the part shape in either a straight, staggered or nested grid
patterns.
Programming Features
• English and metric operation for worldwide use. Each axis can have its own encoder-to-
unit edge rate.
• Dynamic kerf compensation with programmable kerf value.
• Automatic corner and plate alignment with programmable scrap clearance.
• Shape Repeat with three grid patterns (straight, stagger, and nested) allows fast cutting of
multiple pieces.
• Part mirroring in both X and Y axes.
• Part rotation.
• Scaling allows quick part resizing to original size.
• Virtually no limit to the number of program names or work file folders that can be stored on
the internal hard disk drive.
• Punch or powder marker control with twelve programmable offsets.
• Choice of industry-standard EIA RS-274D or ISO 6582 ESSI part programming languages.
Manual Data Input (MDI)
• Full screen ASCII text editor.
• Allows writing, editing, and graphical review of part programs at the machine.
Communications Link
• Preview Mode allows machine operator to graphically review and select programs for
download.
• Download part programs from CAD system, remote host computer, or other storage device
via built-in RS-232C/ RS-422 port.
• Can accept EIA RS-274D or ESSI part programs.
• Baud Rates of up to 115K Baud. Communication baud rates of 230K are obtainable using
the communication link software provided with the control.
• Optional network card for connecting directly to a PC Network for part file allocation.
Graphical program display
• Visually display any part program.
• Display of real-time position and I/O information.
• Display of actual cut path while cutting.
Built-in Parametric Shape Library
• Contains 68 commonly used shapes.
• Simple Graphical prompts for entering all part dimensions.
11
Overview
Teach/Trace
• Smart-arc and Smart-Line algorithms for optimum program size and contouring
smoothness.
• Converts your existing optical tracer templates to EIA RS-274D programs, and stored on
the internal hard disk drive.
• Automatic part closure detection.
• Allows multiple pierce points, lead-ins, lead-outs, and rapid traverse segments.
• Upload taught part programs to CAD system, remote host computer, or other storage
device.
• Requires a separate optical tracer control system.
Performance Features
• Digital servo positioning control for any cutting machine. An optional SERCOS Interface
allows expansion of motion axes and distributed I/O.
• Control dynamic accuracy of 0.002 inch (0.051 mm) with 1000 edge/inch encoders.
• Programmable cut speeds up to 3000 IPM (76,200 mmpm).
• Variable segment length look-ahead for optimum contouring performance.
• Automatic corner slowdown and torch height disable for clean, sharp corners.
• Speed Increase/Decrease buttons for optimizing machine cut speed.
• Automatic Plate and Corner Alignment corrects for skewed plates.
• Complete cut-loss recovery with backup and forward along path, off-path re-pierce and
return-to-path, and move pattern functions.
• Rip Mode for straight-line cutting. Jog control cutting.
• Punch, powder or Plasma marker capability.
• Manual jog control with position read-out for positioning torches.
• Nester™ and optional HyperNest
productivity and increased plate utilization.
• Automated Torch Spacing feature to position torch station spacing automatically through
the part program for standard and mirrored multi-torch cutting.
• Rush Job Interrupt and Automated Power Loss Recovery features.
®
– CNC Automatic Nesting features for increased
Installation and Setup Features
• Selectable axis orientation for compatibility with all cutting machines.
• Built in oxy-fuel interface with programmable pre-heat time, ignition, and creep speed.
• Built in plasma interface with programmable purge time, ignition time, arc-off delay time,
and arc-transferred feedback.
• Built in Laser interface with programmable shutter time, power ramp time and pierce time.
• Built in Water Jet interface with programmable abrasive output and pierce time.
12
Overview
• Programmable servo gains, speeds, Watch Window, machine parameters, and com-
munication parameters for flexible application.
• Interfaces easily to most optical tracing systems for integrated control.
• Complete built-in diagnostics for checkout and test.
Hardware Specifications
• 15” TFT Touch Screen with 1024 x 768 resolution.
• ≥60Gbyte hard disk
• ≥1.3 GHz Processor.
• 512 Mbytes of RAM.
• Up to 96 lines of interface signals for cutting and motion logic (gas control, tracing system,
markers, homing, etc.) depending on I/O configuration. An optional SERCOS Interface™
allows expansion of I/O configuration.
• Industrial grade enclosure and keypad designed to minimize RFI/EMI interference.
• Surface mount printed circuit board technology.
• Two axes optically isolated ±10VDC drive outputs and incremental encoder inputs which
are expandable to 6 axes of motion. Up to twelve axes of motion and 1024 I/O available
with optional SERCOS Interface. Optional axes available for dual gantry, dual transverse,
contoured bevel head, two rotate, two tilt angle and eight Sensor™ THC applications..
• +5VDC single ended or differential encoder inputs.
• Optically isolated serial ports with programmable baud rates to 115 K baud.
Communication baud rates of 230K are obtainable using the communication link software
provided with the control. Optional Network Card for connecting directly to a PC Network.
• Universal power input (100-240 VAC; 47-63Hz). Individual models may vary. Refer to
machine interface information for details.
• Operating environment: 0 to 50°C (32 to 122°F); 95% relative humidity (non-condensing).
• An optional Chiller for Mariner style controls is available.
Model Numbering System
The control is available with the following hardware and software configurations. Features and
control configuration options in software are based on the I/O configuration of the control.
Generally, the information presented in this guide is based on the I/O configuration as outlined
below. Please refer to your control I/O configuration for available features and product
information. The specific configuration is determined by the Model Number, as shown below:
13
Overview
H
Axis Configuration
2 = 2 Servo Axes
3 = 3 Servo Axes
4 = 4 Servo Axes
5 = 5 Servo Axes
6 = 6 Servo Axes
7 = 7 Servo Axes
8 = 8 Servo Axes
9 = 9 Servo Axes
A = 10 Servo Axes
B = 11 Servo Axes
C = 12 Servo Axes
S = Sercos
I / O Configuration
B = Burny 3 / 5
M = MicroPath
P = PicoPath
V = Voyager
S = Sercos
D = Edge Ti - DC amps
Power Supplies
0 = Standard Logic Supply
2 = Standard Logic Supply &
Auxiliary Supply with
+5, +/-12 & +24 vdc
Pointing Device
0 = None
1 = Industrial Mouse
LCD Type
X = None
0 = 10.4" Dual Scan DSTN
1 = 10.4" Active Matrix TFT
2 = 15" Active Matrix TFT
3 = 15" Touch Screen
4 = 12.1" Active Matrix TFT
-
Memory
0 = 16 MBytes
1 = 32 MBytes
2 = 64 MBytes
3 = 128 MBytes
4 = 256 MBytes
5 = 512 MBytes
--
Operating System
0 = Windows 95 / 98
1 = Windows NT
2 = Windows XP
APC
0 = None
1 = Laser
2 = Plasma
THC
0 = None
1 = 1 THC
2 = 2 THC's
Speed Pots
0 = None
1 = 1 Speed Pot
2 = 2 Speed Pots
Joystick
0 = None
1 = Joystick
Backup Hard Drive
0 = None
1 = Installed
Processor
0 = 166 MHz
1 = 200 MHz
2 = 266 MHz
3 = 433 MHz
4 = 566 MHz
5 = 1.2 GHz
6 = 2.4 GHz
7 = 3.06 GHz
8 = 1.3 GHz M
Front Panel Layout
This software is designed specifically for 15” TFT Touch Screen operation with 1024 x 768 or
higher resolution and is used on all CNC models. Individual man machine interface (MMI) and
front panels may vary.
Power Switch
Hypertherm Automation controls are equipped with a momentary contact power switch. Press
briefly and release for controlled power on and power off the control. Pressing the power
switch for 10 seconds will force a hard system shutdown of Windows and the control.
Generally, a hard shutdown is not recommended.
Touch Screen
14
Overview
The touch screen software interface allows direct key input on the screen through the use of
check boxes, radial boxes, drop down selections and data input. Data input boxes will
automatically display a numeric or alphanumeric keypad depending on data type.
Front Panel (selected models)
ICON Legend
Emergency Stop
Start
Stop
Forward and Backward on Path
Torch Up / Down
Manual
Speed Pot (Manual Feedrate)
Front Panel Keypad (Voyager III model)
The yellow key labeled with a question mark (?) is for online documentation and help. Simply
press this key at any time and this document will be displayed.
The keys to the lower right of the front panel comprise the alpha numeric keypad, which is used
for entering data. To the far left are keys which control manual motion and cursor location
during data input. These include the MANUAL key (for Manual Mode jogs) and the eight
arrow keys (for jog and cursor direction).
The two keys in the center of the keypad are for program start and stop.
15
Overview
The two keys to the right of the yellow help key are for Forward on Path and Backup on Path
while in the Pause screen.
Key Functions
The alpha–numeric keypad is used to enter numeric data or
text. To enter a number, simply press the key. To enter a
word, press and hold the matching colored shift key (up arrow)
while pressing the desired letter key. The + (plus) and –
(minus) keys are used to add and delete features at selection
and check boxes.
An alternate (ALT) soft key indicates that more
soft keys and features are available by pressing
this soft key on screen.
When the alternate soft key is displayed, the
purple shift can also be used to view additional
soft keys.
These keys activate jogging using the arrow keys when in the manual
mode. Manual key functions (indicated in green) are available at the
Manual, Pause and Align Screens. This keypad is also used for
navigating through a multi-variable dialog box (indicated in yellow).
The Prev/Next buttons are used to move through the field boxes, Page
Up/Down is used to scroll and the arrow keys are used to select items
in a dialog box.
16
Pressing the space key inserts a space into the current data entry field. The space key is also
used to toggle between fixed logic settings ( i.e. setups - preheat sense input open/closed ).
The space key may also be used to add and delete features at selection and check boxes.
Deletes the current character in the data entry field and backs up one position in the field.
Located above the Back Space key are the * and ? characters which are used as wild cards
to search for files.
Can be pressed at any time (except during cut) to return to the previous menu without
saving any changes. Located above the Cancel key are the \ and : characters which are
used for mapping network drives.
Causes the last number entered/toggled to be accepted. Located above the enter key are
the < and > characters which are used for mapping network drives.
PC Keyboard Layout
Overview
Available as standard on selected models but may be added to all controls.
17
Overview
Keyboard Functions
Function Keys F1-F8 are equivalent to the soft keys on the display screen.
Function Key F9 is equivalent to the START key.
Function Key F10 and Pause Key are equivalent to the STOP key.
Function Key F11 is equivalent to the MANUAL MODE key.
Function Key F12 is equivalent to the HELP key.
Arrow direction keys are used for manual motion.
The HOME key is equivalent to the PREV field key.
The END key is equivalent to the NEXT field key.
The [ key is equivalent to the purple arrow shift key.
The ] key is equivalent to the blue arrow shift key.
The Esc key is equivalent to the CANCEL key.
To exit the control software press Alt F4. Warning: This will terminate the current application.
To switch between applications press Alt Tab. Warning: The selected application window to be
on top of the desktop and may cover or hide the control software application window.
Operation Summary
The programming and operation of the control is menu-driven. The following diagram shows
the Screen Hierarchy for the menu structure.
The menu that appears in the display when the unit is first turned on is referred to throughout
this manual as the Main Menu. All other menus and functions are accessed at some level under
Main Menu, or else appear as part of a special operational sequence, such as when the cutting
process is interrupted during the middle of a part.
18
Overview
The OK and CANCEL keys have special functions in relation to the menu structure. The OK
soft key returns to the menu from which the present selection was entered and retains any
changes that were made. The CANCEL key returns to the menu from which it was entered and
deletes/discards any changes that were made. There are, however, some operations during
which CANCEL is not active.
Screen Hierarchy
Main Screen
Cut Chart
Load from Disk
Save to Disk
Save Log to Disk
Download from Host
Upload to Host
Setups
Cut Types Password 1Diagnostics
Oxy Fuel
Timing Diagram
Water Jet
Timing Diagram
Plasma
Timing Diagram
Cut Chart
Marker
Timing Diagram
Cut Chart
Laser
Timing Diagram
Cut Chart
Process Monitoring
Change Consumable
Manual
Control Information
I / O
Oscilloscope
Serial Port
Drives and Motors
Plasma System
Manual Options
Manual Options
Home Axes
Inputs
Outputs
Analog Inputs
Inputs
Outputs
Supply Information
Part OptionsFiles
Repeat
Align
Manual Options
Speeds
Link
I/O
Sercos
Axes
Transverse
Rail
Dual Gantry
CBH
Tilt
Rotate
THC
Lens
Cut
Pause
Change Consumable
Manual Options
Cutting
WatchMachine
Password 3
Station Configuration
Password 2
System Tools
Backup Hard Drive
Scan Hard Disk
Defrag Hard Disk
Format Floppy Disk
Network Tools
Remote Assistant
Shape Manager
Shape Library
Simple Shape
View Text
Part Options
Repeat
Align
Manual Options
Nester
Nester Setups
Load from Disk
Download from Host
Shape Library
Simple Shape
Shape Wizard
Part Options
Repeat
Align
Manual Options
19
Text Editor
Teach Trace
HyperCAD
HyperNest
Overview
Key and Menu Functions
The following is a short form description of all menu functions in the control. This is only a
brief description of each function. Please consult the subsequent manual sections for more
complete information on operational usage of specific keys. Note: Screens and features will
vary depending on interface selection of Beginner, Intermediate or Advanced. For
convenience, information provided here is in Advanced Mode showing all options.
Screen Navigation
The eight keys located directly at the bottom of the display act as programmable soft keys. Soft
keys allow many different functions to be included without an excessive number of separate
keys. It also provides complete flexibility for future software features and enhancements.
Soft keys to accept (OK) and reject (Cancel) changes.
The touch screen software interface allows direct key input on the screen through the use of
check boxes, radio boxes, dropdown lists and data input.
20
Overview
Dropdown List
Press the arrow in the dropdown list to view options.
Radio Buttons
Press the round button to select the corresponding option.
Check Box
Press the square box to enable the corresponding option.
Data Input
Data input boxes automatically displays a numeric or alphanumeric keypad depending on data
type. Double click on the field to enter data.
Alpha Numeric Keypad
21
Overview
Numeric Keypad
Help Screen
This controller is equipped with an easy to follow help screen function. To access the internal
help screens press the Help soft key. Help information for the screen currently being accessed
will be displayed. Pressing the OK soft key will exit the help screens and return you to the last
control screen accessed.
22
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