Thermal Dynamics IHC XT Operating Manual

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Victor Thermal Dynamics product. We are proud to have you as
our customer and will strive to provide you with the best service and reliability in the industry.
This product is backed by our extensive warranty and world-wide service network. To locate your
nearest distributor or service agency call 1-800-752-7622, or visit us on the web at www.thermal­dynamics.com.

This Operating Manual has been designed to instruct you on the correct use and operation of
your Victor Thermal Dynamics product. Your satisfaction with this product and its safe operation
is our ultimate concern. Therefore please take the time to read the entire manual, especially the
Safety Precautions. They will help you to avoid potential hazards that may exist when working
with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.
Victor Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products
for Victor Technologies.

We distinguish ourselves from our competition through market-leading, dependable products
that have stood the test of time. We pride ourselves on technical innovation, competitive prices,
excellent delivery, superior customer service and technical support, together with excellence in
sales and marketing expertise.

Above all, we are committed to developing technologically advanced products to achieve a safer
working environment within the welding industry

iHC XT plasma Height Controller
Operating Manual No. 0-5352

Published by:
Thermal Dynamics Corporation.
2800 Airport Rd.
Denton, Texas 76207

www.thermal-dynamics.com

© Copyright 2015 by
Thermal Dynamics Coporation.

All rights reserved.

Reproduction of this work, in whole or in part, without written permission of the pub­lisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.

Original Publication Date: August 19, 2015

Record the following information for Warranty purposes:

Where Purchased:_______________________________________________

Purchase Date:__________________________________________________

Power Supply Serial #:___________________________________________

Torch Serial #:___________________________________________________

i

!

WARNING

Read and understand this entire Manual and your employer’s safety practices
before installing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s
best judgement, the Manufacturer assumes no liability for its use.

Be sure this information reaches the operator.

You can get extra copies through your supplier.

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully fa­miliar with the principles of operation and safe practices for arc welding and
cutting equipment, we urge you to read our booklet, “Precautions and Safe
Practices for Arc Welding, Cutting, and Gouging,” Booklet 0-5407. Do NOT
permit untrained persons to install, operate, or maintain this equipment. Do
NOT attempt to install or operate this equipment until you have read and
fully understand these instructions. If you do not fully understand these in­structions, contact your supplier for further information. Be sure to read the
Safety Precautions before installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and
accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with
the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained
equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be
replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends
that a telephone or written request for service advice be made to the Authorized Distributor from whom it was
purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manu­facturer. The user of this equipment shall have the sole responsibility for any malfunction which results from
improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufac-

turer or a service facility designated by the manufacturer.

!

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR

OPERATING.

PROTECT YOURSELF AN D OTHERS!

ASSUREZ-VOUS QUE CETTE INFORMATION EST DISTRIBUÉE À L’OPÉRATEUR.

VOUS POUVEZ OBTENIR DES COPIES SUPPLÉMENTAIRES CHEZ VOTRE

FOURNISSEUR.

ATTENTION

       

seulement. Si vous n’avez pas une connaissance approfondie des prin-

cipes de fonctionnement et des règles de sécurité pour le soudage à l’arc

et l’équipement de coupage, nous vous suggérons de lire notre brochure

« Precautions and Safe Practices for Arc Welding, Cutting and Gouging, »

         -

taller, d’opérer ou de faire l’entretien de cet équipement. Ne tentez PAS

d’installer ou d’opérer cet équipement avant de lire et de bien comprendre

ces instructions. Si vous ne comprenez pas bien les instructions, commu-

niquez avec votre fournisseur pour plus de renseignements. Assurez-vous

de lire les Règles de Sécurité avant d’installer ou d’opérer cet équipement.

RESPONSABILITÉS DE L’UTILISATEUR

Cet équipement opérera conformément à la description contenue dans ce manuel, les étiquettes

d’accompagnement et/ou les feuillets d’information si l’équipement est installé, opéré, entretenu et réparé



utiliser un équipement qui ne fonctionne pas bien ou n’est pas bien entretenu. Les pièces qui sont brisées,
usées, déformées ou contaminées doivent être remplacées immédiatement. Dans le cas où une réparation
ou un remplacement est nécessaire, il est recommandé par le fabricant de faire une demande de conseil de
service écrite ou par téléphone chez le Distributeur Autorisé de votre équipement.



fabricant. L’utilisateur de l’équipement sera le seul responsable de toute défaillance résultant d’une utilisa-



personne autre que le fabricant ou un centre de service désigné par le fabricant.

!

ASSUREZ-VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D’UTILISATION AVANT

D’INSTALLER OU D’OPÉRER L’UNITÉ.

PROTÉGEZ-VOUS ET LES AUTRES!

This Page Intentionally Blank

TABLE OF CONTENTS

SECTION 1: SAFETY ........................................................................................ 1-1

1.01 Safety Precautions - ENGLISH ........................................................................ 1-1

1.02 Précautions de sécurité - FRENCH CANADIAN ............................................... 1-6

SECTION 2:

SPECIFICATIONS

..................................................................................... 2-1

2.01 System Description ......................................................................................... 2-1

2.02 Specifications ................................................................................................. 2-1

2.03 Basic System Schematic ................................................................................. 2-2

2.04 iHC XT Dimensions ......................................................................................... 2-2

2.05 Motor Dimensions .......................................................................................... 2-3

2.06 Lifter Dimensions ........................................................................................... 2-4

SECTION 3: INSTALLATION

............................................................................... 3-1

3.01 Installation IO requirements ............................................................................ 3-1

3.02 Mechanical ...................................................................................................... 3-2

3.03 Voltage Divider and Plasma IO ........................................................................ 3-2

3.04 Lifter Cable ..................................................................................................... 3-2

3.05 Collision Sensor .............................................................................................. 3-2

3.06 CNC IO ............................................................................................................ 3-3

3.07 Power and E-Stop ........................................................................................... 3-3

3.08 Software Setups ............................................................................................. 3-3

SECTION 4:

OPERATION

........................................................................................... 4-1

4.01 Buttons ........................................................................................................... 4-1

4.02 Main Display ................................................................................................... 4-1

4.03 Basic Operation with Embedded Cut Charts .................................................... 4-2

4.04 Basic Operation without Embedded Cut Charts ............................................... 4-3

4.05 Menu Structure ............................................................................................... 4-4

4.06 Basic Parameters ............................................................................................ 4-5

4.07 Status and State Messages ............................................................................. 4-5

4.08 Error Messages ............................................................................................... 4-5

4.09 Advanced Parameters ..................................................................................... 4-6

SECTION 5:

TROUBLESHOOTING AND MAINTENANCE

....................................................... 5-1

5.01 Maintenance ................................................................................................... 5-1

5.02 Troubleshooting .............................................................................................. 5-1

TABLE OF CONTENTS

SECTION 6:

PINOUTS AND CABLE EXAMPLES ................................................................. 6-1

6.01 IO example connections .................................................................................. 6-1

6.02 Connector locations ........................................................................................ 6-2

6.03 Power and E-stop connector ........................................................................... 6-3

6.04 J54 Lifter ........................................................................................................ 6-3

6.05 J55 Plasma ..................................................................................................... 6-4

6.06 J53 CNC .......................................................................................................... 6-5

6.07 Power cable general example ......................................................................... 6-6

6.08 iHT XT with servo motor cable ........................................................................ 6-7

6.09 CNC IO cable ................................................................................................... 6-8

6.10 Lifter cable ...................................................................................................... 6-9

6.11 Limit, Collision, Laser pointer cable .............................................................. 6-10

6.12 Plasma adapter cable .................................................................................... 6-11

6.13 Plasma cable with UC XT .............................................................................. 6-12

6.14 Plasma cable with AC XT .............................................................................. 6-13

6.15 Plasma cable with CutMaster ........................................................................ 6-14

6.16 Plasma and VDC general example ................................................................ 6-15

6.17 Voltage divider example ................................................................................ 6-16

6.18 CNC IO to Burny 10 LCD Plus example ......................................................... 6-17

6.19 CNC IO to Burny 10 LCD Plus OEM example ................................................ 6-18

6.20 CNC IO to Hypertherm MicroEdge example ......................................................19

SECTION 7:

REPLACEMENT PARTS

.............................................................................. 7-1

SECTION 8:

SOFTWARE UPDATE

................................................................................. 8-1

8.01 Preparations

......................................................................................................... 8-1

8.02 Installing the bootloader software

......................................................................... 8-1

8.03 Updating iHC XT processor card

........................................................................... 8-1

8.04 Updating iHC XT remote

....................................................................................... 8-3

8.05 Installing the cut chart server

............................................................................... 8-6

8.06 Updating the cut chart

.......................................................................................... 8-6

(Signature)

Declaration of Conformity

We Thermal Dynamics

of 2800 Airport Road

Denton, TX 76207 U.S.A.

in accordance with the following Directive(s):

2006/95/EC The Low Voltage Directive

2004/108/EC The Electromagnetic Compatibility Directive

hereby declare that:

Equipment: Plasma Cutting Height Controller
Model Name/Number: iHC XT
Market Release Date: August 19, 2015

is in conformity with the applicable requirements of the following harmonized standards:

Conforms to requirements of IEC 61326-1:2012
IEC 61000-4-2: 2008, Electro Static Discharge Immunity
IEC 61000-4-3:2006 +A1:2007 +A2:2010, Radiated, Radio-Frequency, Electromagnetic Immunity
IEC 61000-4-4:2012, Electrical Fast Transient/Burst Immunity
IEC 61000-4-6: 2008, Conducted Radio-Frequency Electromagnetic Immunity
IEC 61000-4-8:2009, Power Frequency Magnetic Field Immunity
CISPR 11:2009 +A1:2010, AC Mains Conducted Emissions
CISPR 11:2009 +A1:2010, Radiated Emissions
Meets IEC 61010-1:2010 Safety requirements for electrical equipment for measurement, control, and

laboratory use - Part 1: General requirements

Classification: The equipment described in this document is Class A and intended for industrial use.

!

WARNING

This Class A equipment is not intended for use in residential locations where the electrical power
is provided by the public low-voltage supply system. There may be potential difficulties in ensuring
electromagnetic compatibility in those locations, due to conducted as well as radiated distur­bances.

Manufacturer’s Authorized Representative
Steve Ward V.P. Europe and General Manager
Address:Victor Technologies International Inc.

Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX

Date: August 19, 2015

Steve Ward

Full Name

V.P. Europe and General Manager

(Position)

!

WARNING

This Class A equipment is not intended for use in residential locations where the electrical power
is provided by the public low-voltage supply system. There may be potential difficulties in ensuring
electromagnetic compatibility in those locations, due to conducted as well as radiated distur­bances.

iHC XT

Manual 0-5352 SAFETY INSTRUCTIONS 1-1

SECTION 1: SAFETY

1.01 Safety Precautions - ENGLISH

!

WARNING: These Safety Precautions are for your protection. They summarize precautionary informa­tion from the references listed in Additional Safety Information section. Before performing any instal-

lation or operating procedures, be sure to read and follow the safety precautions listed below as well
as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result
in injury or death.

PROTECT YOURSELF AND OTHERS -- Some welding, cutting, and gouging processes are noisy
and require ear protection. The arc, like the sun, emits ultraviolet (UV) and other radiation and
can injure skin and eyes. Hot metal can cause burns. Training in the proper use of the pro-

cesses and equipment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any work area, even if welding helmets, face shields,
and goggles are also required.

2. Use a face shield fitted with the correct filter and cover plates to protect your eyes, face, neck, and
ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not
to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuffless trousers, high-topped shoes,
and a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal.
A flameproof apron may also be desirable as protection against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars
should be kept buttoned, and open pockets eliminated from the front of clothing.

5. Protect other personnel from arc rays and hot sparks with a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can
fly far. Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat from flames and arcs can start fires. Hot slag or sparks can also
cause fires and explosions. Therefore:

1. Remove all combustible materials well away from the work area or cover the materials with a protective
non-flammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels,
solvents, paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a
hidden smoldering fire or fires on the floor below. Make certain that such openings are protected
from hot sparks and metal.“

3. Do not weld, cut or perform other hot work until the work piece has been completely cleaned so that
there are no substances on the work piece which might produce flammable or toxic vapors. Do not
do hot work on closed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use, such as a garden hose, water pail, sand
bucket, or portable fire extinguisher. Be sure you are trained in its use.

5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and
create a fire hazard.

6. After completing operations, inspect the work area to make certain there are no hot sparks or hot
metal which could cause a later fire. Use fire watchers when necessary.

7. For additional information, refer to NFPA Standard 51B, “Fire Prevention in Use of Cutting and Weld­ing Processes”, available from the National Fire Protection Association, Battery march Park, Quincy,
MA 02269.

iHC XT

1-2 SAFETY INSTRUCTIONS Manual 0-5352

ELECTRICAL SHOCK -- Contact with live electrical parts and ground can cause severe injury or death.
DO NOT use AC welding current in damp areas, if movement is confined, or if there is danger of
falling.

1. Be sure the power source frame (chassis) is connected to the ground system of the input power.

2. Connect the work piece to a good electrical ground.

3. Connect the work cable to the work piece. A poor or missing connection can expose you or others
to a fatal shock.

4. Use well-maintained equipment. Replace worn or damaged cables.

5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from work and from ground.

7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on
dry boards or an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific grounding recommendations. Do
not mistake the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current flowing through any
conductor causes localized Electric and Magnetic Fields (EMF ). Welding and cutting current creates
EMF around welding cables and welding machines. Therefore:

1. Welders having pacemakers should consult their physician before welding. EMF may interfere with
some pacemakers.

2. Exposure to EMF may have other health effects which are unknown.

3. Welders should use the following procedures to minimize exposure to EMF:

A. Route the electrode and work cables together. Secure them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work cables. Route cables on the same side of your

body.
D. Connect the work cable to the work piece as close as possible to the area being welded.
E. Keep welding power source and cables as far away from your body as possible.

FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in confined

spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation.

Therefore:

1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld,
cut, or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or
cadmium unless positive mechanical ventilation is provided. Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that
ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work
area. Do not continue to operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations.

5. WARNING: This product contains chemicals, including lead, known to the State of California to cause
birth defects and other reproductive harm. Wash hands after handling.

iHC XT

Manual 0-5352 SAFETY INSTRUCTIONS 1-3

CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden
rupture of cylinder, valve, or relief device can injure or kill. Therefore:

1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate
from the compressed gas cylinder. Do not use adaptors. Maintain hoses and fittings in good condition.
Follow manufacturer’s operating instructions for mounting regulator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercar­riages, benches, walls, post, or racks. Never secure cylinders to work tables or fixtures where they
may become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not con­nected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and flames. Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1, “Precautions for Safe Handling of Compressed
Gases in Cylinders”, which is available from Compressed Gas Association, 1235 Jefferson Davis
Highway, Arlington, VA 22202.

!

EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death.
Therefore:

1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do
not perform any electrical work unless you are qualified to perform such work.

2. Before performing any maintenance work inside a power source, disconnect the power source from
the incoming electrical power.

3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order.
Do not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position and in good repair.

6. Use equipment only for its intended purpose. Do not modify it in any manner.

!

ADDITIONAL SAFETY INFORMATION -- For more information on safe practices for electric arc weld­ing and cutting equipment, ask your supplier for a copy of “Precautions and Safe Practices for Arc
Welding, Cutting and Gouging”, Form 52-529.

The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.

2. AWS C5.1 - “Recommended Practices for Plasma Arc Welding”.

3. AWS C5.2 - “Recommended Practices for Plasma Arc Cutting”.

4. AWS C5.3 - “Recommended Practices for Air Carbon Arc Gouging and Cutting”.

5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.

6. AWS C5.6 - “Recommended Practices for Gas Metal Arc Welding”.

7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, “Recommended Safe Practices for Welding and Cutting of Containers That Have Held
Hazardous Substances.”

9. CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.

iHC XT

1-4 SAFETY INSTRUCTIONS Manual 0-5352

!

Meaning of symbols - As used throughout this manual: Means Attention! Be Alert! Your safety is involved.

DANGER

Means immediate hazards which, if not avoided, will result in immediate, serious
personal injury or loss of life.

CAUTION

Means potential hazards which could result in personal injury or loss of life.

WARNING

Means hazards which could result in minor personal injury.

Enclosure Class

The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or
water. Protection is provided against touch with a finger, penetration of solid objects greater than 12mm and
against spraying water up to 60 degrees from vertical. Equipment marked IP21S may be stored, but is not
intended to be used outside during precipitation unless sheltered.

CAUTION

This product is solely intended for plasma cutting. Any other use may result in per­sonal injury and / or equipment damage.

CAUTION

If equipment is placed on a surface that slopes more
than 15°, toppling over may occur. Personal injury and
/ or signicant damage to equipment is possible.

15°

Art# A-12726

Art# A-12736

CAUTION

To avoid personal injury and/or equipment damage,
lift using method and attachment points shown here.

iHC XT

Manual 0-5352 SAFETY INSTRUCTIONS 1-5

This Page Intentionally Blank

iHC XT

1-6 SAFETY INSTRUCTIONS Manual 0-5352

1.02 Précautions de sécurité - FRENCH CANADIAN

!

AVERTISSEMENT : Ces règles de sécurité ont pour but d’assurer votre protection. Ils récapitulent les
informations de précaution provenant des références dans la section des Informations de sécurité

supplémentaires. Avant de procéder à l’installation ou d’utiliser l’unité, assurez-vous de lire et de
suivre les précautions de sécurité ci-dessous, dans les manuels, les fiches d’information sur la sécurité du
matériel et sur les étiquettes, etc. Tout défaut d’observer ces précautions de sécurité peut entraîner des bles­sures graves ou mortelles.

PROTÉGEZ-VOUS -- Les processus de soudage, de coupage et de gougeage produisent un
niveau de bruit élevé et exige l’emploi d’une protection auditive. L’arc, tout comme le soleil,

émet des rayons ultraviolets en plus d’autre rayons qui peuvent causer des blessures à la peau
et les yeux. Le métal incandescent peut causer des brûlures. Une formation reliée à l’usage des processus et
de l’équipement est essentielle pour prévenir les accidents. Par conséquent:

1. Portez des lunettes protectrices munies d’écrans latéraux lorsque vous êtes dans l’aire de travail, même
si vous devez porter un casque de soudeur, un écran facial ou des lunettes étanches.

2. Portez un écran facial muni de verres filtrants et de plaques protectrices appropriées afin de protéger
vos yeux, votre visage, votre cou et vos oreilles des étincelles et des rayons de l’arc lors d’une opé­ration ou lorsque vous observez une opération. Avertissez les personnes se trouvant à proximité de
ne pas regarder l’arc et de ne pas s’exposer aux rayons de l’arc électrique ou le métal incandescent.

3. Portez des gants ignifugiés à crispin, une chemise épaisse à manches longues, des pantalons sans
rebord et des chaussures montantes afin de vous protéger des rayons de l’arc, des étincelles et du
métal incandescent, en plus d’un casque de soudeur ou casquette pour protéger vos cheveux. Il est
également recommandé de porter un tablier ininflammable afin de vous protéger des étincelles et de
la chaleur par rayonnement.

4. Les étincelles et les projections de métal incandescent risquent de se loger dans les manches retrous­sées, les rebords de pantalons ou les poches. Il est recommandé de garder boutonnés le col et les
manches et de porter des vêtements sans poches en avant.

5. Protégez toute personne se trouvant à proximité des étincelles et des rayons de l’arc à l’aide d’un
rideau ou d’une cloison ininflammable.

6. Portez des lunettes étanches par dessus vos lunettes de sécurité lors des opérations d’écaillage ou de
meulage du laitier. Les écailles de laitier incandescent peuvent être projetées à des distances consi­dérables. Les personnes se trouvant à proximité doivent également porter des lunettes étanches par
dessus leur lunettes de sécurité.

INCENDIES ET EXPLOSIONS -- La chaleur provenant des flammes ou de l’arc peut provoquer un
incendie. Le laitier incandescent ou les étincelles peuvent également provoquer un incendie ou une
explosion. Par conséquent :

1. Éloignez suffisamment tous les matériaux combustibles de l’aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininflammable. Les matériaux combustibles incluent le bois, les vête­ments, la sciure, le gaz et les liquides combustibles, les solvants, les peintures et les revêtements, le
papier, etc.

2. Les étincelles et les projections de métal incandescent peuvent tomber dans les fissures dans les
planchers ou dans les ouvertures des murs et déclencher un incendie couvant à l’étage inférieur
Assurez-vous que ces ouvertures sont bien protégées des étincelles et du métal incandescent.

3. N’exécutez pas de soudure, de coupe ou autre travail à chaud avant d’avoir complètement nettoyé la
surface de la pièce à traiter de façon à ce qu’il n’ait aucune substance présente qui pourrait produire
des vapeurs inflammables ou toxiques. N’exécutez pas de travail à chaud sur des contenants fermés
car ces derniers pourraient exploser.

4. Assurez-vous qu’un équipement d’extinction d’incendie est disponible et prêt à servir, tel qu’un tuyau
d’arrosage, un seau d’eau, un seau de sable ou un extincteur portatif. Assurez-vous d’être bien instruit
par rapport à l’usage de cet équipement.

iHC XT

Manual 0-5352 SAFETY INSTRUCTIONS 1-7

5. Assurez-vous de ne pas excéder la capacité de l’équipement. Par exemple, un câble de soudage
surchargé peut surchauffer et provoquer un incendie.

6. Une fois les opérations terminées, inspectez l’aire de travail pour assurer qu’aucune étincelle ou
projection de métal incandescent ne risque de provoquer un incendie ultérieurement. Employez des
guetteurs d’incendie au besoin.

7. Pour obtenir des informations supplémentaires, consultez le NFPA Standard 51B, “Fire Prevention
in Use of Cutting and Welding Processes”, disponible au National Fire Protection Association, Batte­rymarch Park, Quincy, MA 02269.

CHOC ÉLECTRI QUE -- Le contact avec des pièces électriques ou les pièces de mise à la terre sous
tension peut causer des blessures graves ou mortelles. NE PAS utiliser un courant de soudage c.a.
dans un endroit humide, en espace restreint ou si un danger de chute se pose.

1. Assurez-vous que le châssis de la source d’alimentation est branché au système de mise à la terre
de l’alimentation d’entrée.

2. Branchez la pièce à traiter à une bonne mise de terre électrique.

3. Branchez le câble de masse à la pièce à traiter et assurez une bonne connexion afin d’éviter le risque
de choc électrique mortel.

4. Utilisez toujours un équipement correctement entretenu. Remplacez les câbles usés ou endommagés.

5. Veillez à garder votre environnement sec, incluant les vêtements, l’aire de travail, les câbles, le por­teélectrode/torche et la source d’alimentation.

6. Assurez-vous que tout votre corps est bien isolé de la pièce à traiter et des pièces de la mise à la terre.

7. Si vous devez effectuer votre travail dans un espace restreint ou humide, ne tenez vous pas directement
sur le métal ou sur la terre; tenez-vous sur des planches sèches ou une plate-forme isolée et portez
des chaussures à semelles de caoutchouc.

8. Avant de mettre l’équipement sous tension, isolez vos mains avec des gants secs et sans trous.

9. Mettez l’équipement hors tension avant d’enlever vos gants.

10. Consultez ANSI/ASC Standard Z49.1 (listé à la page suivante) pour des recommandations spécifiques
concernant les procédures de mise à la terre. Ne pas confondre le câble de masse avec le câble de
mise à la terre.

CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de danger. Le courant élec­trique qui passe dans n’importe quel conducteur produit des champs électriques et magnétiques
localisés. Le soudage et le courant de coupage créent des champs électriques et magnétiques

autour des câbles de soudage et l’équipement. Par conséquent :

1. Un soudeur ayant un stimulateur cardiaque doit consulter son médecin avant d’entreprendre une
opération de soudage. Les champs électriques et magnétiques peuvent causer des ennuis pour cer­tains stimulateurs cardiaques.

2. L’exposition à des champs électriques et magnétiques peut avoir des effets néfastes inconnus pour
la santé.

3. Les soudeurs doivent suivre les procédures suivantes pour minimiser l’exposition aux champs élec­triques et magnétiques :

A. Acheminez l’électrode et les câbles de masse ensemble. Fixez-les à l’aide d’une bande adhésive

lorsque possible.
B. Ne jamais enrouler la torche ou le câble de masse autour de votre corps.
C. Ne jamais vous placer entre la torche et les câbles de masse. Acheminez tous les câbles sur le

même côté de votre corps.
D. Branchez le câble de masse à la pièce à traiter le plus près possible de la section à souder.
E. Veillez à garder la source d’alimentation pour le soudage et les câbles à une distance appropriée

de votre corps.

iHC XT

1-8 SAFETY INSTRUCTIONS Manual 0-5352

LES VAPEURS ET LES GAZ -- peuvent causer un malaise ou des dommages corporels, plus par­ticulièrement dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le gaz de protec­tion risque de causer l’asphyxie.

Par conséquent :

1. Assurez en permanence une ventilation adéquate dans l’aire de travail en maintenant une ventilation
naturelle ou à l’aide de moyens mécanique. N’effectuez jamais de travaux de soudage, de coupage
ou de gougeage sur des matériaux tels que l’acier galvanisé, l’acier inoxydable, le cuivre, le zinc, le
plomb, le berylliym ou le cadmium en l’absence de moyens mécaniques de ventilation efficaces. Ne
respirez pas les vapeurs de ces matériaux.

2. N’effectuez jamais de travaux à proximité d’une opération de dégraissage ou de pulvérisation. Lors­que la chaleur ou le rayonnement de l’arc entre en contact avec les vapeurs d’hydrocarbure chloré,
ceci peut déclencher la formation de phosgène ou d’autres gaz irritants, tous extrêmement toxiques.

3. Une irritation momentanée des yeux, du nez ou de la gorge au cours d’une opération indique que
la ventilation n’est pas adéquate. Cessez votre travail afin de prendre les mesures nécessaires pour
améliorer la ventilation dans l’aire de travail. Ne poursuivez pas l’opération si le malaise persiste.

4. Consultez ANSI/ASC Standard Z49.1 (à la page suivante) pour des recommandations spécifiques
concernant la ventilation.

5. AVERTISSEMENT : Ce produitcontient des produits chimiques, notamment du plomb, reconnu par
l’Étatde la Californie pour causerdes malformations congénitaleset d’autresdommages touchant le
système reproductif.

Se laver les mainsaprès manipulation.

MANIPULATION DES CYLINDRES -- La manipulation d’un cylindre, sans observer les précautions
nécessaires, peut produire des fissures et un échappement dangereux des gaz. Une brisure sou­daine du cylindre, de la soupape ou du dispositif de surpression peut causer des blessures graves

ou mortelles. Par conséquent :

1. Utilisez toujours le gaz prévu pour une opération et le détendeur approprié conçu pour utilisation sur
les cylindres de gaz comprimé. N’utilisez jamais d’adaptateur. Maintenez en bon état les tuyaux et
les raccords. Observez les instructions d’opération du fabricant pour assembler le détendeur sur un
cylindre de gaz comprimé.

2. Fixez les cylindres dans une position verticale, à l’aide d’une chaîne ou une sangle, sur un chariot
manuel, un châssis de roulement, un banc, un mur, une colonne ou un support convenable. Ne fixez
jamais un cylindre à un poste de travail ou toute autre dispositif faisant partie d’un circuit électrique.

3. Lorsque les cylindres ne servent pas, gardez les soupapes fermées. Si le détendeur n’est pas branché,
assurez-vous que le bouchon de protection de la soupape est bien en place. Fixez et déplacez les
cylindres à l’aide d’un chariot manuel approprié. Toujours manipuler les cylindres avec soin.

4. Placez les cylindres à une distance appropriée de toute source de chaleur, des étincelles et des flam­mes. Ne jamais amorcer l’arc sur un cylindre.

5. Pour de l’information supplémentaire, consultez CGA Standard P-1, “Precautions for Safe Handling of
Compressed Gases in Cylinders”, mis à votre disposition par le Compressed Gas Association, 1235
Jefferson Davis Highway, Arlington, VA 22202.

!

ENTRETIEN DE L’ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou inadéquate peut
causer des blessures graves ou mortelles. Par conséquent :

1. Efforcez-vous de toujours confier les tâches d’installation, de dépannage et d’entretien à un personnel
qualifié. N’effectuez aucune réparation électrique à moins d’être qualifié à cet effet.

2. Avant de procéder à une tâche d’entretien à l’intérieur de la source d’alimentation, débranchez l’ali­mentation électrique.

3. Maintenez les câbles, les fils de mise à la terre, les branchements, le cordon d’alimentation et la source
d’alimentation en bon état. N’utilisez jamais un équipement s’il présente une défectuosité quelconque.

iHC XT

Manual 0-5352 SAFETY INSTRUCTIONS 1-9

4. N’utilisez pas l’équipement de façon abusive. Gardez l’équipement à l’écart de toute source de chaleur,
notamment des fours, de l’humidité, des flaques d’eau, de l’huile ou de la graisse, des atmosphères
corrosives et des intempéries.

5. Laissez en place tous les dispositifs de sécurité et tous les panneaux de la console et maintenez-les
en bon état.

6. Utilisez l’équipement conformément à son usage prévu et n’effectuez aucune modification.

!

INFORMATIONS SUPPLÉMENTAIRES RELATI VES À LA SÉCURITÉ -- Pour obtenir de l’information
supplémentaire sur les règles de sécurité à observer pour l’équipement de soudage à l’arc électrique
et le coupage, demandez un exemplaire du livret “Precautions and Safe Practices for Arc Welding,

Cutting and Gouging”, Form 52-529.
Les publications suivantes sont également recommandées et mises à votre disposition par l’American Welding

Society, 550 N.W. LeJuene Road, Miami, FL 33126 :

1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.

2. AWS C5.1 - “Recommended Practices for Plasma Arc Welding”.

3. AWS C5.2 - “Recommended Practices for Plasma Arc Cutting”.

4. AWS C5.3 - “Recommended Practices for Air Carbon Arc Gouging and Cutting”.

5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.

6. AWS C5.6 - “Recommended Practices for Gas Metal Arc Welding”.

7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, “Recommended Safe Practices for Welding and Cutting of Containers That Have
Held Hazardous Substances.”

9. CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.

!

SIGNIFICATION DES SYMBOLES - Ce symbole, utilisé partout dans ce manuel, signie “Attention” ! Soyez
vigilant ! Votre sécurité est en jeu.

DANGER

Signie un danger immédiat. La situation peut entraîner des blessures graves ou
mortelles.

MISE EN GARDE

Signie un danger potentiel qui peut entraîner des blessures graves ou
mortelles.

AVERTISSEMENT

Signie un danger qui peut entraîner des blessures corporelles mineures.

Classe de protection de l’enveloppe

L’indice de protection (codification IP) indique la classe de protection de l’enveloppe, c’est-à-dire, le degré de
protection contre les corps solides étrangers ou l’eau. L’enveloppe protège contre le toucher, la pénétration
d’objets solides dont le diamètre dépasse 12 mm et contre l’eau pulvérisée à un angle de jusqu’à 60 degrés
de la verticale. Les équipements portant la marque IP21S peuvent être entreposés à l’extérieur, mais ne sont
pas conçus pour être utilisés à l’extérieur pendant une précipitation à moins d’être à l’abri.

MISE EN GARDE

Ce produit a été conçu pour la découpe au plasma seulement. Toute autre
utilisation pourrait causer des blessures et/ou endommager l’appareil.

iHC XT

1-10 SAFETY INSTRUCTIONS Manual 0-5352

MISE EN GARDE

L’équipement pourrait basculer s’il est placé sur une
surface dont la pente dépasse 15°. Vous pourriez
vous blesser ou endommager l’équipement de façon
importante.

15°

Art# A-12726

Art# A-12736

MISE EN GARDE

Soulevez à l’aide de la méthode et des points d’attache
illustrés an d’éviter de vous blesser ou d’endommager
l’équipement.

iHC XT

Manual 0-5352 SPECIFICATIONS 2-1

SECTION 2:

SPECIFICATIONS

2.01 System Description

iHC XT is a torch height control designed for plasma cutting. iHC XT uses the plasma arc as a feedback to control the
cutting height between the torch and work piece while cutting. Initial height sensing is done by ohmic sensing or by the
use of collision sensor. iHC XT is made to be used with most plasma cutting systems.

2.02 Specifications

Input power requirement 24VDC / 5A
Input fuse 5A, slow blow
Input power cable wire size 1.5mm², AWG 17
Dimensions

see “2.03 iHC XT Dimensions” on page <?>,
Weight 3kg
Display 40 x 4 LCD
Buttons 6 + 1 Up and Down, IHS Test, Find Plate, Menu, Enter, Digital potentiom-

eter
Arc voltage division 1:80
Arc voltage measurement range 0 - 327V
Arc voltage measurement resolution 0.02V
Arc voltage measurement accuracy ± 0.2%
Arc voltage set range 50 - 300V
Motor type Oriental Motor PKP266D28A-L
Motor step angle 1.8 °
Motor holding torque 1.4 Nm
Lifter max speed >5000 mm/min with 5 mm ball screw lead (@ 1000rpm)

!

CAUTION

Wire sizes are for reference only. The installation must conform to national and local codes for
the type and method of wire being used

iHC XT

Manual 0-5352 INSTALLATION 3-1

SECTION 3: INSTALLATION

3.01 Installation IO requirements

Signal name Description Requirement

Ok To Move Input from plasma device Required (See details below)
Hold Input from CNC device Required (See details below)
External stop Output to CNC device Required (See details below)
IHS start Input from CNC device Required (See details below)
Limit switch Input from lifter Required (if using other than Victor Technologies provided

lifter)

Collision Input from collision sensor Required (if using other than Victor Technologies provided

collision sensor). (See details below)

Voltage divider Victor Technologies provided voltage

divider

Required (See details below)

Plasma start Output to plasma device Optional
IHS active Output to plasma device Optional

NOTE!

Not providing the connections and functionality related to signals marked as
“Required” will void warranty. See IO and cable info from section 6.

Ok To Move (Motion, Main arc) This needs to be a dry contact signal from a plasma device. This signal is used to determine
that the plasma arc has been established and still on.

Hold (Corner Freeze) This needs to be a dry contact signal from a CNC device. This signal is used to lock the height for
example slowing down in corners.

External Stop This is a dry contact signal from iHC XT to a CNC device input. This signal is used to tell the CNC device that
example a torch crash has happened. CNC device should stop all motion and turn off outputs when this signal is triggered.

IHS Start This needs to be a dry contact signal from a CNC device. This signal is used to start the piercing process and must
stay on to the end of cut.

Limit Switch This needs to be a dry contact signal from the lifter upper limit. This signal is used as a position reference when
powered up. The Victor Technologies provided lifter and cables has this signal wired.

Collision This needs to be a dry contact signal from the collision sensor. Please note that the sensor must be usable for
vertical plate sensing while the iHC uses this signal also as a safety backup for ohmic plate sensing.

Collision trigger during cutting will open external stop contatcs, drive the torch to upper limit, removes main arc output, turns
plasma on output OFF. External stop output contacts will remain open 2 seconds after the torch has reached upper limit. When
this happens IHS start needs to be recycled in order to continue cutting.

Collision trigger during transfer height will move the torch to upper limit.
Voltage Divider Victor Technologies provided voltage divider must be used and wires connected (ohmic sensing is required

unless collision sensor can be reliably used for IHS). Victor Technologies provided cables have all signals wired.
Plasma Start (Start/Stop)This is a dry contact signal to a plasma device. This signal is used to start the plasma arc. Victor

Technologies provided cables has this signal wired.
IHS Active (Preflow) This is a dry contact signal to a plasma device. This signal is used to start preflow when torch starts to

find the plate, this will reduce over all piercing time.

iHC XT

3-2 INSTALLATION Manual 0-5352

3.02 Mechanical

1. Start by mounting the iHC XT cabinet. See “2.03 iHC XT Dimensions” on page <?>.

2. Screw the cabinet in place with M4 screws from the bottom.

3. Mount the lifter. See “Lifter Dimensions” on page <?>.

3.03 Voltage Divider and Plasma IO

Art # A-12561

Art # A-12560

1. Locate a suitable location for the V-D Board inside the plasma and drill out mounting holes if needed.

2. Install the V-D board standoffs and the V-D Board. Connect the V-D cable 15-1210 or connect the voltage divider
wires to the 6 pin screw terminal.

3. Connect your plasma IO cables or prepare your plasma IO cable, see “SECTION 6:
PINOUTS AND CABLE EXAMPLES” on page <?> and route your cable from the iHC XT connector J55 Plasma to
the plasma power supply.

4. Connect wires to the voltage divider board marked Work and Electrode to the appropriate terminal inside the plasma.
Note that work has to be a low ohm connection to the table work (under 5 ohm).

Ohmic or Shield (cup) cable.

Some height controls including the iHC XT find the plate using an electrical or resistance measurement, thus “ohmic”, contact
between the conductive end of the torch and the metal or “plate” being cut. A wire, usually a single highly flexible wire that
withstands the reflective heat from the arc, is connected between the V-D board and the torch shield cup.

Ferrite cores

It is recommended that the Ohmic Sensing wire be wrapped through a ferrite core with several turns, at least 3 but more is
better, to reduce the energy conducted to the V-D board and into the plasma supply. The ferrite core should be located on
the wire where it enters the plasma supply. A second ferrite core added several feet (couple of meters) from the torch will
further reduce the conducted EMI that may couple to other cable/wires and cause interference.

3.04 Lifter Cable

1. Route your lifter cable or prepare the lifter cable according to the example picture on page <?>.

2. Connect the motor terminal to the motor.

3. Connect the upper limit and collision sensor connector.

4. Route cables to the iHC XT connector J54 Lifter.

3.05 Collision Sensor

1. Make sure the collision sensor sits tight in its place. Adjust the springs and alignment screws if necessary.

2. Make sure that the possible inductive sensors are correctly aligned so they detect the metal pressing against them.

iHC XT

Manual 0-5352 INSTALLATION 3-3

3.06 CNC IO

1. Locate the CNC connector J53 CNC IO at the back of the iHC XT.

2. Route CNC IO cable 15- according to the example picture on page <?>.

3. Route the cable between the iHC XT and the CNC device.

3.07 Power and E-Stop

1. Connect the power cable or connect your 24VDC power supply to pins 24VDC and GND. See more details on section
6

2. Wire a dry normally closed switch to pins E1 and E2. Note that the device will not power up without a closed contact
between these pins.

3.08 Software Setups

If you purchased the full package containing the lifter from Victor technologies you can skip to step “4. Plasma selec­tion”.

1. Encoder value

Navigate to

Menu --> System --> Parameters

Encoder pulses: Press ENTER and set up the encode value by the calculation below. Press ENTER again to save and

exit.
Encoder value is 6400000 / lifter screw rise in mm
Example lifter screw is 5 mm rise per 1 motor rotation
6400000 / 5 mm = 128 0000
Encoder value = 1280000

3. Collision sensor polarity

Navigate to

Select NO/NC based on your configuration

4. Plasma selection

Navigate to

Menu --> System and scroll down to:

Plasma: Press ENTER and select your plasma type from the list. Press ENTER again to select and exit.

Note

that if you set the plasma to Unknown all selections below will become hidden. See “4.04 Basic Operation without

Embedded Cut Charts” on page <?>.

Materials: Press ENTER and select the materials you want to be shown in the process selection in the main screen.

Categories: Press ENTER and select the processes you want to be shown in the process selection in the main screen.

Amperage/Gasses: The appearing list has already filtered out the processes excluded by the selections above.
Press ENTER and deselect individual processes you want to exclude from the process selection in the main screen.

iHC XT

3-4 INSTALLATION Manual 0-5352

This Page Intentionally Blank

iHC XT

Manual 0-5352 OPERATION 4-3

4.04 Basic Operation without Embedded Cut Charts

The instructions below are for systems where plasma type has been set to Unknown, see “4. Plasma selection” on
page <?>. Numbers inside parenthesis refer to the “Pierce/Cut Flow Sequence” illustration.

1. Long press MENU so that you get to basic parameters.

2. Use the Digital potentiometer to scroll to the wanted parameter.

3. Press ENTER on the selected parameter.

4. Use the digital potentiometer to set the value and press ENTER to apply.

5. Repeat steps 2-3 for:
Ignition height (4.): Height when igniting the pilot arc. Typical value is 50-70% less than pierce height.
Set arc voltage (9.): Arc voltage to be used in cutting process.
Cut height (8.): Height for cutting when not in arc voltage control.
Pierce height (6.): Height when piercing.
Pierce height time (7.- 8.): Time the torch stays in pierce height before moving to cut height (usually same as Pierce delay).
Pierce delay (7. - 8.): Time after the height control gives ‘OK to Move’ to the CNC device.

AVC ON : Set arc voltage control during cutting ON or OFF.
AVC Delay (8. - 9.): Delay after torch has reached cut height and will begin arc voltage control.

6. Find the initial plate position by pressing FIND PLATE.

7. Cut part.

NOTE!

Pierce delay is set as default by iHC XT. Put pierce delay to 0 seconds at the CNC. If
you want to set the pierce delay at the CNC please put Pierce delay to 0 at iHC XT.

NOTE!

Some cut charts do not have all the values explained above. Below are some
examples on finding usable parameters.

8. Ignition height can usually be set lower than pierce height or use the same value. Too high value can cause ignition

problems. Too low values can damage consumables.

9. Pierce height should be set as high as possible for best consumable life. Too high value can cause pierce problems.

Too low value can damage consumables.

10. Pierce height time is usually set equal to pierce delay. Too low value can cause the torch to crash to the slag puddle

created when piercing. Too high value can affect cut quality at the beginning of the cut.

11. AVC delay will keep the torch in cut height at the beginning of the cut. Too low value can cause the torch to crash.

Too high value can affect cut quality at the beginning of the cut.

iHC XT

4-4 OPERATION Manual 0-5352

4.05 Menu Structure

MAIN SCREEN

Toggle Laser pointer
Ignition Height
Set arc voltage
Cut Height
Pierce Height
Pierce Height Time
Pierce Delay
AVC
AVC Delay
Retract Height
Start Homing
Unit
Collision Retract
Info
System

Basic parameters

Plasma Type
Cutchart version
Software versions
Serial number

System info

Parameters
Inputs
Outputs
Restore Default Values

Advanced parameters and I/O

Encoder pulses
Home distance
High Jog Speed
Find Plate Speed
Low Jog Speed
Plate c. rel. spd
Slow down height
Hold off AVC delay
Adjust Speed
Hold on Limit
Hold off Limit
Homing Speed
Main arc lost time out
Upper sw limit dist.
Lower sw limit dist.
Transfer height timeout
Full speed
Manual acceleration
Machine acceleration
Voltage gain
Manual deceleration
Machine deceleration
Collis. retract hgt
Collis. recovery delay
Arc shutdown voltage
Total starts
Arc on time
Out of material time
Out of material count
IHS enabled
Collision Retract
Torch collision polarity
Ohmic plate contact
Multiple ignitions
iHC starts plasma
Collision plate sense
Pre plasma start
AVC sampling
AVC integrator
Pierce down time
Collis. rebound offset
AVC Acceleration
AVC Deceleration
AVC deadband
Test use IHS active
Mark set arc voltage
Mark pierce height
Mark cut height
Mark ignition height
Mark pierce delay
Mark pierce height time
Mark pierce down time

Advanced parameters

Using menu:

- Pressing Menu button over 1 second in the main screen will get you to basic
parameters.

- Move up and down in the menu by using the digital potentiometer.

- Use enter to select a parameter to be changed.

- Use the digital potentiometer to adjust the parameter and enter to apply. If you
keep enter pressed in while rotating the digital potentiometer, you will change
the parameter in higher increments.

- Use enter to go to the sub menus. Example pressing enter in Info, you will move to
the System info screen.

- Use Menu button to go backwards from sub menus or from parameter change.

Art# A-12558

iHC XT

Manual 0-5352 OPERATION 4-5

4.06 Basic Parameters

Parameter Description

Toggle Laser Pointer Turn Laser pointer ON/OFF
Ign. Height Height from plate where the plasma arc is ignited
Set Arc Voltage Arc voltage value used when cutting
Cut Height Cut height used while not in arc voltage control
Pierce Height Height from plate when piercing
Pierce Height Time Time to stay in pierce height before moving to cut height

(usually same as pierce delay)

Pierce Delay Time to pierce the plate (after timer ends OK to Move is given

to CNC)
AVC Arc voltage control ON/OFF
AVC Delay Delay after torch has reached cut height and will begin arc

voltage control
Retract Height Height from plate where torch will retract after end of cut
Start homing Perform homing procedure
Unit Shown units, metric or imperial
Collision Retract Automatically retract from plate if plate contact has happened

during cutting
Info System info
System Enter System menu

4.07 Status and State Messages

Status Description

Homing Lifter performing homing
Cutting Lifter in cutting mode
Find Plate Lifter finding the initial plate position
To Ignition Lifter moving to ignition height
To Pierce Lifter moving to pierce height
Manual Jog Manual up/down movement active
Parking Lifter moving to parking position
End of Cut Lifter in the end of the cutting path

IHS test completed IHS test performed
Find plate completed Find plate action completed

4.08 Error Messages

Message Description

No Arc Voltage Cutting started but no arc voltage detected
Collision retract Collision retract feature active
Lower soft limit Lifter reached lower software limit
Upper soft limit Lifter reached upper software limit
Continuous plate contact Plate contact has been ON over 5 sec
Continuous torch collision Torch collision has been ON over 5 sec
E-Stop Active E-stop input active

iHC XT

4-6 OPERATION Manual 0-5352

4.09 Advanced Parameters

Parameter name Default Description

Encoder pulses Motor steps/meter
Home distance Distance from upper limit switch
High jog speed Manual up/down speed while not

cutting

Low jog speed Manual up/down speed while cutting
Plate c. rel. speed Speed when retracting from plate
Slow down height Height to slow down during IHS
Hold off AVC delay Delay to enable AVC after hold signal

goes OFF

Adjust speed Maximum speed in AVC control
Hold on limit Voltage to disable AVC control on kerf

crossing

Hold off limit Voltage to recover AVC control on kerf

crossing

Transfer height Raise height between pierces
Homing speed Speed during lifter homing
Main arc lost time out Time to stop cutting after main arc

signal is lost

Upper sw limit distance Upper software limit distance from

hardware switch

Lower sw limit distance Lower software limit distance from

hardware switch

Transfer height time-out Time after the lifter moves from trans-

fer height to home position

Full Speed Maximum speed
Manual acceleration Acceleration when moving torch

manually

Machine acceleration Acceleration when in automatic mode
Voltage gain Gain setting in AVC
Manual deceleration Deceleration when moving torch

manually

Machine deceleration Deceleration when in automatic mode
Collis. retract height Distance moved to prevent collision
Collis. recovery delay Time to recover to AVC from retract

height

Arc shutdown voltage Voltage level to determine plasma arc

is OFF

Total starts Number of plasma starts detected
Arc on time Time that plasma arc has been ON
Out of material time Time cut out of material
Out of material count Number of cuts out from plate
IHS enabled Initial height sensing enabled/disabled
Collision retract

Automatically retract from plate
if plate contact has happened
during cutting

Torch collision polarity Torch collision sensor input polarity
Ohmic plate contact Ohmic sensing enabled/disabled

iHC XT

Manual 0-5352 OPERATION 4-7

Parameter name Default Description

Multiple ignitions Automatic plasma re-start enabled/

disabled

iHC starts plasma Height controller commands plasma

ON/OFF enabled/disabled

Collision plate sense Use collision sensor for plate sensing

enabled/disabled

Pre plasma start Apply IHS and plasma start on at the

same time enabled/disabled

AVC sampling Use measured arc voltage instead of

cut chart value enabled/disable

AVC integrator Arc voltage integrator
Pierce down time Time to move from pierce height to cut

height

Collision rebound offset Offset when using collision sensor to

detect plate

AVC acceleration Acceleration used in AVC
AVC deceleration Deceleration used in AVC
AVC deadband Deadband value for AVC
AVC integrator limit Max used integrator gain
AVC integrator divider Integrator divider value
Tests use IHS active
Mark set arc voltage Marking arc voltage
Mark pierce height Marking pierce height
Mark cut height Marking cut height
Mark ignition height Marking ignition height
Mark pierce delay Marking pierce delay
Mark pierce height time Marking pierce height time
Mark pierce down time Time to move from marking pierce

height to marking cut height

iHC XT

4-8 OPERATION Manual 0-5352

This Page Intentionally Blank

iHC XT

Manual 0-5352 MAINTENANCE 5-1

SECTION 5:

TROUBLESHOOTING AND MAINTENANCE

5.01 Maintenance

Once a week

- Check for tears in cables

Once a month

- Check motor to lifter axis coupler tightness

- Clean lifer guides and ball screw

- Lubricate ballscrew and bearings. Grease recommendation Hiwin G02 Grease. Grease should be compatible with plastics
and steel, have a low dust generation, wide temperature range, be wear resistant and have a NLGI grade of 2.

5.02 Troubleshooting

Symptom Possible Cause

System will not power up

1. E-Stop input not connected. Check that you have a NC con­nection on power connector pins E1 and E2

2. Fuse blown. Check fuse T5.

3. Defective power supply. Measure voltage on power connec­tor pins 24V and GND for 24VDC.

No arc voltage

1. Loose or poor connections to voltage divider. Check for
loose and broken cables.

Arc voltage reading wrong

1. None or poor connection to table work from iHC XT ground
stud. Measure ohms from iHC XT chassis to table work,
reading should be under 5ohm.

Lifter stalls

1. Maximum speed too high. Reduce maximum speed.

2. Acceleration too high. Reduce acceleration.

3. Lifter jammed. Check for smooth movement by moving the
lifter up and down by hand.

Lifter does not move

1. Poor or no connection to lifter motor. Check cable and wires.

2. Loose or broken axis coupler. Open the lifter cover and check
axis coupler.

3. Lifter above upper limit switch and hitting hard stop after
power ON. Turn power OFF and push lifter to middle posi­tion. Turn power ON and observe for proper homing.

4. Limit switch trip dog loose or incorrectly placed and lifter is
jamming to hard stop. Open lifter cover and check the trip
dog.

5. Upper limit switch broken. Open lifter cover and remove the
motor. If the motor spins correctly when free check limit
switch operation.

Lifter crashes to the plate after
piercing

1. Bad Consumables. Replace consumables

2. AVC delay too short. Increase AVC delay.

Lifter sits in pierce point

1. Pierce delay set both in CNC and iHC XT. Change either pierce
delay to 0sec

Process missing from list

1. Process filtered out. Check your filter settings.

iHC XT

5-2 MAINTENANCE Manual 0-5352

This page intentionally blank.

iHC XT

Manual 0-5352 Pinout and Cable 6-1

SECTION 6:

PINOUTS AND CABLE EXAMPLES

6.01 IO example connections

Output example

Input example using a relay

iHC XT internal plasma start relay

J55 pin #3

J55 pin #15

To plasma power supply start input

To plasma power supply start input

IHS Start input

J53 pin #1

J53 pin #5

CNC device controlled external relay

Art# A-12577

Input example using an optocoupler

CNC device controlled output

J53 pin #1

J53 pin #5

IHS Start input

Input

GND

Input

GND

Common

Output

iHC XT

Manual 0-5352 Pinout and Cable 6-3

6.03 Power and E-stop connector

Pin Name Description

1 24VDC 24VDC power input, 5A
2 GND Power input GND
3 E1 Force motor power OFF, provide a dry closing contact to

E2 to enable motor power

4 E2 Force motor power OFF, provide a dry closing contact to

E1 to enable motor power

Mating connector: WR-TBL, Wurth p/n 691364300004

6.03.1 Power supply mains connector

iHC XT comes with a 24VDC 5A power supply. The mains connector type to the power supply is IEC C13, cable should be
rated for 10A 250V.

!

CAUTION

Wire sizes are for reference only. The installation must conform to national and local codes for
the type and method of wire being used.

6.04 J54 Lifter

Pin Name Description

1 Jumper Jumper to J55 pin #1
2 N/A Not in use
3 Shield Cable shield
4 GND Out 2 GND for 5VDC in pin #16
5 Stepper A+ Motor current output max 40V 2.5A
6 Stepper A- Motor current output max 40V 2.5A
7 Shield Cable shield
8 Limit In Upper limit input
9 Stepper B+ Motor current output max 40V 2.5A
10 Stepper B- Motor current output max 40V 2.5A
11 Motor Step - Step pulse - output
12 Collision In Collision sensor input
13 Limit Shield Cable shield
14 N/A Not in use
15 N/A Not in use
16 5V Out 5VDC output max 0.5A
17 Optional In Optional input
18 Optional 2 NO 24VDC Optional 24VDC output, max 0.5A
19 Optional 2 NO 24V GND Optional 24VDC GND output
20 Limit VCC Limits switch 24VDC output
21 N/A Reserved for future use
22 Motor direction - Motor direction - output
23 Motor direction + Motor direction + output
24 Limit GND Limit switch GND
25 Motor Step + Motor Step + output

Mating connector: D-sub male 25pin, Wurth p/n 618 025 248 23

iHC XT

6-4 Pinout and Cable Manual 0-5352

6.05 J55 Plasma

Pin Name Description

1 Jumper Jumper to connector J54 pin #1
2 N/A Not in use
3 Plasma Start NO NO Relay contact, max 48V 0.5A
4 IHS active COM NO Relay contact, max 48V 0.5A
5 Marking COM NO Relay contact, max 48V 0.5A
6 Input GND Input gnd
7 Optional In Optional input, activate by providing a dry closing con-

tact to Input GND pin
8 Arc voltage + Input from voltage divider board
9 Sense relay 24VDC Output to voltage divider board
10 Plate contact in Input from voltage divider board
11 N/A Reserved for future use
12 N/A Reserved for future use
13 N/A Reserved for future use
14 N/A Not in use
15 Plasma Start COM NO Relay contact, max 48V 0.5A
16 IHS Active NO NO Relay contact, max 48V 0.5A
17 Marking NO NO Relay contact, max 48V 0.5A
18 IO Shield IO cable shield
19 OK to Move In OK to Move signal input, activate by providing a dry

closing contact to Input GND pin
20 Arc voltage - Input from voltage divider board
21 Sense relay GND Output to voltage divider board
22 Plate contact GND Input from voltage divider board
23 Divider shield Cable shield
24 N/A Reserved for future use
25 N/A Reserved for future use

Mating connector: D-sub female 25pin, Wurth p/n 618 025 249 23

iHC XT

Manual 0-5352 Pinout and Cable 6-5

6.06 J53 CNC

Pin Name Description

1 IHS Start In IHS Start input, activate by providing a dry closing con-

tact to Input GND2 pin

2 Up In Torch Up input, activate by providing a dry closing con-

tact to Input GND2 pin

3 Marking In Marking input, activate by providing a dry closing con-

tact to Input GND2 pin

4 Optional In Optional input, activate by providing a dry closing con-

tact to Input GND2 pin
5 Input GND2 Input GND2
6 N/A Not used
7 24VDC Out 24VDC Output max 0.5A
8 N/A Not used
9 N/A Not used
10 N/A Not used
11 N/A Not used
12 N/A Not used
13 IO Shield Cable shield
14 OK to Move COM OK to Move output, NO Relay contact, max 48V 0.5A
15 OK to Move NO OK to Move output, NO Relay contact, max 48V 0.5A
16 System Error COM System error output NO Relay contact, max 48V 0.5A
17 System Error NO System error output, NO Relay contact, max 48V 0.5A
18 Optional 1 COM Optional output, NO Relay contact, max 48V 0.5A
19 Optional 1 NO Optional output, NO Relay contact, max 48V 0.5A
20 Hold In Hold input, activate by providing a dry closing contact to

Input GND2 pin
21 Down In Torch down input, activate by providing a dry closing

contact to Input GND2 pin
22 Maintain In Reserved for future use
23 Input GND2 Input GND2
24 IO Shield Cable shield
25 Shield Cable shield
26 GND Out1 GND for 24VDC output in pin #7
27 N/A Not used
28 N/A Not used
29 N/A Not used
30 N/A Not used
31 N/A Not used
32 N/A Not used
33 N/A Not used
34 N/A Not used
35 N/A Not used
36 N/A Not used
37 N/A

Mating connector: D-sub male 37pin, 618 037 248 23

iHC XT

6-6 Pinout and Cable Manual 0-5352

6.07 Power cable general example

iHC XT power cable, general example

Art# A-12576

iHC XT

Manual 0-5352 Pinout and Cable 6-7

6.08 iHT XT with servo motor cable

- Height control does not provide a servo enable signal

- Motor rotation direction should be adjusted in

servo drive parameters.

- Maximum step frequency 146kHz

#25

GND

J53 GND #26

#7

COM+

J53 24VDC #7

#6

#5

Panasonic

Minas A5

X4

Z-axis

PULS 1

#3

PULS 2

#4

J54 X STEP- #11

J54 X STEP+ #25

Cable shield to J54 connector casing or GND

SIGN 1

SIGN 2

J54 X DIR- #22

J54 X DIR+ #23

iHC XT with servo motor example

iHC XT

6-8 Pinout and Cable Manual 0-5352

6.09 CNC IO cable

iHC XT CNC IO cable

P/N

15-5016 3 ft (1.2m)

15-5017 10 ft (3m)

Art# A-12575

iHC XT

Manual 0-5352 Pinout and Cable 6-9

6.10 Lifter cable

iHC XT lifter cable

P/N

15-5018 10 ft (3m)

15-5019 25 ft (7.6m)

15-5020 50 ft (15.2m)

15-5021 75 ft (22.8m)

15-5022 100ft (30.4m)

Connects to 15-XXXX

Art# A-12574

iHC XT

6-10 Pinout and Cable Manual 0-5352

6.11 Limit, Collision, Laser pointer cable

iHC XT Limit, Collision sensor, Laser pointer cable

P/N 15-XXXX

Art# A-12573

iHC XT

Manual 0-5352 Pinout and Cable 6-11

iHC XT plasma adapter cable

P/N

15-5023 25 ft (7.6m)

15-5024 50 ft (15.2m)

15-5025 75 ft (22.8m)

15-5026 100 ft (30.4m)

Connects to P/N

15-5029 UC XT

15-5030 Auto Cut and Cut Master

Art# A-12572

6.12 Plasma adapter cable

iHC XT

6-12 Pinout and Cable Manual 0-5352

iHC XT plasma cable used with UltraCut XT

Art# A-12570

6.13 Plasma cable with UC XT

iHC XT

Manual 0-5352 Pinout and Cable 6-13

iHC XT plasma cable used with AutoCut XT

P/N

15-5030

Connects to

15-5023 25 ft (7.6m)

15-5024 50 ft (15.2m)

15-5025 75 ft (22.8m)

15-5026 100 ft (30.4m)

Art# A-12569

6.14 Plasma cable with AC XT

iHC XT

6-14 Pinout and Cable Manual 0-5352

iHC XT plasma cable used with CutMaster

Connects to

15-5023 25 ft (7.6m)

15-5024 50 ft (15.2m)

15-5025 75 ft (22.8m)

15-5026 100 ft (30.4m)

P/N 15-5030

Art# A-12579

6.15 Plasma cable with CutMaster

iHC XT

Manual 0-5352 Pinout and Cable 6-15

iHC XT plasma IO and VDC general example

Connects to J55

Cable material: shielded and twisted pair, example Igus CF211-02-04-02, 24AWG,

Art# A-12580

6.16 Plasma and VDC general example

iHC XT

6-16 Pinout and Cable Manual 0-5352

iHC XT voltage divder

Art# A-12581

6.17 Voltage divider example

iHC XT

Manual 0-5352 Pinout and Cable 6-17

iHC XT CNC IO to Burny 10 LCD Plus

Picture for reference only, always verify connections from latest manuals. Please take care

on the wiring of external stop signal as it may already have other e-stop functions connected.

Plate marker connection is optional.

Art# A-12585

6.18 CNC IO to Burny 10 LCD Plus example

iHC XT

6-18 Pinout and Cable Manual 0-5352

iHC XT CNC IO to Burny 10 LCD Plus OEM

Picture for reference only, always verify connections from latest manuals. Please take care

on the wiring of external stop signal as it may already have other e-stop functions connected.

Plate marker connection is optional.

Art# A-12586

6.19 CNC IO to Burny 10 LCD Plus OEM example

iHC XT

Manual 0-5352 Pinout and Cable 19

iHC XT CNC IO to Hypertherm MicroEdge

Picture for reference only, always verify connections from latest manuals. Marker connection

is optional

Art# A-12587

6.20 CNC IO to Hypertherm MicroEdge example

iHC XT

20 Pinout and Cable Manual 0-5352

This Page Intentionally Blank

iHC XT

Manual 0-5352 REPLACEMENT PARTS 7-1

SECTION 7:

REPLACEMENT PARTS

1.

4.

2.

5.

3.

6.

Art# A-12582

Item Name Part number

1 Power switch 15-5037
2 Remote cable 15-5014
3 iHC XT PCB 15-5012
4 iHC XT Remote PCB 15-5013
5 Button sticker 15-5011
6 FUSE 5A 250V SLOW-

BLOW 5X20mm

N/A

Item Name Part number

Power Supply 24VDC PSU 15-6025
Lifter motor Stepper motor 15-2044
Axis coupler Axis coupler 15-XXXX
Collision sensor Inductive sensor 1pc. 15-2119
Collision sensor cable Inductive sensor cable 1pc. 15-2114
Laser pointer Laser pointer 15-2091
Voltage divider board Voltage divider board 15-5005

iHC XT

7-2 REPLACEMENT PARTS Manual 0-5352

This Page Intentionally Blank

iHC XT

Manual 0-5352 SOFTWARE UPDATE 8-5

10. Click open HEX file, navigate to the folder where you have the .hex file.

A-12745

!

CAUTION

The correct .hex file will have remote in its name. DO NOT USE
anything without remote in the name.

10. Make sure program flash and write data EEPROM boxes are checked

A-12746

12. Click start write

13. When the update is done you can exit.

14. Turn off the power

15. Remove the serial cable

16. Put the dip switch back to RUN

iHC XT

8-8 SOFTWARE UPDATE Manual 0-5352

7. You can check the box Beep at end to get a beeping sound after update is finished. Cut chart update can
take up to 30min.

8. When the update is done you can exit.

9. Turn off the power

10. Remove the serial cable

11. Put the dip switch back to RUN

12. Done

This page intentionally blank.

THE AMERICAS

Denton, TX USA
U.S. Customer Care

Ph 1-800-426-1888 (tollfree)
Fax: [phone] (tollfree)

International Customer Care

Ph 1-940-381-1212
Fax: [phone]

Oakville, Ontario, Canada
Canada Customer Care

Ph 1-905-827-4515
Fax: [phone] (tollfree)

EUROPE

Chorley, United Kingdom
Customer Care

Ph [phone]
Fax: [phone]

Milan, Italy
Customer Care

Ph [phone]
Fax: [phone]

ASIA/PACIFIC

Cikarang, Indonesia

Customer Care
Ph 6221-8990-6095

Fax: [phone]

Rawang, Malaysia
Customer Care

Ph [phone]
Fax: [phone]

Melbourne, Australia
Australia Customer Care

Ph 1300-654-674 (tollfree)
Ph 61-3-9474-7400
Fax: [phone]

International

Ph 61-3-9474-7508
Fax: [phone]

Shanghai, China
Sales Office

Ph [phone]
Fax: [phone]

Singapore
Sales Office

Ph [phone]
Fax: [phone]

© 2012 Victor Technologies International, Inc. www.victortechnologies.com Printed in Finland

U.S. Customer Care: 800-426-1888 / FAX [phone]
Canada Customer Care: 905-827-4515 / FAX [phone]
International Customer Care: 940-381-1212 / FAX [phone]