ArcGlide® THC
Torch Height Control
Instruction Manual
806450 | Revision 5 | English
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© 2015 Hypertherm Inc.
ArcGlide
Instruction Manual
806450
Revision 5
English
March 2015
Hypertherm Inc.
Hanover, NH 03755 USA
Hypertherm Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
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
Contents
Safety ....................................................................................................................................... SC-13
Recognize safety information ...............................................................................................................................................SC-13
Follow safety instructions ......................................................................................................................................................SC-13
Electrical hazards ....................................................................................................................................................................SC-13
Electric shock can kill ............................................................................................................................................................SC-14
Cutting can cause fire or explosion ....................................................................................................................................SC-15
Fire prevention .................................................................................................................................................................SC-15
Explosion prevention ......................................................................................................................................................SC-15
Toxic fumes can cause injury or death ...............................................................................................................................SC-16
Grounding safety ....................................................................................................................................................................SC-17
Static electricity can damage circuit boards ....................................................................................................................SC-17
A plasma arc can cause injury and burns .........................................................................................................................SC-18
Compressed gas equipment safety ...................................................................................................................................SC-18
Gas cylinders can explode if damaged .............................................................................................................................SC-18
Arc rays can burn eyes and skin .........................................................................................................................................SC-19
Pacemaker and hearing aid operation ...............................................................................................................................SC-20
Noise can damage hearing ...................................................................................................................................................SC-20
A plasma arc can damage frozen pipes ............................................................................................................................SC-20
Dry dust collection information ............................................................................................................................................SC-21
Laser radiation .........................................................................................................................................................................SC-22
Additional safety information ................................................................................................................................................SC-22
Warning labels ........................................................................................................................................................................SC-23
Symbols and marks ................................................................................................................................................................SC-25
Product Stewardship ...........................................................................................................SC-27
Introduction ..............................................................................................................................................................................SC-27
National and local safety regulations ..................................................................................................................................SC-27
Certification test marks .........................................................................................................................................................SC-27
ArcGlide THC Instruction Manual 806450 5
Contents
Differences in national standards .......................................................................................................................................SC-27
Safe installation and use of shape cutting equipment ...................................................................................................SC-27
Procedures for periodic inspection and testing ..............................................................................................................SC-27
Qualification of test personnel .............................................................................................................................................SC-28
Residual current devices (RCDs) .......................................................................................................................................SC-28
Higher-level systems ..............................................................................................................................................................SC-28
Environmental Stewardship .............................................................................................. SC-29
Introduction ..............................................................................................................................................................................SC-29
National and local environmental regulations ...................................................................................................................SC-29
The RoHS directive ................................................................................................................................................................SC-29
Proper disposal of Hypertherm products ..........................................................................................................................SC-29
The WEEE Directive ..............................................................................................................................................................SC-29
The REACH regulation ..........................................................................................................................................................SC-29
Proper handling and safe use of chemicals .....................................................................................................................SC-30
Fumes emission and air quality ...........................................................................................................................................SC-30
Electromagnetic Compatibility (EMC) ............................................................................ SC-31
Introduction ..............................................................................................................................................................................SC-31
Installation and use .................................................................................................................................................................SC-31
Assessment of area ................................................................................................................................................................SC-31
Methods of reducing emissions ..........................................................................................................................................SC-31
Mains supply ....................................................................................................................................................................SC-31
Maintenance of cutting equipment .....................................................................................................................................SC-31
Cutting cables .........................................................................................................................................................................SC-31
Equipotential bonding ....................................................................................................................................................SC-31
Earthing of the workpiece .............................................................................................................................................SC-31
Screening and shielding .......................................................................................................................................................SC-32
Warranty ..................................................................................................................................SC-33
Attention ...................................................................................................................................................................................SC-33
General .....................................................................................................................................................................................SC-33
Patent indemnity .....................................................................................................................................................................SC-33
Limitation of liability ................................................................................................................................................................SC-33
National and local codes ......................................................................................................................................................SC-33
Liability cap ..............................................................................................................................................................................SC-33
Insurance ..................................................................................................................................................................................SC-34
Transfer of rights .....................................................................................................................................................................SC-34
1 Specifications .............................................................................................................................. 35
Introduction .................................................................................................................................................................................... 35
6 ArcGlide THC Instruction Manual 806450
Contents
ArcGlide control module ..................................................................................................................................................... 36
Lifter assembly ....................................................................................................................................................................... 36
Human machine interface (HMI) ........................................................................................................................................ 37
Plasma interface board ........................................................................................................................................................ 37
Industrial Ethernet switch .................................................................................................................................................... 37
Specifications ................................................................................................................................................................................ 38
ArcGlide system .................................................................................................................................................................... 38
ArcGlide control module (090054) .................................................................................................................................. 39
Lifter assembly (090053) ................................................................................................................................................... 40
Optional HMI (090055) ...................................................................................................................................................... 43
Discrete plasma interface board (141094) .................................................................................................................... 44
Hypernet plasma interface board (141162) ................................................................................................................... 45
Ethernet switch ...................................................................................................................................................................... 46
ArcGlide communication ............................................................................................................................................................ 48
Hypernet communication .................................................................................................................................................... 48
Discrete communication ...................................................................................................................................................... 50
Mixed communication .......................................................................................................................................................... 51
Serial communication ........................................................................................................................................................... 51
2 Installation .................................................................................................................................... 53
Hardware setup ............................................................................................................................................................................. 53
Claims ...................................................................................................................................................................................... 53
Installation requirements ..................................................................................................................................................... 54
Placement of system components .................................................................................................................................... 54
Recommended grounding and shielding practices .............................................................................................................. 55
Introduction ............................................................................................................................................................................ 55
Types of grounding ............................................................................................................................................................... 55
Grounding practices ............................................................................................................................................................ 55
System description for a Hypernet configuration .................................................................................................................. 59
System description for a discrete configuration .................................................................................................................... 60
ArcGlide communication configuration examples ................................................................................................................. 61
Install the lifter ................................................................................................................................................................................ 77
Connect the ohmic wire from HPRXD plasma systems .............................................................................................. 79
Connect the ohmic wire to other plasma systems ........................................................................................................ 80
Ground the lifter .................................................................................................................................................................... 80
Extended torch sleeve option ............................................................................................................................................. 81
Install the optional pneumatic breakaway ....................................................................................................................... 82
Install the control module ............................................................................................................................................................ 84
Modify Retract Delay Time for an HT2000 plasma system ........................................................................................ 85
Ground the control module ................................................................................................................................................ 86
Install the optional HMI ................................................................................................................................................................ 87
ArcGlide THC Instruction Manual 806450 7
Contents
Ground the HMI ............................................................................................................................................................................ 89
Install the plasma interface board in a plasma system ......................................................................................................... 90
Discrete plasma interface board (141094) .................................................................................................................... 90
Hypernet plasma interface board (141162) .................................................................................................................. 91
Connect Hypernet cables ........................................................................................................................................................... 92
Connect discrete cables ............................................................................................................................................................. 95
Ground all cables with circular connectors .................................................................................................................... 95
Control module cable connections .................................................................................................................................. 95
Cables ............................................................................................................................................................................................. 97
Power cable ........................................................................................................................................................................... 97
Lifter interface cable ............................................................................................................................................................. 98
Hypernet and HMI interface cable .................................................................................................................................. 100
Optional operator console I/O cable ............................................................................................................................. 101
Optional operator console I/O signals ................................................................................................................... 103
ArcGlide control module CNC interlock kit (228594) ............................................................................................... 104
CNC I/O cable .................................................................................................................................................................... 105
CNC discrete I/O ............................................................................................................................................................... 108
Plasma interface I/O cable ............................................................................................................................................... 110
Plasma discrete I/O ............................................................................................................................................................ 113
Non-serial plasma interface cable .................................................................................................................................. 115
Serial plasma interface cable ........................................................................................................................................... 116
ArcGlide discrete interface signal examples ........................................................................................................................ 117
Inputs ..................................................................................................................................................................................... 117
Relay outputs ....................................................................................................................................................................... 118
ArcGlide setup in Phoenix™ software .................................................................................................................................... 119
Set up ArcGlide and Hypernet ........................................................................................................................................ 119
ArcGlide axis setup ............................................................................................................................................................ 120
ArcGlide axis setup parameters ...................................................................................................................................... 121
Gains ............................................................................................................................................................................. 121
Speeds .......................................................................................................................................................................... 122
Mechanical ................................................................................................................................................................... 123
Miscellaneous .............................................................................................................................................................. 124
Assign an ArcGlide THC to a station ............................................................................................................................ 125
3 Operation .................................................................................................................................... 127
Operator controls ....................................................................................................................................................................... 127
Control module .................................................................................................................................................................... 127
Lifter ....................................................................................................................................................................................... 128
HMI ......................................................................................................................................................................................... 129
Daily operations .......................................................................................................................................................................... 130
Startup procedure .............................................................................................................................................................. 130
8 ArcGlide THC Instruction Manual 806450
Contents
Automatic diagnostic tests ............................................................................................................................................... 130
Verify workpiece sensing .................................................................................................................................................. 130
Shutdown procedure ......................................................................................................................................................... 130
ArcGlide THC operating modes ............................................................................................................................................. 131
Manual mode ....................................................................................................................................................................... 131
Automatic modes ................................................................................................................................................................ 131
Voltage Control Off mode ......................................................................................................................................... 132
Set Arc Voltage mode ................................................................................................................................................ 132
Sample Voltage mode ................................................................................................................................................ 132
Initial height sense ...................................................................................................................................................................... 133
Performing a first IHS on the ArcGlide .......................................................................................................................... 133
Operating the control module .................................................................................................................................................. 135
Screen 0 – Idle Park .......................................................................................................................................................... 136
Screen 1 – ArcGlide control state ................................................................................................................................. 136
Screen 2 – Options ........................................................................................................................................................... 137
Screen 3 – Inputs from the CNC .................................................................................................................................... 138
Screen 4 – Outputs to the CNC .................................................................................................................................... 138
Screen 5 – Inputs from the lifter control board ........................................................................................................... 139
Screen 6 – Outputs from the lifter control board ........................................................................................................ 139
Screen 7 – Inputs from the operator console .............................................................................................................. 140
Screen 8 – Outputs to the operator console ............................................................................................................... 140
Screen 9 – Inputs from the plasma system .................................................................................................................. 141
Screen 10 – Outputs to the plasma system ................................................................................................................ 141
Screen 11 – Last errors .................................................................................................................................................... 142
Screen 12 – Total lifter operating time .......................................................................................................................... 142
Operating the HMI ...................................................................................................................................................................... 143
HMI screen hierarchy ......................................................................................................................................................... 144
Main screen .......................................................................................................................................................................... 146
Setup screen ........................................................................................................................................................................ 147
Diagnostics screen ............................................................................................................................................................. 148
Installation Data screen ..................................................................................................................................................... 153
Manual mode ....................................................................................................................................................................... 155
Lifter Disabled mode .......................................................................................................................................................... 155
ArcGlide operating parameters ............................................................................................................................................... 156
THC mode ............................................................................................................................................................................ 157
Cut chart values .................................................................................................................................................................. 157
Options .................................................................................................................................................................................. 158
Automatically-set parameters ........................................................................................................................................... 158
Plasma cutting tips ..................................................................................................................................................................... 161
Cut quality issues ................................................................................................................................................................ 161
Basic steps to improve cut quality .................................................................................................................................. 164
ArcGlide THC Instruction Manual 806450 9
Contents
4 Maintenance .............................................................................................................................. 169
Introduction .................................................................................................................................................................................. 169
Lifter routine maintenance ........................................................................................................................................................ 169
Carriage ................................................................................................................................................................................ 169
Sealing strip ......................................................................................................................................................................... 171
Cable connections ............................................................................................................................................................. 171
System grounding .............................................................................................................................................................. 171
Calibrate arc voltage .................................................................................................................................................................. 172
Flow of ArcGlide operations .................................................................................................................................................... 174
Basic flow for all ArcGlide operating states ................................................................................................................. 177
Common machine-cutting faults ............................................................................................................................................. 178
Update ArcGlide firmware ........................................................................................................................................................ 180
Download through Phoenix software ............................................................................................................................. 180
Download from a laptop .................................................................................................................................................... 180
Operator tests ............................................................................................................................................................................. 181
Problems and solutions ............................................................................................................................................................. 182
Troubleshooting routines .......................................................................................................................................................... 185
Hypertherm CNC will not communicate with HPR plasma system ........................................................................ 185
Error 19 – Excess plate contact ..................................................................................................................................... 186
Error 21 – Ohmic tip sense .............................................................................................................................................. 188
Error message troubleshooting .............................................................................................................................................. 191
Error message displays ..................................................................................................................................................... 191
ArcGlide errors .................................................................................................................................................................... 191
Printed circuit board (PCB) block diagram for a Hypernet configuration ..................................................................... 209
Printed circuit board (PCB) block diagram for a discrete configuration ....................................................................... 210
ArcGlide PCBs ........................................................................................................................................................................... 211
HMI processor board (228581) ...................................................................................................................................... 211
HMI 7-segment display interface board (228582) ..................................................................................................... 214
THC control interface board (228577) ......................................................................................................................... 215
THC processor board (228578) .................................................................................................................................... 220
Discrete plasma interface board (141094) .................................................................................................................. 224
Hypernet plasma interface board (141162) ................................................................................................................ 228
Lifter interface board (228580) ....................................................................................................................................... 231
5 Parts List ..................................................................................................................................... 235
Lifter parts .................................................................................................................................................................................... 235
Lifter motor and slide parts ...................................................................................................................................................... 237
Control module parts ................................................................................................................................................................. 238
HMI parts ...................................................................................................................................................................................... 239
Plasma interface boards ........................................................................................................................................................... 240
10 ArcGlide THC Instruction Manual 806450
Contents
6 Wiring Diagrams ....................................................................................................................... 241
Wiring diagram symbols ........................................................................................................................................................... 242
1 – Lifter interface board (141097) ....................................................................................................................................... 245
2 – THC control interface board (141088) ......................................................................................................................... 246
3 – THC Processor board (141091) ..................................................................................................................................... 247
4 – HMI processor board (141082) ...................................................................................................................................... 248
A ArcGlide THC Serial Communication Protocol ................................................................ 249
Overview ....................................................................................................................................................................................... 249
ArcGlide THC Operation .......................................................................................................................................................... 249
Serial Protocol ............................................................................................................................................................................. 249
ArcGlide THC Responses ................................................................................................................................................ 250
Calculating the Checksum ............................................................................................................................................... 250
ArcGlide Commands and Examples ...................................................................................................................................... 251
Setup Commands ...................................................................................................................................................................... 252
Operating Commands ............................................................................................................................................................... 255
ArcGlide THC Extended Commands .................................................................................................................................... 260
ArcGlide THC to Command THC error conversions ......................................................................................................... 266
B ArcGlide THC Serial Communication Installation ........................................................... 269
Introduction .................................................................................................................................................................................. 269
Kit 228846 (Command THC replacement) .................................................................................................................. 269
Kit 228851 (New ArcGlide installation) ........................................................................................................................ 270
Specifications .............................................................................................................................................................................. 270
Limitations ............................................................................................................................................................................. 271
RS-422 serial protocol ...................................................................................................................................................... 271
Serial communication configurations ..................................................................................................................................... 272
Replacing a Command THC ............................................................................................................................................ 272
System description for a serial configuration ....................................................................................................................... 274
ArcGlide THC replacement for Command THC ......................................................................................................... 274
ArcGlide THC in a new installation ................................................................................................................................ 275
Connect serial cables ................................................................................................................................................................ 276
Connecting cables for a Command THC replacement ............................................................................................. 276
Connecting cables in a new serial system .................................................................................................................... 278
Cables ........................................................................................................................................................................................... 280
Plasma I/O split cable (Z) (223253) .............................................................................................................................. 280
Adjusting ArcGlide parameters with the HMI ....................................................................................................... 283
Plasma board adapter cable (223260) ......................................................................................................................... 284
Plasma I/O split cable (Y) (223262) .............................................................................................................................. 285
ArcGlide THC Instruction Manual 806450 11
Contents
12 ArcGlide THC Instruction Manual 806450
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.
Safety and Compliance SC-13
• 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.
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.
ELECTRIC SHOCK CAN KILL
SC-14 Safety and Compliance
CUTTING CAN CAUSE FIRE OR EXPLOSION
Safety
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.
WAR N ING
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.
WAR N ING
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.
WAR N ING
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.
Safety and Compliance SC-15
Safety
TOXIC FUMES CAN CAUSE INJURY OR DEATH
The plasma arc by itself is the heat source used for
cutting. Accordingly, although the plasma arc has not
been identified as a source of toxic fumes, the material
being cut can be a source of toxic fumes or gases that
deplete oxygen.
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.
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.
SC-16 Safety and Compliance
GROUNDING SAFETY
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.
Safety and Compliance SC-17
Safety
COMPRESSED GAS EQUIPMENT SAFETY
• Never lubricate cylinder valves or regulators with oil
or grease.
• Use only correct gas cylinders, regulators, hoses and
fittings designed for the specific application.
• Maintain all compressed gas equipment and
associated parts in good condition.
• Label and color-code all gas hoses to identify the
type of gas in each hose. Consult applicable national
and local 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.
A PLASMA ARC CAN CAUSE INJURY AND BURNS
Instant-on torches
Plasma arc comes on immediately when the torch
switch is activated.
The plasma arc will cut quickly through gloves and skin.
• Keep away from the torch tip.
• Do not hold metal near the cutting path.
• Never point the torch toward yourself or others.
SC-18 Safety and Compliance
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.
• 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.
Safety
Minimum
Arc current
(amps)
protective shade
number
(ANSIZ49.1:2005)
Less than 40 A
41 to 60 A
61 to 80 A
81 to 125 A
126 to 150 A
151 to 175 A
176 to 250 A
251 to 300 A
301 to 400 A
401 to 800 A
5589
6689
8889
8989
89810
89811
89812
89813
912913
10 14 10 N /A
Safety and Compliance SC-19
Suggested shade
number for
comfort
OSHA 29CFR
1910.133(a)(5)
EN168:2002
(ANSI Z49.1:2005)
Europe
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 areas
and/or take measures to reduce reverberation in
working areas by putting up noise absorbers.
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.
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.
SC-20 Safety and Compliance
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.
Safety and Compliance SC-21
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.
ADDITIONAL SAFETY INFORMATION
1. ANSI Standard Z49.1, Safety in Welding and Cutting,
American Welding Society, 550 LeJeune Road P.O. Box
351020, Miami, FL 33135
2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting
and Welding Processes, American National Standards Institute
1430 Broadway, New York, NY 10018
3. ANSI Standard Z87.1, Safe Practices for Occupation and
Educational Eye and Face Protection, American National
Standards Institute, 1430 Broadway, New York, NY 10018
4. AWS F4.1, Recommended Safe Practices for the Preparation
for Welding and Cutting of Containers and Piping That Have
Held Hazardous Substances, American Welding Society 550
LeJeune Road, P.O. Box 351040, Miami, FL 33135
5. AWS F5.2, Recommended Safe Practices for Plasma Arc
Cutting, American Welding Society 550 LeJeune Road, P.O.
Box 351040, Miami, FL 33135
• Modifying the laser or product in any way can
increase the risk of laser radiation.
• Use of adjustments or performance of procedures
other than those specified in this manual may result
in hazardous laser radiation exposure.
• Do not operate in explosive atmospheres, such as in
the presence of flammable liquids, gases, or dust.
• Use only laser parts and accessories that are
recommended or provided by the manufacturer for
your model.
• Repairs and servicing MUST be performed by
qualified personnel.
• Do not remove or deface the laser safety label.
6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in
Cylinders, Compressed Gas Association 1235 Jefferson Davis
Highway, Arlington, VA 22202
7. CSA Standard W117.2, Code for Safety in Welding and
Cutting, Canadian Standards Association Standard Sales
178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada
8. NFPA Standard 51B, Cutting and Welding Processes,
National Fire Protection Association 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/
SC-22 Safety and Compliance
WARNING LABELS
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
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.
6. Become trained.
Only qualified personnel should operate this
equipment. Use torches specified in the manual. Keep non-qualified
personnel and children away.
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.
7. Do not remove, destroy, or cover this label.
Replace if it is missing, damaged, or worn (PN 110584 Rev C).
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.
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).
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.
Safety
Safety and Compliance SC-23
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.
SC-24 Safety and Compliance
Safety
s
Symbols and marks
Your product may have one or more of the following markings on or near the data plate. Due to differences and conflicts
in national regulations, not all marks are applied to every version of a product.
S mark
The S mark indicates that the power supply and torch are suitable for operations carried out in environments
with increased hazard of electrical shock according to IEC 60974-1.
CSA mark
Products with a CSA mark meet the United States and Canadian regulations for product safety. The products
were evaluated, tested, and certified by CSA-International. Alternatively, the product may have a mark by one
of the other Nationally Recognized Testing Laboratories (NRTL) accredited in both the United States and
Canada, such as UL or TÜV.
CE mark
The CE marking signifies the manufacturer’s declaration of conformity to applicable European directives and
standards. Only those versions of products with a CE marking located on or near the data plate have been
tested for compliance with the European Low Voltage Directive and the European Electromagnetic
Compatibility (EMC) Directive. EMC filters needed to comply with the European EMC Directive are
incorporated within versions of the product with a CE marking.
Eurasian Customs Union (CU) mark
CE versions of products that include an EAC mark of conformity meet the product safety and EMC
requirements for export to Russia, Belarus, and Kazakhstan.
GOST-TR mark
CE versions of products that include a GOST-TR mark of conformity meet the product safety and EMC
requirements for export to the Russian Federation.
C-Tick mark
CE versions of products with a C-Tick mark comply with the EMC regulations required for sale in Australia
and New Zealand.
CCC mark
The China Compulsory Certification (CCC) mark indicates that the product has been tested and found
compliant with product safety regulations required for sale in China.
UkrSEPRO mark
The CE versions of products that include a UkrSEPRO mark of conformity meet the product safety and EMC
requirements for export to the Ukraine.
Serbian AAA mark
CE versions of products that include a AAA Serbian mark meet the product safety and EMC requirements for
export to Serbia.
Safety and Compliance SC-25
Safety
SC-26 Safety and Compliance
Product Stewardship
Introduction
Hypertherm maintains a global Regulatory Management System to
ensure that products comply with regulatory and environmental
requirements.
National and local safety regulations
National and Local safety regulations shall take precedence over any
instructions provided with the product. The product shall be imported,
installed, operated and disposed of in accordance with national and local
regulations applicable to the installed site.
Certification test marks
Certified products are identified by one or more certification test marks
from accredited testing laboratories. The certification test marks are
located on or near the data plate.
Each certification test mark means that the product and its safety-critical
components conform to the relevant national safety standards as
reviewed and determined by that testing laboratory. Hypertherm places
a certification test mark on its products only after that product is
manufactured with safety-critical components that have been authorized
by the accredited testing laboratory.
Once the product has left the Hypertherm factory, the certification test
marks are invalidated if any of the following occurs:
• The product is modified in a manner that creates a hazard or
non-conformance with the applicable standards.
• Safety-critical components are replaced with unauthorized spare
parts.
• Any unauthorized assembly, or accessory that uses or generates a
hazardous voltage is added.
• There is any tampering with a safety circuit or other feature that is
designed into the product as part of the certification, or otherwise.
CE marking constitutes a manufacturer’s declaration of conformity to
applicable European directives and standards. Only those versions of
Hypertherm products with a CE Marking located on or near the data
plate have been tested for compliance with the European Low Voltage
Directive and the European EMC Directive. EMC filters needed to
comply with the European EMC Directive are incorporated within
versions of the power supply with a CE Marking.
Certificates of compliance for Hypertherm products are available from
the Downloads Library on the Hypertherm web site at
https://www.hypertherm.com
.
Differences in national standards
Nations may apply different performance, safety or other standards.
National differences in standards include, but are not limited to:
•Voltages
• Plug and cord ratings
• Language requirements
• Electromagnetic compatibility requirements
These differences in national or other standards may make it impossible
or impractical for all certification test marks to be placed on the same
version of a product. For example, the CSA versions of Hypertherm’s
products do not comply with European EMC requirements, and therefore
do not have a CE marking on the data plate.
Countries that require CE marking or have compulsory EMC regulations
must use CE versions of Hypertherm products with the CE marking on
the data plate. These include, but are not limited to:
•Australia
• New Zealand
• Countries in the European Union
• Russia
It is important that the product and its certification test mark be suitable
for the end-use installation site. When Hypertherm products are shipped
to one country for export to another country; the product must be
configured and certified properly for the end-use site.
Safe installation and use of shape cutting equipment
IEC 60974-9, titled Arc Welding Equipment – Installation and use,
provides guidance in the safe installation and use of shape cutting
equipment and the safe performance of cutting operations. The
requirements of national and local regulations shall be taken into
consideration during installation, including, but not limited to, grounding
or protective earth connections, fuses, supply disconnecting device, and
type of supply circuit. Read these instructions before installing the
equipment. The first and most important step is the safety assessment of
the installation.
The safety assessment must be performed by an expert, and determines
what steps are necessary to create a safe environment, and what
precautions should be adopted during the actual installation and
operation.
Procedures for periodic inspection and testing
Where required by local national regulations, IEC 60974-4 specifies test
procedures for periodic inspection and after repair or maintenance, to
ensure electrical safety for plasma cutting power sources built in
conformity with IEC 60974-1. Hypertherm performs the continuity of the
protective circuit and insulation resistance tests in the factory as
non-operating tests. The tests are performed with the power and ground
connections removed.
Safety and Compliance SC-27
English
Product Stewardship
Hypertherm also removes some protective devices that would cause
false test results. Where required by local national regulations, a label
shall be attached to the equipment to indicate that it has passed the
tests prescribed by IEC 60974-4. The repair report shall indicate the
results of all tests unless an indication is made that a particular test has
not been performed.
Qualification of test personnel
Electrical safety tests for shape cutting equipment can be hazardous and
shall be carried out by an expert in the field of electrical repair, preferably
someone also familiar with welding, cutting, and allied processes. The
safety risks to personnel and equipment, when unqualified personnel are
performing these tests, may be much greater than the benefit of periodic
inspection and testing.
Hypertherm recommends that only visual inspection be performed unless
the electrical safety tests are specifically required by local national
regulations in the country where the equipment is installed.
Residual current devices (RCDs)
In Australia and some other countries, local codes may require the use of
a Residual Current Devices (RCD) when portable electrical equipment is
used in the workplace or at construction sites to protect operators from
electrical faults in the equipment. RCDs are designed to safely
disconnect the mains electrical supply when an imbalance is detected
between the supply and return current (there is a leakage current to
earth). RCDs are available with both fixed and adjustable trip currents
between 6 to 40 milliamperes and a range of trip times up to
300 milliseconds selected for the equipment installation, application and
intended use. Where RCDs are used, the trip current and trip time on
RCDs should be selected or adjusted high enough to avoid nuisance
tripping during normal operation of the plasma cutting equipment and
low enough in the extremely unlikely event of an electrical fault in the
equipment to disconnect the supply before the leakage current under a
fault condition can pose a life threatening electrical hazard to operators.
To verify that the RCDs continue to function properly over time, both the
trip current and the trip time should be tested periodically. Portable
electrical equipment and RCDs used in commercial and industrial areas
in Australia and New Zealand are tested to the Australian standard
AS/NZS 3760. When you test the insulation of plasma cutting
equipment to AS/NZS 3760, measure the insulation resistance
according to Appendix B of the standard, at 250 VDC with the power
switch in the ON position to verify proper testing and to avoid the false
failure of the leakage current test. False failures are possible because the
metal oxide varistors (MOVs) and electromagnetic compatibility (EMC)
filters, used to reduce emissions and protect the equipment from power
surges, may conduct up to 10 milliamperes leakage current to earth
under normal conditions.
If you have any questions regarding the application or interpretation of
any IEC standards described here, you are required to consult with an
appropriate legal or other advisor familiar with the International
Electrotechnical standards, and shall not rely on Hypertherm in any
respect regarding the interpretation or application of such standards.
Higher-level systems
When a system integrator adds additional equipment; such as cutting
tables, motor drives, motion controllers or robots; to a Hypertherm
plasma cutting system, the combined system may be considered a
higher-level system. A higher-level system with hazardous moving parts
may constitute industrial machinery or robotic equipment, in which case
the OEM or end-use customer may be subject to additional regulations
and standards than those relevant to the plasma cutting system as
manufactured by Hypertherm.
It is the responsibility of the end-use customer and the OEM to perform a
risk assessment for the higher-level system, and to provide protection
against hazardous moving parts. Unless the higher-level system is
certified when the OEM incorporates Hypertherm products into it, the
installation also may be subject to approval by local authorities. Seek
advice from legal counsel and local regulatory experts if you are uncertain
about compliance.
External interconnecting cables between component parts of the higher
level system must be suitable for contaminants and movement as
required by the final end use installation site. When the external
interconnecting cables are subject to oil, dust, water, or other
contaminants, hard usage ratings may be required.
When external interconnecting cables are subject to continuous
movement, constant flexing ratings may be required. It is the
responsibility of the end-use customer or the OEM to ensure the cables
are suitable for the application. Since there are differences in the ratings
and costs that can be required by local regulations for higher level
systems, it is necessary to verify that any external interconnecting cables
are suitable for the end-use installation site.
SC-28 Safety and Compliance
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.
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 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.
• Consult with legal or other compliance experts when appropriate.
.
The WEEE Directive
On January 27, 2003, the European Parliament and the Council of the
European Union authorized Directive 2002/96/EC or WEEE (Waste
Electrical and Electronic Equipment).
As required by the legislation, any Hypertherm product covered by the
directive and sold in the EU after August 13, 2005 is marked with the
WEEE symbol. This directive encourages and sets specific criteria for
the collection, handling, and recycling of EEE waste. Consumer and
business-to-business wastes are treated differently (all Hypertherm
products are considered business-to-business). Disposal instructions for
the CE versions of Powermax plasma systems can be found at
www.hypertherm.com/weee
The URL is printed on the symbol-only warning label for each of these
CE version Powermax series units shipped since 2006. The CSA
versions of Powermax and other products manufactured by Hypertherm
are either out of scope or exempt from WEEE.
.
The REACH regulation
The REACH regulation (1907/2006), in force since June1, 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).
Safety and Compliance SC-29
English
Environmental Stewardship
Proper handling and safe use of chemicals
Chemical Regulations in the USA, Europe, and other locations require
that Material Safety Data Sheets (MSDS) be made available for all
chemicals. The list of chemicals is provided by Hypertherm. The MSDS
are for chemicals provided with the product and other chemicals used in
or on the product. MSDS can be downloaded from the Downloads
Library on the Hypertherm web site at https://www.hypertherm.com
On the Search screen, insert MSDS in the document title and click on
Search.
In the USA, OSHA does not require Material Safety Data Sheets for
articles such as electrodes, swirl rings, retaining caps, nozzles, shields,
deflectors and other solid parts of the torch.
Hypertherm does not manufacture or provide the materials that are cut
and has no knowledge whether the fumes released from materials that
are cut will pose a physical hazard or health risk. Please consult with your
supplier or other technical advisor if you need guidance concerning the
properties of the material you will cut using a Hypertherm product.
.
Fumes emission and air quality
Note: The following information on air quality is intended for general
information only and should not be used as a substitute for reviewing and
implementing applicable government regulations or legal standards in
the country where the cutting equipment will be installed and operated.
In the USA, the National Institute for Occupational Safety and Health
(NIOSH) Manual of Analytical Methods (NMAM) is a collection of
methods for sampling and analyzing contaminants in workplace air.
Methods published by others, such as OSHA, MSHA, EPA, ASTM, ISO
or commercial suppliers of sampling and analytical equipment, may have
advantages over NIOSH methods.
For example, ASTM Practice D 4185 is a standard practice for the
collection, dissolution, and determination of trace metals in workplace
atmospheres. The sensitivity, detection limit, and optimum working
concentrations for 23 metals are listed in ASTM D 4185. An industrial
hygienist should be used to determine the optimum sampling protocol,
considering analytical accuracy, cost, and optimum sample number.
Hypertherm uses a third party industrial hygienist to perform and interpret
air quality testing results taken by air sampling equipment positioned at
operator stations in Hypertherm buildings where plasma cutting tables
are installed and operated.
Where applicable, Hypertherm also uses a third party industrial hygienist
to obtain air and water permits.
If you are not fully aware and up to date on all applicable government
regulations and legal standards for the installation site, you should
consult a local expert prior to purchasing, installing, and operating the
equipment.
SC-30 Safety and Compliance
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
workpiece. In other cases, it could involve constructing an
electromagnetic screen enclosing the power source and the work
complete with associated input filters. In all cases, electromagnetic
disturbances must be reduced to the point where they are no longer
troublesome.
Methods of reducing emissions
Mains supply
Cutting equipment must be connected to the mains supply according to
the manufacturer’s recommendations. If interference occurs, it may be
necessary to take additional precautions such as filtering of the mains
supply.
Consideration should be given to shielding the supply cable of
permanently installed cutting equipment, in metallic conduit or
equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the cutting mains supply so
that good electrical contact is maintained between the conduit and the
cutting power source enclosure.
Maintenance of cutting equipment
The cutting equipment must be routinely maintained according to the
manufacturer’s recommendations. All access and service doors and
covers should be closed and properly fastened when the cutting
equipment is in operation. The cutting equipment should not be modified
in any way, except as set forth in and in accordance with the
manufacturer’s written instructions. For example, the spark gaps of arc
striking and stabilizing devices should be adjusted and maintained
according to the manufacturer’s recommendations.
Cutting cables
Assessment of area
Before installing the equipment, the user shall make an assessment of
potential electromagnetic problems in the surrounding area. The
following shall be taken into account:
a. Other supply cables, control cables, signaling and telephone
cables; above, below and adjacent to the cutting equipment.
b. Radio and television transmitters and receivers.
c. Computer and other control equipment.
d. Safety critical equipment, for example guarding of industrial
equipment.
e. Health of the people around, for example the use of pacemakers
and hearing aids.
f. Equipment used for calibration or measurement.
g. Immunity of other equipment in the environment. User shall
ensure that other equipment being used in the environment is
compatible. This may require additional protection measures.
h. Time of day that cutting or other activities are to be carried out.
The size of the surrounding area to be considered will depend on the
structure of the building and other activities that are taking place. The
surrounding area may extend beyond the boundaries of the premises.
The cutting cables should be kept as short as possible and should be
positioned close together, running at or close to the floor level.
Equipotential bonding
Bonding of all metallic components in the cutting installation and
adjacent to it should be considered.
However, metallic components bonded to the workpiece will increase
the risk that the operator could receive a shock by touching these
metallic components and the electrode (nozzle for laser heads) at the
same time.
The operator should be insulated from all such bonded metallic
components.
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.
Safety and Compliance SC-31
Electromagnetic Compatibility (EMC)
Note: The cutting circuit may or may not be earthed for safety reasons.
Changing the earthing arrangements should only be authorized by a
person who is competent to assess whether the changes will in crease
the risk of injury, for example, by allowing parallel cutting current return
paths which may damage the earth circuits of other equipment. Further
guidance is provided in IEC 60974-9, Arc Welding Equipment, Part 9:
Installation and Use.
Screening and shielding
Selective screening and shielding of other cables and equipment in the
surrounding area may alleviate problems of interference. Screening of the
entire plasma cutting installation may be considered for special
applications.
SC-32 Safety and Compliance
Warranty
Attention
Genuine Hypertherm parts are the factory-recommended replacement
parts for your Hypertherm system. Any damage or injury caused by the
use of other than genuine Hypertherm parts may not be covered by the
Hypertherm warranty, and will constitute misuse of the Hypertherm
Product.
You are solely responsible for the safe use of the Product. Hypertherm
does not and cannot make any guarantee or warranty regarding the safe
use of the product in your environment.
General
Hypertherm Inc. warrants that its Products shall be free from defects in
materials and workmanship for the specific periods of time set forth
herein and as follows: if Hypertherm is notified of a defect (i) with respect
to the plasma power supply within a period of two (2) years from the date
of its delivery to you, with the exception of Powermax brand power
supplies, which shall be within a period of three (3) years from the date of
delivery to you, and (ii) with respect to the torch and leads within a period
of one (1) year from its date of delivery to you, with the exception of the
HPRXD short torch with integrated lead, which shall be within a period of
six (6) months from the date of delivery to you, and with respect to torch
lifter assemblies within a period of one (1) year from its date of delivery to
you, and with respect to Automation products one (1) year from its date
of delivery to you, with the exception of the EDGE Pro CNC,
EDGE Pro Ti CNC, MicroEDGE Pro CNC, and ArcGlide THC, which
shall be within a period of two (2) years from the date of delivery to you,
and (iii) with respect to HyIntensity fiber laser components within a
period of two (2) years from the date of its delivery to you, with the
exception of laser heads and beam delivery cables, which shall be within
a period of one (1) year from its date of delivery to you.
This warranty shall not apply to any Powermax brand power supplies that
have been used with phase converters. In addition, Hypertherm does not
warranty systems that have been damaged as a result of poor power
quality, whether from phase converters or incoming line power. This
warranty shall not apply to any product which has been incorrectly
installed, modified, or otherwise damaged.
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.
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.
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.
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.
Safety and Compliance SC-33
Warranty
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.
SC-34 Safety and Compliance
Section 1
1
2
3
4
5
6
7
8
9
10
1 Plasma system
2 ArcGlide HMI (optional)
3 CNC
4 Rails
5 Star ground
6 ArcGlide control module
7 Gantry
8 ArcGlide lifter
9 Workpiece
10 Cutting machine
Specifications
Introduction
The Hypertherm ArcGlide THC is a voltage sensing, torch height control (THC) system that is designed for plasma
cutting applications on an X-Y cutting machine. The system uses the plasma arc voltage to control the physical distance
between the torch and the workpiece during cutting. Up to 4 ArcGlide systems can be installed on a cutting machine.
The system includes the components shown in Figure 1.
Figure 1
ArcGlide THC Instruction Manual 806450 35
1 – Specifications
The ArcGlide control module and Ethernet switch should be located in an electrical cabinet that is electrically grounded
and environmentally clean.
ArcGlide control module
The ArcGlide control module houses a micro-controller, I/O board, and a motor drive. This component provides arc
voltage control and interfaces with the torch lifter, the CNC, and the plasma system through standard discrete I/O
interfaces or through the Hypernet
®
plasma interface board.
Lifter assembly
The torch lifter station, under control of the ArcGlide control module, positions a torch head vertically above the
workpiece.
The lifter has the following features:
Ability to detect the workpiece using ohmic contact sense circuitry or stall force
Lifter station ENABLE/DISABLE switch with an indicator lamp
Manual UP/DOWN switch
Laser pointer for workpiece alignment
Signal interface cable
Optional magnetic or pneumatic torch breakaway with circuitry to indicate a collision
Optional torch mounting block
36 ArcGlide THC Instruction Manual 806450
1 – Specifications
Human machine interface (HMI)
The HMI includes a liquid crystal display (LCD), operating switches, and a selector knob for THC setup and control. The
HMI is an optional operator interface for adjusting or reading settings.
The main functions of the HMI are:
THC system and operation setup
Entry for operating parameters
Manual and automatic operation
Initial height sense (IHS) test
THC status and arc voltage display
THC error display
Multiple language support (English, German, Portuguese, and Spanish)
English or metric unit support
Station ENABLE/DISABLE switch
Plasma interface board
The plasma interface board has 2 main functions:
1. Precise, scaled feedback of the plasma arc voltage to the ArcGlide THC control module.
2. A convenient, control signal interface to the ArcGlide THC.
Hypertherm offers 2 types of plasma interface boards. See Discrete plasma interface board (141094) on page 44 or
Hypernet plasma interface board (141162) on page 45.
Industrial Ethernet switch
An industrial grade Ethernet switch with multiple ports is required in configurations that have more than one cable
connection for Hypernet. See Ethernet switch on page 46 for more information.
ArcGlide THC Instruction Manual 806450 37
1 – Specifications
Specifications
ArcGlide system
Input power 115 VAC, 50/60 Hz, 1-phase
230VAC, 50/60Hz, 1-phase*
Operating temperature -10ºC to 40ºC (14ºF to 104ºF)
Operating humidity 95% relative humidity
Warranty 2 years for electronics and lifter
* Factory default setting
38 ArcGlide THC Instruction Manual 806450
1 – Specifications
7. 2 6 k g
(16.00 lb)
358.65 mm
(14.12 inch)
381.00 mm
(15.37 inch)
157.23 mm
(6.19 inch)
206.25 mm
(8.12 inch)
ArcGlide control module (090054)
Regulatory approvals CE, CSA, C-Tick, GOST-TR, UkrSEPRO
Current rating (selectable)* 2.6 A at 100 VAC – 120 VAC, 50/60 Hz, 1-phase
1.5 A at 200 VAC – 230 VAC, 50/60 Hz, 1-phase**
Slow blow fuse 250 VAC, 5 A, 0.25 inch X 1.25 inch
Parallel digital input range +12 VDC to +24 VDC
Serial digital I/O +5 VDC (Plasma interface serial)
Maximum motor drive output 70 VDC, 6 A
Hypernet communication Shielded RJ-45 Cat5e or Cat6
* To prevent damage to equipment, select the input voltage using the input fuse module on the front of the ArcGlide control module
above the power connector (115 V or 230 V).
** Factory default setting
Figure 2
ArcGlide THC Instruction Manual 806450 39
1 – Specifications
Lifter assembly (090053)
The following table lists specifications that are common for all lifter assemblies. Ta bl e 1 lists specifications that differ from
the model listed below.
Regulatory approvals CE, CSA, C-Tick, GOST-TR, UkrSEPRO
Motor 70 VDC, 3 A continuous, 6 A maximum
Limit switches +24 VDC
Motor Permanent magnet
Motor drive Pulse width modulation (PWM) servo amplifier
Lifter feedback Incremental encoder
Lifter limit switches Home switch and lower limit switch
Lifter control switches Manual UP/DOWN and station ENABLE/DISABLE switches
Maximum Z-axis speed 15,200 mm/min (600 in/min)
Maximum Z-axis stroke 239 mm (9.40 inch)
Breakaway switch +24 VDC
Motor brake +24 VDC
Laser pointer (Class 3B) +5 VDC
Maximum power: 500 mW
Wavelength: 400 – 695 nm
Lifter capacity 11.3 kg (25.0 lb)
40 ArcGlide THC Instruction Manual 806450
Tabl e 1
Part No. Torch mounting block Breakaway options
090082 51 mm (2 inch) 11 kg (25 lb) magnetic
090083 51 mm (2 inch) Pneumatic
090084 44 mm (1.75 inch) Pneumatic
090085 35 mm (1.375 inch) Pneumatic
090086 44 mm (1.75 inch) 11 kg (25 lb) magnetic
090087 35 mm (1.375 inch) 11 kg (25 lb) magnetic
090088 51 mm (2.0 inch) 4.5 kg (10 lb) magnetic
090089 44 mm (1.75 inch) 4.5 kg (10 lb) magnetic
090090 35 mm (1.375 inch) 4.5 kg (10 lb) magnetic
1 – Specifications
090091 Not included Pneumatic
090092 Not included 4.5 kg (10 lb) magnetic
090093 Not included 11 kg (25 lb) magnetic
ArcGlide THC Instruction Manual 806450 41
1 – Specifications
14.00 kg
(30.90 lb)
186.70 mm
(7.35 inch)
149.10 mm
(5.87 inch)
744.2 0 mm
(29.30 inch)
151.10 mm
(5.95 inch)
78.70 mm
(3.10 inch)
269.20 mm
(10.60 inch)
50.80 mm
(2.00 inch)
Figure 3
42 ArcGlide THC Instruction Manual 806450
Optional HMI (090055)
298.00 mm
(11.73 inch)
1.91 kg
(4.20 lb)
117.60 mm
(4.63 inch)
130.50 mm
(5.14 inch)
Regulatory approvals CE, CSA, C-Tick, GOST-TR, UkrSEPRO
Input power 100 VAC, 40 mA, 50/60 Hz, 1-phase
240 VAC, 20 mA, 50/60 Hz, 1-phase
Hypernet communication Shielded RJ-45 Cat5e or Cat6
Operating temperature -10ºC to 40ºC (14ºF to 104ºF)
Operating humidity 95% relative humidity
Figure 4
1 – Specifications
ArcGlide THC Instruction Manual 806450 43
1 – Specifications
0.68 kg
(1.50 lb)
145.29 mm
(5.72 inch)
127.00 mm
(5.00 inch)
50.80 mm
(2.00 inch)
27.69 mm
(1.09 inch)
Discrete plasma interface board (141094)
This plasma interface board is required for configurations that use discrete communication.
Figure 5
Input power 24 V (AC or DC)
Parallel digital I/O +12 VDC to +24 VDC
Serial digital I/O 5 VDC
Voltage divider ratio 50:1 Arc voltage
44 ArcGlide THC Instruction Manual 806450
Hypernet plasma interface board (141162)
0.20 kg
(0.45 lb)
145.29 mm
(5.72 inch)
171.45 mm
(6.75 inch)
This plasma interface board is required for configurations that use Hypernet communication.
Figure 6
1 – Specifications
Input power 24 V (AC or DC)
Parallel digital I/O +12 VDC to +24 VDC
Serial digital I/O 5 VDC
Voltage divider ratio 50:1 Arc voltage
ArcGlide THC Instruction Manual 806450 45
1 – Specifications
Ethernet switch
If the ArcGlide THC has more than one connection to Hypernet that communicates with either the CNC or the plasma
system, you must include an industrial grade Ethernet switch with multiple ports for communication between these
components.
This switch must be an industrial grade switch that supports shielded Cat5e or Cat6 Ethernet cable. The Ethernet
switch should be located in an electrical cabinet that is electrically grounded and environmentally clean.
A plasma arc cutting machine can be configured with the following units:
1 CNC with Hypernet support
Up to 4 plasma systems
4 ArcGlide THC control modules
4 ArcGlide THC lifters
4 ArcGlide TNC HMIs
The total number of Ethernet ports the system requires depends on the number of plasma systems and ArcGlide THCs
installed. Use Ta bl e 2 to help determine the number of Ethernet ports the system needs.
Tabl e 2
For each of these components: You need this many Ethernet ports:
CNC 1
Plasma system (1 to 4) + lifter (1 to 4) 2 to 8
Plasma system (1 to 4) + lifter (1 to 4) + HMI (1 to 4) 3 to 12
For example, a cutting machine with 2 plasma systems + 2 THCs + 2 HMIs + 1 CNC = 7 ports.
Hypernet connections and Ethernet connections to a LAN cannot be made through the same switch. If your cutting
machine is connected to a LAN over Ethernet, you must use a separate Ethernet switch for these connections.
Hypertherm recommends 3 different models of Advantech™ industrial Ethernet switches. These switches are available
from Hypertherm. Ta bl e 3 provides details about each model. Choose the switch that fits your needs.
46 ArcGlide THC Instruction Manual 806450
1 – Specifications
Table 3 – Recommended Advantech Ethernet switches
5 Ports 8 Ports 16 Ports
Hypertherm part number 005657 005655 005656
Advantech part number EKI-2525I-AE EKI-7629C-AE EKI-7626C-AE
Width × height × depth 37 mm X 140 mm X 95 mm
(1.46 inch X 5.51 inch X
3.74 inch)
Maximum power
consumption
Power input (not included) 12 – 48 VDC redundant dual inputs with twisted pair cable.
5 W 6.5 W 6.5 W
79 mm X 152 mm X
10 5 m m
(3.11 inch X 5.98 inch X
4.13 inch)
79 mm X 152 mm X
105 mm
(3.11 inch X 5.98 inch X
4.13 inch)
Ta bl e 4 lists the operating specifications for the recommended Ethernet switches. See the respective Advantech user
manuals for information about installing and operating these switches.
If your cutting machine does not include one of these Advantech Ethernet switches, use the specifications in Table 4 to
select an industrial-grade Ethernet switch that will support your plasma cutting machine.
Table 4 – Advantech Ethernet switch specifications
Ethernet connections Shielded RJ-45 ports
Electrical protection 4000 VDC Ethernet ESD protection, 3000 VDC surge (EFT) protection for
the power line
I/O transmission distance Up to 100 m (109 yard) (4-wire Cat5e or Cat6)
I/O transmission speed 10/100 Mbps auto-negotiation
Operating temperature -10ºC to 60ºC (14ºF to 140ºF)
ArcGlide THC Instruction Manual 806450 47
1 – Specifications
ArcGlide communication
Figure 7 through Figure 10 show discrete and Hypernet communication that the ArcGlide THC uses to exchange signals
with the CNC and the plasma system. Use the following table to distinguish between discrete and Hypernet
communication.
Communication style Data architecture Cabling configuration
Discrete Discrete I/O and serial
data
Hypernet Ethernet data packets A standard, Cat5e or Cat6, shielded, Ethernet cable from the
Both communication styles transmit the same signals. The difference is in the way the signals are “packaged” for
transmission over the two cabling configurations.
Do not use redundant (both discrete and Hypernet) communication between the same two components in the same
ArcGlide configuration.
A dedicated cable to each component from the ArcGlide control
module; within each cable, there is a dedicated wire for each
signal.
Ethernet switch to each component of the cutting machine.
Hypernet communication
ArcGlide THCs in Hypernet configurations connect to the CNC and plasma system using the Hypernet protocol over
shielded, Ethernet Cat5e or Cat6 cables. Both the CNC and plasma systems in this configuration must have a dedicated,
Hypernet-configured, Ethernet port for these connections.
In addition, a Hypernet configuration must include an industrial-grade Ethernet switch to route communication from the
CNC to the other components in the system.
Each ArcGlide THC component (HMI, control module, and plasma interface board) that is connected to the Hypernet
must have the same Hypernet component address. This address must correspond to the station number for the THC
that is selected in Phoenix, on the Station Configuration screen. See Assign an ArcGlide THC to a station on page 125
for more information.
48 ArcGlide THC Instruction Manual 806450
Figure 7
Lifter
1 – Specifications
Station 1
HPR plasma system
HMI
Hypernet address: 1
HyPath CNC Ethernet switch
HMI
Hypernet address: 2
Key:
Hypernet connection
Discrete connection
ArcGlide control module
Hypernet address: 1
ArcGlide control module
Hypernet address: 2
Lifter
Hypernet plasma interface
board
Hypernet address: 1
HPR plasma system
Hypernet plasma interface
board
Hypernet address: 2
Station 2
In a Hypernet configuration, serial communication is carried on the Hypernet cable between the CNC and the ArcGlide
THC and the ArcGlide plasma interface board in the plasma system. Within the plasma system, serial communication is
carried between the ArcGlide plasma interface board and the plasma control board by a serial cable (123760).
ArcGlide
CNC
ArcGlide
plasma
interface
Plasma
control board
board
Hypernet
Cat5e or Cat6
Hypernet
Cat5e or Cat6
RS-422
ArcGlide THC Instruction Manual 806450 49
1 – Specifications
Discrete communication
In a discrete configuration, signals are routed through the ArcGlide control module. Each component in the configuration,
except the HMI, is connected to the ArcGlide control module with discrete cables. The HMI communicates with the
control module using the Hypernet protocol over a shielded, Ethernet Cat5e or Cat6 cable.
Figure 8
Lifter
Plasma system
Picopath CNC ArcGlide control module Plasma interface board
HMI
Key:
Hypernet connection
Discrete connection
50 ArcGlide THC Instruction Manual 806450
1 – Specifications
Mixed communication
In a mixed configuration, Hypernet communication is used between the ArcGlide control module and CNC or plasma
system and discrete communication is used for the alternate connection from the ArcGlide control module. When the
HMI is included, it must be connected to the ArcGlide control module with a Hypernet connection. See Figure 9 and
Figure 10 for details.
Figure 9
Lifter
Plasma system
ArcGlide control module
Hypernet-capable CNC Ethernet switch
HMI
Discrete plasma
interface board
Figure 10
Lifter
CNC ArcGlide control module
Plasma system
Ethernet switch
HMI
Key:
Hypernet connection
Discrete connection
Hypernet plasma
interface board
Serial communication
The ArcGlide THC supports an optional serial interface to a non-Hypernet CNC. See ArcGlide THC Serial
Communication Installation on page 269 for more information on serial communication.
ArcGlide THC Instruction Manual 806450 51
1 – Specifications
52 ArcGlide THC Instruction Manual 806450
Section 2
Installation
Hardware setup
After you receive your new equipment:
Make sure that all items on your order have been received in good condition. Contact your table manufacturer if any
parts are damaged or missing.
Inspect the system components for damage that may have occurred during shipping. See Claims if there is evidence
of damage. All communications regarding this equipment must include the model number and the serial number
located on the back of the unit.
Before you set up and operate this Hypertherm system, read Safety on page 13 for important safety information.
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 the nearest Hypertherm office listed in the front of this manual.
Claims for defective or missing merchandise – If any of the components are missing or defective, contact your
table manufacturer. If you need additional assistance, call the nearest Hypertherm office listed in the front of this
manual.
ArcGlide THC Instruction Manual 806450 53
2 – Installation
Installation requirements
All installation and service of the electrical system must conform to national and local electrical codes. This work should
be performed only by qualified, licensed personnel.
Direct any technical questions to the nearest Hypertherm Technical Service office listed in the front of this manual, or to
your table manufacturer.
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 on page 55 for more
information.
54 ArcGlide THC Instruction Manual 806450
2–Installation
Recommended grounding and shielding practices
WARNING!
ELECTRIC SHOCK CAN KILL
Disconnect electrical power before performing any maintenance.
All work requiring the removal of the plasma system cover must be performed
by a qualified technician.
See the Safety section of your manual for more safety precautions.
Introduction
This section describes practices for grounding and shielding to protect a plasma cutting system against radio frequency
interference (RFI) and electromagnetic interference (EMI) (also called noise). It also describes the DC power ground and
the service ground. The diagram at the end of this section shows these types of grounds in a plasma cutting system.
The grounding practices in this section have been used on many installations with excellent results, and Hypertherm
recommends that these practices be a routine part of the installation process. The actual methods used to implement
these practices may vary from system to system, but should remain as consistent as possible. However, due to the
variation in equipment and installations, these grounding practices may not succeed in every case to eliminate RFI/EMI
noise issues.
Types of grounding
Service ground (also called safety ground or potential earth (PE) ground) is the grounding system that applies to the
incoming line voltage. It prevents a shock hazard to any personnel from any of the equipment or the cutting table. It
includes the service ground coming into the plasma system and other systems such as the CNC and the motor drives, as
well as the supplemental ground rod connected to the cutting table. In the plasma circuits, the ground is carried from the
plasma system chassis to the chassis of each separate console through the interconnecting cables.
DC power ground (also called cutting current ground) is the grounding system that completes the path of the cutting
current from the torch back to the plasma system. It requires that the positive lead from the plasma system be firmly
connected to the cutting table ground bus with a properly sized cable. It also requires that the slats, on which the
workpiece rests, make firm contact with the table and the workpiece.
RFI and EMI grounding and shielding is the grounding system that limits the amount of electrical noise emitted by
the plasma and motor drive systems. It also limits the amount of noise that is received by the CNC and other control and
measurement circuits. The grounding practices described in this section mainly target RFI and EMI grounding and
shielding.
Grounding practices
1. Unless noted, use only 16 mm2 (6 AWG) welding cables (047040) for the EMI ground cables shown on the diagram
at the end of this section.
2. The cutting table is used for the common, or star, EMI ground point and should have threaded studs welded to the
table with a copper bus bar mounted on them. A separate bus bar should be mounted on the gantry as close to
ArcGlide THC Instruction Manual 806450 55
2 – Installation
each motor as possible. If there are motors at each end of the gantry, run a separate EMI ground cable from the
far motor to the gantry bus bar. The gantry bus bar should have a separate, heavy EMI ground cable 21.2 mm
2
(4 AWG; 047031) to the table bus bar. The EMI ground cables for the torch lifter and the RHF console must each
run separately to the table ground bus.
3. A ground rod that meets all applicable local and national electrical codes must be installed within 6 m (20 ft) of the
cutting table. This is a PE ground and should be connected to the cutting table ground bus bar using 16 mm
2
(6 AWG) green and yellow grounding cable (047121) or equivalent.
4. For the most effective shielding, use the Hypertherm CNC interface cables for I/O signals, serial communication
signals, between plasma systems in multi-drop connections, and for interconnections between all parts of the
Hypertherm system.
5. All hardware used in the ground system must be brass or copper. While you can use steel studs welded to the
cutting table for mounting the ground bus, no other aluminum or steel hardware can be used in the ground system.
6. AC power, PE, and service grounds must be connected to all equipment according to local and national codes.
7. For a system with a remote high frequency console (RHF), the positive, negative, and pilot arc leads should be
bundled together for as long a distance as possible. The torch lead, work lead, and the pilot arc (nozzle) leads may be
run parallel to other wires or cables only if they are separated by at least 150 mm (6 inches). If possible, run power
and signal cables in separate cable tracks.
8. For a system with an RHF console, the ignition console should be mounted as closely as possible to the torch, and
must have a separate ground cable that connects directly to the cutting table ground bus bar.
9. Each Hypertherm component, as well as any other CNC or motor drive cabinet or enclosure, must have a separate
ground cable to the common (star) ground on the table. This includes the ignition console, whether it is bolted to the
plasma system or to the cutting table.
10. The metal braided shield on the torch lead must be connected firmly to the ignition console and to the torch. It must
be electrically insulated from any metal and from any contact with the floor or building. The torch lead can be run in a
plastic cable tray or track, or covered with a plastic or leather sheath.
11 . The torch holder and the torch breakaway mechanism – the part mounted to the lifter, not the part mounted to the
torch – must be connected to the stationary part of the lifter with copper braid at least 12.7 mm (0.5 inches) wide. A
separate cable must run from the lifter to the gantry ground bus bar. The valve assembly should also have a separate
ground connection to the gantry ground bus bar.
12. If the gantry runs on rails that are not welded to the table, then each rail must be connected with a ground cable from
the end of the rail to the table. The rail ground cables connect directly to the table and do not need to connect to the
table ground bus bar.
13. If you are installing a voltage divider board, mount it as closely as possible to where the arc voltage is sampled.
One recommended location is inside the plasma system enclosure. If a Hypertherm voltage divider board is used, the
output signal is isolated from all other circuits. The processed signal should be run in twisted shielded cable
(Belden 1800F or equivalent). Use a cable with a braided shield, not a foil shield. Connect the shield to the chassis
of the plasma system and leave it unconnected at the other end.
14. All other signals (analog, digital, serial, and encoder) should run in twisted pairs inside a shielded cable. Connectors
on these cables should have a metal housing. The shield, not the drain, should be connected to the metal housing of
the connector at each end of the cable. Never run the shield or the drain through the connector on any of the pins.
56 ArcGlide THC Instruction Manual 806450
2–Installation
1 Gantry ground bus
2 Ground rod
3 Plasma system lead (+)
4 Remote high frequency (RHF) console
5 CNC enclosure
6 Torch holder
7 Plasma system chassis
1 2 3
4
5 6 7
1 Cable to the cutting table ground bus
2 Ground cables from components on the gantry
1 2
The following picture shows an example of a cutting table ground bus. The components shown here may differ from your
system.
The following picture shows an example of a gantry ground bus. It is bolted to the gantry, close to the motor. All of the
individual ground cables from the components mounted on the gantry connect to the bus. A single heavy cable then
connects the gantry ground bus to the table ground bus.
ArcGlide THC Instruction Manual 806450 57
2 – Installation
Chassis and RFI ground
AC earth ground
1
2
3
4
5
6
7
8 9
10
11
12
13
1 Cutting table
2 Gantry
3 Plasma system
4 Table ground bus bar
5 Gantry ground bus bar
6 Torch height control lifter (ArcGlide, Sensor THC,
Sensor PHC, or other)
7 RHF console (not on all systems). Connect to table
ground bus bar.
8, 9 System-specific component such as metering
console, gas console, or selection console
10 CNC chassis
11 Torch height control module
(ArcGlide, Command THC)
12 System-specific component such as a cooler or
chiller
13 DC power ground
The following diagram shows an example of grounding the components in a plasma cutting system.
58 ArcGlide THC Instruction Manual 806450
System description for a Hypernet configuration
CNC with Hypernet
HPR plasma system
with Hypernet
ArcGlide lifter
HMI (optional)
Industrial Ethernet
switch
ArcGlide control module
Key:
Hypernet connection
– – – – – –
Discrete connection
——————
Figure 11 shows the cable and signal connections in a Hypernet communication configuration.
Hypernet cables transmit serial communication.
Figure 11
2–Installation
ArcGlide THC Instruction Manual 806450 59
2 – Installation
Customer-supplied operator console
(optional):
Station on/off/program switch
Station active light
Lifter UP/DOWN switch
CNC
Plasma system
ArcGlide lifter
HMI (optional)
ArcGlide control module
Key:
Hypernet connection
– – – – – –
Discrete connection
——————
System description for a discrete configuration
Figure 12 shows the cable and signal connections in a discrete communication configuration.
For information on multi-drop configurations, refer to the instruction manual for your plasma system.
Figure 12
60 ArcGlide THC Instruction Manual 806450
2–Installation
ArcGlide communication configuration examples
Ta bl e 5 lists the ArcGlide configurations on the following pages. If you are viewing this manual online, click the page
number in the left column to view that configuration.
Tabl e 5
Drawing
number and
page
Connection to plasma Connection to CNC
1
page 63
2
page 64
3
page 65
4
page 66
5
page 67
6
page 68
7
page 69
Hypernet to multiple HPR or HPRXD plasma
systems, each with plasma interface board
141162. Requires an Ethernet switch.
Discrete to HPR or HPRXD plasma system with
plasma interface board 141094.
Discrete to HPR or HPRXD plasma system with
plasma interface board 141094.
Discrete to HPR or HPRXD plasma system with
plasma interface board 141094.
Discrete to HPR400XD or HPR800XD plasma
system with plasma interface board 141094.
Discrete to HPR or HPRXD plasma system with plasma interface board141094, showing circuits,
signals, and connections to terminal blocks.
Discrete to HSD130 plasma system with the
plasma interface board 141094, machine interface
cable (123209) from the plasma interface board to
the control board in the plasma system.
Hypernet to Hypernet-capable CNCs.
Hypernet to Hypernet-capable CNCs.
Discrete to a CNC with a Picopath interface.
Serial cable from CNC to plasma system, supplied
by the table manufacturer.
Discrete to third party CNC. Serial cable from
CNC to plasma system, supplied by the table
manufacturer.
Discrete to third party CNC. Serial cable from
CNC to plasma system, supplied by the table
manufacturer.
Discrete to a CNC with a Picopath interface.
8
page 70
9
page 71
10
page 72
Discrete to MAX 200, HT2000 or HT2000 LHF
plasma system with plasma interface board
141094. 1 X 6 interface cable between the
plasma interface board and plasma system.
Discrete to MAX 200, HT2000 or HT2000 LHF plasma system with plasma interface board 141094,
showing circuits, signals, and connections to terminal blocks.
Discrete to Powermax plasma systems with
plasma interface board 141094 and Powermax
interface cable 023206 between the plasma
interface board and the Powermax plasma system.
Discrete to a CNC with a Picopath interface.
Discrete to a CNC with a Picopath interface.
ArcGlide THC Instruction Manual 806450 61
2 – Installation
Drawing
number and
page
Connection to plasma Connection to CNC
11
page 73
12
page 74
13
page 75
14
page 76
ArcGlide to Picopath CNC. Discrete to a CNC with a Picopath interface.
Provides suggested cable termination at CNC
port.
Discrete communication to any plasma system with plasma interface board 141094, showing circuits,
signals, and connections to terminal blocks.
Hypernet communication to MAXPRO200 plasma
system with plasma interface board 141162
installed. Requires an Ethernet switch.
Discrete communication to MAXPRO200 plasma
system.
Hypernet to Hypernet-capable CNCs.
Discrete communication to a CNC with a Picopath
interface.
WARNING!
SHOCK HAZARD, ENERGY HAZARD, AND FIRE HAZARD
Connecting directly to the plasma circuit for access to raw arc voltage increases the risk of shock
hazard, energy hazard, and fire hazard in the event of a single fault. The output voltage and the output
current of the circuit are specified on the data plate.
The output of the internal voltage divider board is designed to prevent shock, energy and fire hazards, and is intended
to satisfy most codes and standards for external wiring outside the electrical enclosure.
All external wiring practices for an unprotected raw arc voltage should be reviewed and approved by the local
inspection authorities at the time of installation prior to operation and use. Raw arc voltage wiring terminals and
connections should not be exposed to accidental contact under normal and single fault conditions. External wiring
from an unprotected (that is, no voltage divider used in the power source) raw arc voltage routed inside conduit
between electrical enclosures will normally satisfy all electrical codes and standards worldwide. Failure to address
the hazards associated with live contact, accessibility and single fault failures to this unprotected output can result in
death or fire.
A voltage divider board inside the CNC protects only the CNC and does NOT protect the external interconnecting
wiring between the power source and the CNC. Overcurrent protection may be required to protect the user or machine
in fault conditions.
External wiring outside the electrical enclosure should be suitable for the installation and meet national and local
regulations (for example, NFPA 70 NEC, NFPA 79, Canadian Electrical Code, CSA/CAN E60974-1, IEC 60204-1,
BS 7671) or other codes or standards applicable to the installed site where the equipment will be operated.
62 ArcGlide THC Instruction Manual 806450
Shielded Ethernet cables, up to 61 m
(200 feet) long
Rotary address switch,
set to 1
Industrial Ethernet switch
with 5, 8, or 16 ports
ArcGlide control module
Interlock
ArcGlide lifters
HPR130/HPR260
HPR130XD/HPR260XD
HPR400XD/HPR800XD
with built-in Hypernet adapter or optional
Hypernet kit
(228611) or (228604)
Hypernet
Hypernet plasma interface board
(141162) installed in the plasma system
(below)
Interlock
Optional ArcGlide HMI
Lifter I/O cable
Rotary address switch, set to 1
Rotary address switch, set to 1
Rotary address switch,
set to 2
Optional ArcGlide HMI
EDGE Pro, EDGE Pro Ti,
or MicroEDGE Pro CNC
Shielded Ethernet cables, up to 61 m
(200 feet) long
Rotary address switch,
set to 2
ArcGlide control module
Lifter I/O cable
Rotary address switch,
set to 2
Hypernet plasma interface board
(141162) installed in the plasma system
(below)
1 – Multiple ArcGlide THCs with Hypernet connection to a Hypernet-enabled CNC and HPR or HPRXD plasma system
2 – Installation
ArcGlide THC Instruction Manual 806450 63
2 – Installation
Lifter I/O cable
ArcGlide lifter
Hypernet
Rotary address switch, set to 1
Shielded Ethernet cable up to 61 m (200 foot) long
DB37 to DB37 cable
(123760)
DB50
Arc voltage sense wiresDiscrete plasma interface board (141094)
HPR130/260 or HPR130/260XD plasma system
EDGE Pro, EDGE Pro Ti,
or MicroEDGE Pro CNC
2 – ArcGlide THC with Hypernet connection to a Hypernet-enabled CNC and discrete connection to an HPR130/260 or HPR130/260XD plasma system
64 ArcGlide THC Instruction Manual 806450
3 – ArcGlide THC with discrete connection to a Picopath interface CNC and HPR130/260 or HPR130/260XD plasma system
CNC I/O cable
ArcGlide control module
Optional ArcGlide HMI
Rotary address switch, set to 1
Rotary address switch,
set to 1
Lifter I/O cable
Discrete plasma interface board (141094) Arc voltage sense wires
ArcGlide lifter
Shielded Ethernet cable, up
to 61 m (200 feet) long
Plasma I/O cable
Serial cable supplied by the
table manufacturer
RS-422 serial port
Serial cable supplied by
the table manufacturer
To CNC RS-422 serial port,
terminate as required
DB37 (female)
DB37 (male)
HPR control board
Cable 223192 without serial
(with red band)
To plasma
interface board
Cable 223192
without serial (with
red band)
DB50
(male)
HPR130/260 or HPR130/260XD plasma system
DB37 (female)
Picopath interface CNC
Axes 3, 4
Axes 1, 2
I/O
2 – Installation
ArcGlide THC Instruction Manual 806450 65
2 – Installation
Discrete plasma interface board (141094) Arc voltage sense wires
Serial cable supplied by the
table manufacturer
Serial cable supplied by the table
manufacturer
To CNC RS-422 serial port,
terminate as required
DB37 (female)
HPR control board
Cable 223192 without serial
(with red band)
To plasma
interface board
Cable 223192
without serial
(with red band)
DB37 (female)
DB37 (male)
CNC I/O cable
Optional ArcGlide HMI
Rotary address switch, set to 1
ArcGlide control module
Rotary address switch,
set to 1
ArcGlide lifter
Shielded Ethernet cable, up
to 61 m (200 feet) long
Plasma I/O cable
DB50
(male)
Lifter I/O cable
RS-422 serial port
Generic CNC with serial
communication
HPR130/260 or HPR130/260XD plasma system
Axes 3, 4
Axes 1, 2
I/O
4 – ArcGlide THC with discrete connection to a generic CNC and HPR130/260 or HPR130/260XD plasma system
66 ArcGlide THC Instruction Manual 806450
5 – ArcGlide THC with discrete connection to a generic CNC and HPR400/800XD plasma system
CNC I/O cable
RS-422 serial port
Optional ArcGlide HMI
Rotary address switch, set to 1
Rotary address switch,
set to 1
Shielded Ethernet cable, up
to 61 m (200 feet) long
Plasma I/O cable
Lifter I/O cable
ArcGlide control module
ArcGlide lifter
DB50
(male)
DB37 (female)
Cable 223192 without serial
(with red band)
Serial cable supplied by the table manufacturer
Arc voltage
sense wires
To CNC RS-422 serial port, terminate as required
Generic CNC with serial
communication
Discrete plasma interface board
(141094)
HPR400XD plasma system
Axes 3, 4
Axes 1, 2
I/O
2 – Installation
ArcGlide THC Instruction Manual 806450 67
2 – Installation
1
2
7
8
6
5
PULL UP
24V *
J2-2
FIELD COMMON
J2-1
J2-3
FIELD COMMON
J2-4
J2-6
FIELD COMMON
J2-5
J2-7
FIELD COMMON
J2-8
J2-10
FIELD COMMON
J2-9
J2-11
J2-12
J2-13
J2-14
J2-16
J2-15
J3-2
J3-1
RELAY
CORNER
PIERCE
RELAY
J3-3
J3-4
J3-8
J3-7
RELAY
PLASMA START
HOLD
RELAY
J3-5
J3-6
SPARE
RELAY
J3-9
J3-10
J3-12
J3-11
RELAY
REMOTE ON
J2-14
FIELD COMMON
J2-13
J2-15
+24V THC
J2-16
24V
3
4
2
1
9
10
11
12
13
14
15
16
24V *
PULL UP
PULL UP
24V *
PULL UP
24V *
4
3
6
5
8
7
10
9
12
14
11
13
FUTURE USE
FOR I/O USE IF NEEDED
500MA MAX
ARC XFER
D3
D4
THC ON
D2
PLASMA STRT
PLASMA ON
D1
15
16
5 Rampdown error
2 Common
3 Error
4 Common
6 Common
7 Not ready
8 Common
9 Spare in
14 Common
16 Not connected
12 Remote ON B
11 Remote ON A
14 Common
13 Common
16 Field +24 V out
15 Field +24 V out
1 Motion**
6 Hold B
5 Hold A
8 Plasma Start**
7 Plasma Start A**
10 Spare out B
9 Spare out A
DB37 to DB37 interface cable
(123760)
2 Corner B
1 Corner A
4 Pierce B
3 Pierce A
To terminal block 2,
pins 1 and 3
Electrode -
Work +
J2 Inputs
J3 Outputs
J2 Inputs
J3 Outputs
** Motion and Start are the minimum connections. Use other signals if they are
supported by the plasma system.
10 Common
11 Common
12 Common
13 Common
15 Not connected
Discrete plasma interface board (141094)
Arc voltage sense wires to
plasma system, use ~0.9 mm
2
(18 AWG) twisted pair wire,
rated 600 V or greater.
To plasma system Electrode-
To plasma system Work+
6 – Discrete plasma interface board with connection to an HPR or HPRXD plasma system
68 ArcGlide THC Instruction Manual 806450
* 24 V pull-up resistors on inputs are active only if they are set to dry (D) on the ArcGlide control module
7 – ArcGlide THC with discrete communication to a Picopath interface CNC and HSD130 plasma system
Electrode -
Work +
Arc voltage sense wires to plasma system, use ~0.9 mm
2
(18 AWG) twisted pair wire,
rated 600 V or greater.
Optional ArcGlide HMI
Rotary address switch, set to 1
Shielded Ethernet cable, up
to 61 m (200 feet) long
Lifter I/O cable
ArcGlide control module
ArcGlide THC lifter
DB50 (male)
Rotary address switch, set to 1
Plasma I/O cable
CNC I/O cable
See the table in the drawing on page 73 for information about
wiring Picopath I/O.
Plasma interface board (141094), mounted externally by the customer
Interface cable 123209
1.5 m (5 feet)
Discrete plasma interface
board (141094)
HSD130
CNC with Picopath interface
DB37
Axes 1, 2
I/O
Axes 3, 4
2 – Installation
ArcGlide THC Instruction Manual 806450 69
2 – Installation
MACHINE
1X6
Arc voltage sense wires to plasma system, use ~0.9 mm2 (18 AWG) twisted pair wire,
rated 600 V or greater.
Rotary address switch, set to 1
Lifter I/O cable
ArcGlide control module
ArcGlide lifter
Rotary address switch, set to 1
Plasma I/O cable
CNC I/O cable
See the table in the drawing on page 73 for information
about wiring Picopath I/O.
Discrete plasma
interface board
(141094)
MAX200
Shielded Ethernet cable
Picopath interface CNC
Optional ArcGlide HMI
1 X 6 machine interface cable
Axes 1, 2
I/O
Axes 3, 4
See the table in the drawing on page 73 for information
about wiring Picopath I/O.
8 – ArcGlide THC with discrete connections to a Picopath interface CNC and MAX200, HT2000, or HT2000LHF plasma system
70 ArcGlide THC Instruction Manual 806450
9 – Discrete plasma interface board with connection to MAX200, HT2000, or HT2000 LHF plasma system
1
2
7
8
6
5
IHS SYNC
J3-5
J3-6
HOLD
1
RELAY
RELAY
PLASMA START
PULL UP
24V
J2-2
FIELD COMMON
J2-1
J3-8
J3-7
HOLD IGNITION
MACHINE MOTION
DELAYED
36(37)
31(32)
9
START
15
5
J2 J3
COMMON
COMMON
1X6
MACHINE
( ) - FOR HT2000, HT2000LHF
+24V
+24V
Plasma interface board (141094), mounted externally
by the customer
Discrete plasma interface board
(141094)
1 x 6 machine interface cable
Remove
Replace with
bushing (008245)
Electrode -
Work +
Motion - Red
Hold A - White
Start B - Black
Hold B- Black
Common - Blue
Not connected
Plasma interface termination
Signal Wire color Pin Cable label
Plasma Start A Blue 9 82
Plasma Start B Black 15 83
Hold A White 1 87
Hold B Black 5 86
Motion Red 36 (37*) 84
Common Blue 31 (32*) 85
Ring terminal to ground stud Shield wire No connection
Set plasma inputs to dry (D) using the input switch on the control module. ( * ) For HT2000, HT2000LHF
ArcGlide plasma interface terminal blocks
Machine interface 1 X 6 CPC connector
To plasma system
Wor k +
To plasma system
Electrode -
Refer to the HT2000 Instruction
Manual (802070) or the
HT2000LHF Instruction Manual
(803020) for information about the
1 X 6 connection
Arc voltage sense wires to plasma system, use ~0.9 mm
2
(18 AWG) twisted pair wire,
rated 600 V or greater.
Start A - Blue
2 – Installation
ArcGlide THC Instruction Manual 806450 71
2 – Installation
1
2
7
8
RELAY
PLASMA START
PULL UP
24V
J2-2
FIELD COMMON
J2-1
J3-8
J3-7
MACHINE MOTION
12
14
3
START
4
J2 J3
COMMON
J6 J5
J3 J2 J1
J27
WORK
LEAD
J26
RED
J18
ORG
J17
J11
B
R
J28
J15
J16
+24V
Optional ArcGlide HMI
Motion - Red
CNC with Picopath interface
Start - Green
Start - Black
Common -
Black
Powermax machine interface
connector
Terminal blocks on the
discrete plasma interface
board
For Work and Electrode connections, see the table at right.
Powermax
65/85/105/125
Powermax
1000/1230/1650
Plasma Interface Termination
Signal Wire color Powermax pins
Plasma Start A Green 3
Plasma Start B Black 4
Motion A Red 12
Common Black 14
Arc voltage
1000/1230/1650 Electrode- 0.9 mm2 (18 AWG) J16
Work+ 0.9 mm
2
(18 AWG) J15
65/85 CSA Electrode-
0.9 mm
2
(18 AWG)
See Field Service Bulletin
Machine Interface for
Raw Arc Voltage
(807060)
J28
Work+ J26
65/85 CE Electrode- J29
Work+ J27
105/125 CSA or CE Electrode- J28
Work+ J27
ArcGlide control module
CNC I/O cable
Shielded Ethernet cable
Rotary address switch, set to 1
Rotary address switch, set to 1
Set ArcGlide plasma inputs to dry (D) using the plasma input
switch on the THC processor board in the control module.
Lifter I/O cable
Plasma I/O cable
Discrete plasma interface
board (141094)
ArcGlide lifter
Powermax
1000/1230/1650
Powermax
65/85/105/125
Powermax machine interface cable
(023206)
Electrode -
Wor k +
Arc voltage sense wires to plasma system.
Use ~0.9 mm
2
(18 AWG) twisted pair wire,
rated 600 V or greater.
Axes 1, 2
I/O
Axes 3, 4
10 – Discrete plasma interface board with connection to Powermax plasma systems
72 ArcGlide THC Instruction Manual 806450
11 – ArcGlide with discrete connection to a Picopath interface CNC
A
B
D S D S
CNC PLASMA
17
18
INPUT 12
OUTPUT 10
OUTPUT 11
OUTPUT 12
5
7
1
26
25
INTERLOCK
12
32
31
30
MOTION
CYCLE START
AVC DISABLE
IHS SYNC
24V COMMON
COMMON
31
24V
PULL UP
24V
PULL UP
24V
PULL UP
CUT/MARK
SENSE
RELAY
BREAKAWAY
BREAKAWAY
37
11
INPUT 11
22
21
COMMON
JUMPER
JUMPER
COMMON
29
30
TORCH
INPUT
24V
+24V
+24V
Picopath CNC end A
CNC I/O cable
Picopath interface CNC
I/O
Axes 1, 2
Axes 3, 4
ArcGlide control module
ArcGlide control module end B
Set dry contacts by sliding
the switch to D.
Picopath connector kit (228490)
End A of the Hypertherm ArcGlide CNC I/O cable is terminated during installation and will work only if the I/O setup in Phoenix software corresponds to the setup
described in this half of this table.
End B of the Hypertherm ArcGlide CNC I/O cable is terminated at the
factory as described in this half of the table.
Pin No. Function* Phoenix mapping name Wire color* Pin No. Signal
32 Output 12 Cut Control Red 1 Cycle start input +
31 Output 11 Hold Ignition Blue 7 IHS sync input +
30 Output 10 Torch Height Disable Green 5 AVC disable input +
12 Input 12** Cut/Mark Sense Green 17 Machine motion output A
Jumper blue and red, pins 18 and 29.
Red 18 Machine motion output B
Blue 29 Common
11 Input 11** Torch Collision Yellow 21 Torch breakaway output A
Jumper red and green, pins 22 and 30.
Red 22 Torch breakaway output B
Green 30 Common
External switch
Satisfy with switch or jumper.
Orange 25 Interlock input + **
Red 26 Interlock input - **
37 24 V common Yellow 31 Common
Backshell Chassis ground Drain wire Ring terminal Chassis ground
* This example uses CNC outputs 10, 11, 12, and inputs 11 and 12. Assign the I/O points in the Phoenix software.
** Set ArcGlide plasma inputs to dry (D) using the plasma input switch on the THC processor board in the control module.
* Multiple wires are the same color. Verify pin-to-pin connections before plugging cables into equipment.
** ArcGlide interlock must be closed to enable ArcGlide motion.
2 – Installation
ArcGlide THC Instruction Manual 806450 73
2 – Installation
1
2
7
8
6
5
PULL UP
24V *
J2-2
FIELD COMMON
J2-1
J2-3
FIELD COMMON
J2-4
J2-6
FIELD COMMON
J2-5
J2-7
FIELD COMMON
J2-8
J2-10
FIELD COMMON
J2-9
J2-11
J2-12
J2-13
J2-14
J2-16
J2-15
J3-2
J3-1
RELAY
CORNER
PIERCE
RELAY
J3-3
J3-4
J3-8
J3-7
RELAY
PLASMA START
HOLD
RELAY
J3-5
J3-6
SPARE
RELAY
J3-9
J3-10
J3-12
J3-11
RELAY
REMOTE ON
J2-14
FIELD COMMON
J2-13
J2-15
+24V THC
J2-16
24V
3
4
2
1
9
10
11
12
13
14
15
16
24V *
PULL UP
PULL UP
24V *
PULL UP
24V *
4
3
6
5
8
7
10
9
12
14
11
13
FUTURE USE
FOR I/O USE IF NEEDED
500MA MAX
ARC XFER
D3
D4
THC ON
D2
PLASMA STRT
PLASMA ON
D1
15
16
24V *
PULL UP
5 Rampdown error
2 Common
3 Error
4 Common
6 Common
7 Not ready
8 Common
9 Spare in
14 Common
16 Not connected
1 Motion**
10 Common
12 Common
15 Not connected
13 Common
11 Common
12 Remote ON B
11 Remote ON A
14 Common
13 Common
16 Field +24 V out
15 Field +24 V out
6 Hold B
5 Hold A
8 Plasma Start**
7 Plasma Start A**
10 Spare out B
9 Spare out A
2 Corner B
1 Corner A
4 Pierce B
3 Pierce A
J2 Inputs
J3 Outputs
To plasma system Electrode -
To plasma system Work +
Electrode -
Work +
J2 Inputs
J3 Outputs
** Motion and Start are the minimum connections. Use other signals if they
are supported by the plasma system.
Discrete plasma interface
board (141094)
To plasma system
machine interface
* 24 V pull-up resistors on inputs are active only if they are set to dry (D) on the THC processor board in the control module.
No connection
Arc voltage sense wires to plasma system.
Use ~0.9 mm
2
(18 AWG) twisted pair wire,
rated 600 V or greater.
12 – Discrete plasma interface board with connection to any plasma system
74 ArcGlide THC Instruction Manual 806450
13 – ArcGlide THC with Hypernet connection to an EDGE Pro CNC and MAXPRO200 plasma system
ArcGlide lifter
Rotary address switch, set to 1
Optional ArcGlide HMI
Industrial Ethernet switch
with 5, 8, or 16 ports
EDGE Pro, Micro EGDE Pro,
or EDGE Pro Ti CNC
Lifter I/O cable
Interlock
Hypernet
ArcGlide control module
Rotary address switch, set to 1
Shielded Ethernet cables, up to 61 m
(200 feet) long
Rotary address switch, set to 1
Shielded Ethernet cables, up
to 61 m (200 feet) long
Hypernet plasma interface board (141162)
installed in the plasma system
MAXPRO200 with built-in Hypernet adapter
or optional Hypernet kit (428276)
2 – Installation
ArcGlide THC Instruction Manual 806450 75
2 – Installation
25
26
Optional ArcGlide HMI
Lifter I/O cable
ArcGlide control module
Rotary address switch, set to 1
Rotary address switch, set to 1
Plasma I/O cable
Shielded Ethernet cable, up to
61 m (200 feet) long
CNC I/O cable
ArcGlide lifter
Arc voltage sense wires to plasma system. Use
~0.9 mm
2
(18 AWG) twisted pair wire, rated
600 V or greater.
Yellow/black 26- wire
Terminal strip
Discrete plasma interface
module
(228572) or (228576)
Yellow 25+ wire
MAXPRO200
CNC with Picopath
interface
Machine interface cable (223327)
I/O
Axes 1, 2
Axes 3, 4
14 – ArcGlide THC with discrete connection to a Picopath interface CNC and MAXPRO200 plasma system
76 ArcGlide THC Instruction Manual 806450
Install the lifter
114.30 mm
(4.5 inch)
6.75 mm (0.27 inch) diameter
44.45mm (1.75inch)
44.45mm (1.75inch)
44.45mm (1.75inch)
44.45mm (1.75inch)
44.45mm (1.75inch)
44.45mm (1.75inch)
44.45mm (1.75inch)
44.45mm (1.75inch)
44.45mm (1.75inch)
44.45mm (1.75inch)
2–Installation
Figure 13
ArcGlide THC Instruction Manual 806450 77
2 – Installation
Level
Side panel
Side panel
1
2
3
4
b
6
d
5
c
a
b
1. Position the lifter on the gantry:
Low enough that the torch can reach the workpiece.
High enough that the torch does not touch the table.
The bottom of the lifter must be within 20 mm (8 inches) of the
thinnest workpiece.
Mounting holes have the same spacing as the Sensor THC and
Command THC lifters.
2. Mount the lifter on the gantry:
a. Remove the shield panels and side panels to expose the mounting
screw holes.
b. Loosely fasten the screws in a diagonal pattern, top to bottom and
right to left (see the numbers in the illustration on the right).
c. Use a minimum of 4 screws to mount the lifter.
d. Place a level vertically along the side of the lifter to verify that it is
mounted vertically.
e. Tighten the screws using a maximum torque of 9.1 kg∙cm (8.0 in∙lb).
f. When they are tightened, the tops of the screws must be below the
surface of the back panel of the lifter so the side panels can be
replaced.
g. Reinstall the side panels and shield panels.
3. Connect the lifter interface cable and secure it.
a. The cable connector is not rated for hard use or constant flexing.
Support the cable and add enough slack to prevent strain on the
cable and prevent damage to the cable assembly, lifter connector, or
both.
b. Use the cable clamp that is included with the lifter to secure the
cable to either side of the lifter with a generous service loop.
c. Connect the cable ground to the ground connector on the top of the
lifter.
78 ArcGlide THC Instruction Manual 806450
Connect the ohmic wire from HPRXD plasma systems
6
7
5
Front view of the motor
enclosure
Lifter motor
Ohmic wire from an HPRXD
plasma system
Side view of the lifter
Do not splice ohmic wires.
Figure 14
2–Installation
To connect the ohmic wire from an HPRXD torch to the ArcGlide lifter:
1. Remove the top cover of the motor compartment on the lifter.
2. Disconnect the existing ohmic wire from the J5 connector on the underside of the lifter interface board.
3. Remove the ohmic wire from the motor compartment of the lifter.
4. Cut the terminal end off the ohmic wire from the HPRXD torch and strip 5 mm (0.2 inch) of the covering.
5. Insert the end of the ohmic wire from the HPRXD system through the grommet in the bottom of the motor
6. Insert the stripped HPRXD ohmic wire into the J5 connector on the underside of the lifter interface board.
7. Use cable ties to fasten the wire to the mounts on the inside back wall of the lifter compartment.
8. Replace the top cover of the motor compartment.
ArcGlide THC Instruction Manual 806450 79
compartment of the lifter.
2 – Installation
2
Ohmic wire
Connect the ohmic wire to other plasma systems
Do not splice ohmic wires.
If your plasma system is not an HPRXD system, connect the ArcGlide ohmic
wire to the torch:
1. Unfasten the cable tie around the coiled ohmic wire and straighten the
ohmic wire.
2. Install the free end of the ohmic wire on the IHS tab on the torch retaining
cap.
Ground the lifter
The lifter must be grounded correctly to make sure the lifter performs
accurate initial height sense (IHS).
To ground the lifter:
1. Remove the bottom nut and washer of the grounding assembly on
the lifter.
2. Fit the terminal on the ground wire over the grounding post.
3. Replace the bottom nut and washer on the ground post and
finger-tighten it so the terminal is in contact with the washer and
bottom nut.
4. Connect the other end of the ground wire to a terminal on the table
ground bus bar on the cutting machine.
5. Verify that the wire is not in the path of the lifter mechanics
See Recommended grounding and shielding practices on page 55 for
more information.
80 ArcGlide THC Instruction Manual 806450
2–Installation
ArcGlide and HPRXD torch (228354)
with standard sleeve
ArcGlide and HPRXD torch (228354)
with extended sleeve (220790)
228.60 mm
(9.00 inch)
111.76 mm
(4.40 inch)
355.60 mm
(14.00 inch)
127.00 mm
(5.00 inch)
228.60 mm
(9.00 inch)
355.60 mm
(14.00 inch)
239 mm
(9.40 inch)
Extended torch sleeve option
An extended torch sleeve (220790) is available for torches used with HPR130XD, HPR260XD, HPR400XD, and
HPR800XD plasma systems. This torch sleeve extends the reach of the torch tip 127.00 mm (5.00 inches) and increases
the mounting flexibility of your cutting machine setup.
For additional stability, clamp the torch body as close to the torch tip as possible.
Extended torch sleeve options for the MAXPRO200 plasma system are 220942 and 220943.
Figure 15
ArcGlide THC Instruction Manual 806450 81
2 – Installation
Breakaway pressure switch,
normally-open
Breakaway
Moisture drain
Pressure gauge
Black = 1
Filter/regulator
Inlet port 0.25 inch NPTF*
6.9 bar (100 psi)
Wire to emergency stop
circuit
33.34 mm
(1.31 inch)
Tu bi ng
Pin 1
Pin 4
Pin 3
Blue = 3 (not connected)
Brown = 4
* National pipe thread female
Install the optional pneumatic breakaway
Installing the torch breakaway kit on the lifter assembly also requires using parts of the torch mounting block kit of the
proper diameter.
The maximum inlet pressure of the pressure regulator is 10.2 bar (150 psi). Typically, the maximum inlet pressure
should be set at 6.9 bar (100 psi).
The routing of the leads, stall force, IHS speed, and acceleration or deceleration movements can affect the pressure
setting required to achieve reliable operation.
If air pressure is removed, the breakaway must be manually repositioned when air is applied. The breakaway will not
rest in its position when air pressure is lost.
Figure 16
2 hexagonal screws, 4 mm X
40 mm (8-32 X 1.50 inch),
supplied by the customer
To install the pneumatic breakaway:
1. Mount the fiberglass bracket to the lifter using the 4 hexagonal screws.
2. Mount the breakaway to the fiberglass bracket using the 6 screws.
3. Attach the torch mounting block to the breakaway with the collar and 2 screws.
4. Wire the electrical output of the breakaway to the torch collision input of the CNC.
5. Mount the filter/regulator.
6. Connect the tubing between the filter/regulator and the breakaway.
82 ArcGlide THC Instruction Manual 806450
2–Installation
7. Install the air supply to the filter/regulator inlet port at 6.9 bar (100 psi), the recommended pressure.
8. Adjust the filter/regulator to indicate 2 bar (30 psi), the recommended starting pressure, on the gauge. Typical
operating pressure is 2.75 bar to 4 bar (40 psi to 60 psi)
9. Simulate a crash by forcing the breakaway to separate by hand.
10. Manually reposition the breakaway in the locked position.
11 . Adjust the air pressure until the desired trip force is achieved.
12. Enable the emergency stop circuit at the CNC after the breakaway is installed.
ArcGlide THC Instruction Manual 806450 83
2 – Installation
358.65 mm
(14.12 inch)
25.40 mm
(1.00 inch)
166.62 mm
(6.56 inch)
157.23 mm
(6.19 inch)
107. 95 mm
(4.25 inch)
Front view
Right side view
Rear view
377.70 mm
(14.87 inch)
71.63 mm
(2.82 inch)
127.00 mm
(5.00 inch)
165.00 mm
(6.50 inch)
5.10 mm (0.20 inch) wide
6.35 mm (0.25 inch) bolt
168.91 mm
(6.65 inch)
381.00 mm
(15.37 inch)
371.35 mm
(14.62 inch)
Install the control module
Install the control module where it will be easy to read the display and to reach the controls during installation and
troubleshooting. A dry, dust-free wiring cabinet is ideal. Leave a clearance space of 200 mm (8 inches) from the front of
the control module and 6.00 mm (0.25 inch) from the heatsink.
Figure 17
84 ArcGlide THC Instruction Manual 806450
2–Installation
1
1
2
1 Switch 1 set to ON 2 THC processor board (228578)
1. Mount the control module with 4 screws.
2. Connect the end of the lifter interface cable with the red band to the connector marked Lifter (with the red circle).
See Connect Hypernet cables on page 92 or Connect discrete cables on page 95 for more information.
3. Attach one end of the power cord to the AC power connector on the front of the control module. Prepare the other
end for the 100 VAC – 120 VAC or 200 VAC – 230 VAC power outlet.
Modify Retract Delay Time for an HT2000 plasma system
If you are installing an ArcGlide THC with an HT2000 plasma system, set switch 1 on the auxiliary DIP switch options
( ) to ON on the THC processor board (228578) in the control module. This setting modifies Retract Delay Time for
correct operation.
Figure 18
ArcGlide THC Instruction Manual 806450 85
2 – Installation
Ground the control module
To ground the control module:
1. Remove the top nut and washer of the grounding assembly on the front of the control module.
2. Fit the ground wire terminal over the grounding post.
3. Replace the top nut and washer on the ground post and finger-tighten it so the terminal is in contact with the washer
and the bottom nut.
4. Connect the other end of the ground wire to a terminal on the table ground bus bar on the cutting machine.
See Recommended grounding and shielding practices on page 55 for more information.
Figure 19
See Operating the control module on page 135 for more information.
86 ArcGlide THC Instruction Manual 806450
Install the optional HMI
117.60 mm
(4.63 inch)
Front view
Bottom view
63.50 mm
(2.50 inch)
5.00 mm
(0.20 inch)
diameter
10-32 X 9.52 mm
(0.375 inch)
Phillips screw
Right side view
19.43 mm
(0.77 inch)
65.00 mm
(2.50 inch)
9.55 mm
(0.38 inch)
203.20 mm
(8.00 inch)
298.00 mm
(11.73 inch)
130.58 mm
(5.14 inch)
101 .6 0 m m
(4.00 inch)
2–Installation
Figure 20
ArcGlide THC Instruction Manual 806450 87
2 – Installation
Two HMIs stacked and mounted
level under a surface.
HMI mounted on a surface
and tilted down.
HMI mounted on a surface
and tilted up.
The mounting brackets on the top and bottom of the HMI allow you to install it singly or stacked, under or on another
piece of equipment, and level or tilted. See Figure 21.
Figure 21
To install the HMI:
1. Remove the mounting bracket from the HMI.
2. Place the mounting bracket on the surface where you will mount the HMI and attach the bracket with screws through
the holes in the bottom of the bracket.
3. Remount the HMI in the mounting bracket by loosely fastening the screws through the sides of the bracket into the
top or bottom holes in the sides of the HMI.
4. Adjust the HMI to the angle you want it and tighten the screws.
5. Attach one end of the power cord to the AC power connector on the back of the HMI. Prepare the other end for the
100VAC–120VAC or 200–230VAC power outlet.
You can also mount the HMI on top of the EDGE Pro CNC. The
EDGE Pro enclosure has 4 mounting holes for the HMI bracket.
Use 4 10-32 x 1/2 inch screws to fasten the HMI to the EDGE Pro
CNC enclosure.
88 ArcGlide THC Instruction Manual 806450
2–Installation
Ground the HMI
To ground the HMI:
1. Remove the top nut and washer of the grounding assembly on the back of the HMI.
2. Fit the ground wire terminal over the grounding post.
3. Replace the top nut and the washer on the ground post and finger-tighten it so the terminal is in contact with the
washer and bottom nut.
4. Connect the other end of the ground wire to a terminal on the gantry ground bus bar of the cutting machine.
See Recommended grounding and shielding practices on page 55 for more information.
Figure 22
See Operating the HMI on page 143 for more information.
ArcGlide THC Instruction Manual 806450 89
2 – Installation
152.40 mm
(6.00 inch)
114.30 mm
(4.50 inch)
Install the plasma interface board in a plasma system
The plasma interface board includes the voltage divider and allows the ArcGlide THC to communicate with the plasma
system.
If you are replacing a Command THC with an ArcGlide THC, you must replace the Command THC plasma interface
board in your plasma system with an ArcGlide plasma interface board.
Discrete plasma interface board (141094)
The discrete plasma interface board is mounted in an enclosure that is installed in your plasma system, either internally or
externally. For specific instructions and safety-related information about mounting the enclosure, refer to the manual that
came with your plasma system.
Figure 23
See Discrete plasma interface board (141094) on page 224 for information about electrical installation.
90 ArcGlide THC Instruction Manual 806450
2–Installation
HPR130XD and HPR260XD HPR400XD
Hypernet plasma
interface board
Hypernet plasma interface board (141162)
The Hypernet plasma interface board is mounted inside an HPRXD plasma system on standoffs built into the plasma
system, as shown in Figure 24.
Figure 24
See Hypernet plasma interface board (141162) on page 228 for information about electrical installation.
ArcGlide THC Instruction Manual 806450 91
2 – Installation
Connect Hypernet cables
A system configuration in which there is more than one Hypernet connection requires an industrial-grade Ethernet switch.
See Ethernet switch on page 46 for more information.
In this type of configuration, Hypernet connections are made from the ArcGlide control module directly to the Ethernet
switch and from there to the CNC or plasma system. See Figure 11 on page 59 for an example.
Each unit assigned to a station must have the same Hypernet address. This common address between units allows
the Ethernet switch to direct communications to the appropriate station. See Figure 25 for an example.
Figure 25
Station 1
Lifter
HPR plasma system
HMI
Hypernet address: 1
HyPath CNC Ethernet switch
HMI
Hypernet address: 2
Key:
Hypernet connection
Discrete connection
ArcGlide control module
Hypernet address: 1
ArcGlide control module
Hypernet address: 2
Lifter
See the following pages for details:
Hypernet plasma interface
board
Hypernet address: 1
Station 2
HPR plasma system
Hypernet plasma interface
board
Hypernet address: 2
See Assign an ArcGlide THC to a station on page 125 for information about linking unit addresses to a station in
Phoenix software on a Hypertherm CNC.
See the following sections for the location of the unit address switches:
HMI processor board (228581) on page 211
THC processor board (228578) on page 220
Hypernet plasma interface board (141162) on page 228
Hypernet connections and Ethernet connection to a LAN cannot be made through the same switch. If your cutting
machine is connected to a LAN over Ethernet, you must use a separate Ethernet switch for these connections.
92 ArcGlide THC Instruction Manual 806450
Figure 26
PWR2PWR1
1A @24V
123456
To Ethernet switch power supply 2
To Ethernet switch power supply 1
+
+
+--
Power connections to the Ethernet switch Hypernet connections to the Ethernet switch
To the Ethernet
switch
To the Ethernet
switch
2–Installation
It is also possible to have a mixed Hypernet and discrete configuration in which the ArcGlide THC communicates with
only the CNC or plasma system over Hypernet and uses discrete communication for the alternate connection. See Mixed
communication on page 51.
Use the portions of the following instructions that apply to your configuration.
1. Use a Hypernet cable to connect the control module to
the Ethernet switch:
a. Insert one end of the Hypernet cable into the
Hypernet port on the front of the control module.
b. Insert the other end of the cable into one of the ports
of the Ethernet switch.
2. Use a Hypernet cable to connect the CNC to the Ethernet
switch.
a. Insert one end of the Hypernet cable into the Hypernet
port on the back of a Hypertherm CNC or to a
dedicated, Hypernet port on any other CNC.
b. Insert the other end of the cable into one of the ports
of the Ethernet switch.
ArcGlide THC Instruction Manual 806450 93
2 – Installation
To the Ethernet
switch
To the Ethernet
switch
3. Use a Hypernet cable to connect the plasma system to the
Ethernet switch:
a. Insert one end of the Hypernet cable into the Hypernet
port on the plasma interface board in the plasma
system.
b. Insert the other end of the cable into one of the ports
of the Ethernet switch.
Refer to the manual for your plasma system for detailed
instructions about these connections.
4. If your configuration includes the optional HMI, use a
Hypernet cable to connect it to the Ethernet switch:
a. Insert one end of the Hypernet cable into the Hypernet
port on the HMI.
b. Insert the other end of the cable into one of the ports
of the Ethernet switch.
94 ArcGlide THC Instruction Manual 806450
2–Installation
Hypernet connection
between the HMI and the
control module
Connect discrete cables
In a discrete configuration, the communication connections are made from the control module to the HMI, CNC, plasma
system, and optional operator console. In this type of configuration, the control module and HMI communicate over a
single Hypernet connection. Therefore, this is the only configuration that does not require an Ethernet switch. See
Figure 12 on page 60.
It is also possible to have a mixed Hypernet and discrete configuration in which the ArcGlide THC communicates with the
CNC or the plasma system over a discrete connection and uses Hypernet communication for the remaining connection.
In configurations where there is more than one connection of Hypernet, an industrial-grade Ethernet switch is required for
the Hypernet connections.
Use the portions of the following instructions that apply to your configuration.
Each port on the front of the control module is color-coded to match the connector on the interface cable that connects
to it, as shown in the illustrations for each cable later in this section.
To extract pins and sockets from the Amp style connectors used to create and troubleshoot discrete I/O cables, use
the AMP pin extractor tool (008197).
Ground all cables with circular connectors
See Recommended grounding and shielding practices on page 55 for more information on
system grounding.
1. Remove the top nut and washer of the grounding assembly.
2. Fit the ground wire terminal on the cable over the grounding post.
3. Replace the top nut and the washer on the ground post and finger-tighten it so the
terminal is in contact with the washer and bottom nut.
Control module cable connections
1. Connect the HMI to the control module:
a. Insert one end of the HMI cable into the Hypernet connector on
the front of the control module.
b. Insert the other end of the cable into the Hypernet port on the
back of the HMI.
ArcGlide THC Instruction Manual 806450 95
2 – Installation
Discrete connection to the CNC
Discrete connection to the plasma
system
Connection to the operator
console
Connection to the lifter
2. Connect the CNC to the control module:
a. Insert the end of the CNC I/O cable with the yellow band into the
CNC I/O connector on the front of the control module.
b. Connect the wires on the other end of the cable to the I/O signals on
the CNC.
See CNC I/O cable on page 105 for more information.
3. Connect the plasma system to the control module:
a. Insert the end of the plasma interface I/O cable with the blue band
into the Plasma I/O connector on the front of the control module.
b. Connect the other end of the cable into the plasma I/O connector
(J5) on the plasma interface board in the plasma system.
See Plasma interface I/O cable on page 110 for more information.
4. If your configuration includes a, optional, customized operator console,
connect it to the control module:
a. Connect the end of the operator console I/O cable with the green
band into the operator console I/O connector on the front of the
control module.
b. Connect the other end of the cable into the appropriate connectors
on the custom operator console.
See Optional operator console I/O cable on page 101 for more information.
5. See Install the lifter on page 77 for more information on connecting the
ArcGlide lifter to the control module.
96 ArcGlide THC Instruction Manual 806450
2–Installation
Customer-supplied power 220 VAC
Customer-supplied power 120 VAC
L1 – line
L2 – neutral
PE ground
L1 – line
L2 – line
PE ground
Power entry module:
2 Fuses: 250 V, 5 A, slow blow,
0.25 inch x 1.25 inch
Power entry module:
2 Fuses: 250 V, 5 A, slow blow,
0.25 inch x 1.25 inch
Cables
Power cable
An AC power cable is standard equipment for North America, and is shipped with the ArcGlide THC. For other regions,
use a power cable that has an IEC-60320-C13 end which meets the requirements of local code and power connections.
To make a power cable, use the power connector (108842) that ships with the ArcGlide THC and connect a 3-wire
cable for line, neutral, and ground signals according to local electrical codes. Figure 27 shows examples of how power
cables can be made.
Figure 27
ArcGlide THC Instruction Manual 806450 97
2 – Installation
Red band
Diameter = 20.07 mm (0.79 inch)
Bend radius = 150.00 mm (6.00 inch)
Connect one end to the port on the control
module with the red circle. Connect the other
end to the top of the lifter.
Lifter interface cable
Part number Length Part number Length
223219 3.0 m (10 feet) 223115 23.0 m (75 feet)
223220 6.0 m (20 feet) 223116 30.5 m (100 feet)
223120 7.5 m (25 feet) 223117 45.5 m (150 feet)
223221 10.5 m (35 feet) 223118 61.0 m (200 feet)
223007 15.0 m (50 feet)
Pin No.* Color and size Signal name
1 Red 1.31 mm
2 Black 1.31 mm
3 Black 0.82 mm
4 Brown 0.33 mm
5 Brown 0.82 mm
6 Gray 0.33 mm
7 White 0.33 mm
8 Violet 0.33 mm
9 Black 0.33 mm
10 Red 0.33 mm
11 White/Blue 0.33 mm
12 Blue 0.33 mm
13 White/Yellow 0.33 mm
* Pin numbers are the same on both ends of the cable.
2
(16 AWG) Motor +
2
(16 AWG) Motor -
2
(18 AWG) Brake -
2
(22 AWG) Common -
2
(18 AWG) Power +24 VDC
2
(22 AWG) Ohmic contact sense common
2
(22 AWG) Ohmic contact sense
2
(22 AWG) Ohmic contact sense bias +12 VDC
2
(22 AWG) Encoder common
2
(22 AWG) Lifter station active
2
(22 AWG) Encoder input B -
2
(22 AWG) Encoder input B +
2
(22 AWG) Encoder input A -
98 ArcGlide THC Instruction Manual 806450
Pin No.* Color and size Signal name
14 Yellow 0.33 mm2 (22 AWG) Encoder input A +
15 White/Black 0.33 mm
16 White/Red 0.33 mm
17 Green 0.33 mm
18 Orange 0.33 mm
19 White/Violet 0.33 mm
20 White/Orange 0.33 mm
21 White/Green 0.33 mm
22 White/Gray 0.33 mm
23 White/Brown 0.33 mm
2
(22 AWG) Common -
2
(22 AWG) Change consumables switch +
2
(22 AWG) Lifter down switch +
2
(22 AWG) Lifter up switch +
2
(22 AWG) Breakaway switch +
2
(22 AWG) Upper limit switch +
2
(22 AWG) Lower limit switch +
2
(22 AWG) Not connected
2
(22 AWG) Common -
24 Not connected
* Pin numbers are the same on both ends of the cable.
2–Installation
ArcGlide THC Instruction Manual 806450 99
2 – Installation
Diameter = 6.35 mm (0.25 inch)
Bend radius = 152.40 mm (6.00 inch)
Connect one end to the control module or Ethernet switch.
Connect the other end to the ArcGlide HMI.
Hypernet and HMI interface cable
In a Hypernet or mixed configuration where there is more than one Hypernet connection, use these cables to connect the
components of the system to the Ethernet switch.
Part number Length Part number Length
223212 3.0 m (10 feet) 223099 23.0 m (75 feet)
223222 6.0 m (20 feet) 223100 30.5 m (100 feet)
223119 7.5 m (25 feet) 223101 45.5 m (150 feet)
223223 10.5 m (35 feet) 223102 61.0 m (200 feet)
223008 15.0 m (50 feet)
If you use Ethernet cable from another supplier, make sure that the cable is a standard, shielded RJ-45 Cat5e or Cat6
cable.
Pin No.* Signal name
1 Tx + (transmit data +)
2 Tx - (transmit data -)
3 Rx + (receive data +)
4 Not connected
5 Not connected
6 Rx - (receive data -)
7 Not connected
8 Not connected
* Pin numbers are the same on both ends of the cable.
100 ArcGlide THC Instruction Manual 806450
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