EDGE® Connect

Shape Cutting Control

Installation and Setup Manual

809340 | Revision 4 | English
 Register your new Hypertherm system

Benefits of registration

5 Safety: Registration allows us to contact you in the unlikely event a safety or quality notification
is required.

5 Education: Registration gives you free access to online product training content via the
Hypertherm Cutting Institute.

5 Confirmation of ownership: Registration can serve as proof of purchase in case of an

insurance loss.

Go to www.hypertherm.com/registration for easy and fast registration.

If you experience any problems with the product registration process, please contact
[email protected].

For your records

Serial number: __________________________________________________________________________

Purchase date: __________________________________________________________________________
Distributor: _____________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________

Maintenance notes: ______________________________________________________________________

_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________

EDGE, Phoenix, HPR, HPRXD, HPR130XD, HPR260XD, HPR400XD, CutPro, Remote Help, XPR, Powermax, and Hypertherm
are trademarks of Hypertherm Inc. and may be registered in the United States and other countries. EtherCAT is a trademark of
Beckhoff Automation. All other trademarks are the property of their respective holders.

Environmental stewardship is one of Hypertherm’s core values, and it is critical to our success and our customers’ success. We
are striving to reduce the environmental impact of everything we do. For more information: www.hypertherm.com/environment.

© 2020 Hypertherm, Inc.

 EDGE Connect

Installation and Setup Manual

809340
Revision 4

English
Original Instructions

October 2020

Hypertherm, Inc.
Hanover, NH 03755 USA
www.hypertherm.com
Hypertherm, Inc. Hypertherm Europe B.V.
Etna Road, P.O. Box 5010 Vaartveld 9, 4704 SE
Hanover, NH 03755 USA Roosendaal, Nederland
603-643-3441 Tel (Main Office) 31 165 596907 Tel
603-643-5352 Fax (All Departments) 31 165 596901 Fax
[email protected] (Main Office Email) 31 165 596908 Tel (Marketing)
800-643-9878 Tel (Technical Service) 31 (0) 165 596900 Tel (Technical Service)
[email protected] (Technical Service Email)
00 800 4973 7843 Tel (Technical Service)
800-737-2978 Tel (Customer Service) [email protected]
[email protected] (Customer Service Email)
(Technical Service Email)
866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization) Hypertherm (Shanghai) Trading Co., Ltd.
[email protected] (RMA email) B301, 495 ShangZhong Road
Shanghai, 200231
Hypertherm México, S.A. de C.V. PR China
Avenida Toluca No. 444, Anexo 1, 86-21-80231122 Tel
Colonia Olivar de los Padres 86-21-80231120 Fax
Delegación Álvaro Obregón 86-21-80231128 Tel (Technical Service)
México, D.F. C.P. 01780 [email protected]
52 55 5681 8109 Tel (Technical Service Email)
52 55 5683 2127 Fax
[email protected] (Technical Service Email) South America & Central America: Hypertherm Brasil Ltda.
Rua Bras Cubas, 231 – Jardim Maia
Hypertherm Plasmatechnik GmbH Guarulhos, SP – Brasil
Sophie-Scholl-Platz 5 CEP 07115-030
63452 Hanau 55 11 2409 2636 Tel
Germany [email protected] (Technical Service Email)
00 800 33 24 97 37 Tel
00 800 49 73 73 29 Fax Hypertherm Korea Branch
31 (0) 165 596900 Tel (Technical Service) #3904. APEC-ro 17. Heaundae-gu. Busan.
00 800 4973 7843 Tel (Technical Service) Korea 48060
[email protected] (Technical Service Email) 82 (0)51 747 0358 Tel
82 (0)51 701 0358 Fax
Hypertherm (Singapore) Pte Ltd. [email protected] (Marketing Email)
82 Genting Lane [email protected]
Media Centre (Technical Service Email)
Annexe Block #A01-01
Singapore 349567, Republic of Singapore Hypertherm Pty Limited
65 6841 2489 Tel GPO Box 4836
65 6841 2490 Fax Sydney NSW 2001, Australia
[email protected] (Marketing Email)
61 (0) 437 606 995 Tel
[email protected] (Technical Service Email) 61 7 3219 9010 Fax
[email protected] (Main Office Email)
Hypertherm Japan Ltd. [email protected]
Level 9, Edobori Center Building (Technical Service Email)
2-1-1 Edobori, Nishi-ku
Osaka 550-0002 Japan Hypertherm (India) Thermal Cutting Pvt. Ltd
81 6 6225 1183 Tel A-18 / B-1 Extension,
81 6 6225 1184 Fax Mohan Co-Operative Industrial Estate,
[email protected] (Main Office Email)
Mathura Road, New Delhi 110044, India
[email protected] (Technical Service Email) 91-11-40521201/ 2/ 3 Tel
91-11 40521204 Fax
[email protected] (Main Office Email)
[email protected]
(Technical Service Email)

For training and education resources, go to the Hypertherm Cutting Institute (HCI) online at
www.hypertherm.com/hci.
ENGLISH ET (EESTI/ESTONIAN)
WARNING! Before operating any Hypertherm equipment, read the safety HOIATUS! Enne Hyperthermi mis tahes seadme kasutamist lugege läbi toote
instructions in your product’s manual, the Safety and Compliance Manual kasutusjuhendis olevad ohutusjuhised ning Ohutus- ja vastavusjuhend
(80669C), Waterjet Safety and Compliance Manual (80943C), and (80669C), Veejoa ohutuse ja vastavuse juhend (80943C) ja Raadiosageduse
Radio Frequency Warning Manual (80945C). Failure to follow safety hoiatusjuhend (80945C). Ohutusjuhiste eiramine võib põhjustada vigastusi
instructions can result in personal injury or in damage to equipment. ja kahjustada seadmeid.
Copies of the manuals may accompany the product in electronic and printed Juhiste koopiad võivad olla tootega kaasas elektroonilises ja trükivormingus.
formats. You can also obtain copies of the manuals, in all languages available Juhiste koopiaid kõigis iga käsiraamatu jaoks saadaolevas keeles saate
for each manual, from the “Documents library” at www.hypertherm.com. hankida ka „Documents library (dokumentide raamatukogust)” lehel
www.hypertherm.com.
BG (БЪЛГAPCКИ/BULGARIAN)
ПРЕДУПРЕЖДЕНИЕ! Преди да работите с което и да е оборудване FI (SUOMI/FINNISH)
Hypertherm, прочетете инструкциите за безопасност в ръководството VAROITUS! Ennen minkään Hypertherm-laitteen käyttöä lue
на вашия продукт, „Инструкция за безопасност и съответствие“ (80669C), tuotteen käyttöoppaassa olevat turvallisuusohjeet, turvallisuuden
„Инструкция за безопасност и съответствие на Waterjet“ (80943С) ja vaatimustenmukaisuuden käsikirja (80669C), vesileikkauksen
и „Инструкция за предупреждение за радиочестота“ (80945С). turvallisuuden ja vaatimustenmukaisuuden käsikirja (80943C)
Копия на ръководствата може да придружават продукта в електронен ja radiotaajuusvaroitusten käsikirja (80945C).
и в печатен формат. Можете да получите копия на ръководствата, Käyttöoppaiden kopiot voivat olla tuotteen mukana elektronisessa
предлагани на всички езици, от „Documents library“ (Библиотека ja tulostetussa muodossa. Voit saada käyttöoppaiden kopiot kaikilla
за документи) на адрес www.hypertherm.com. kielillä ”latauskirjastosta”, joka on osoitteessa www.hypertherm.com.

CS (ČESKY/CZECH) FR (FRANÇAIS/FRENCH)
VAROVÁNÍ! Před uvedením jakéhokoli zařízení Hypertherm do provozu AVERTISSEMENT! Avant d’utiliser tout équipement Hypertherm, lire les
si přečtěte bezpečnostní pokyny v příručce k produktu a v Manuálu pro consignes de sécurité du manuel de votre produit, du Manuel de sécurité
bezpečnost a dodržování předpisů (80669C), Manuálu pro bezpečnost et de conformité (80669C), du Manuel de sécurité et de conformité du jet
a dodržování předpisů při řezání vodním paprskem (80943C) a Manuálu d’eau (80943C) et du Manuel d'avertissement relatif aux radiofréqunces
varování ohledně rádiových frekvencí (80945C). (80945C).
Kopie příruček a manuálů mohou být součástí dodávky produktu, Des copies de ces manuels peuvent accompagner le produit en format
a to v elektronické i tištěné formě. Kopie příruček a manuálů ve všech électronique et papier. Vous pouvez également obtenir des copies de chaque
jazykových verzích, v nichž byly dané příručky a manuály vytvořeny, naleznete manuel dans toutes les langues disponibles à partir de la « Bibliothèque
v „Knihovně dokumentů“ na webových stránkách www.hypertherm.com. de documents » sur www.hypertherm.com.

DA (DANSK/DANISH) GR (ΕΛΛΗΝΙΚΆ/GREEK)
ADVARSEL! Inden Hypertherm udstyr tages i brug skal ΠΡΟΕΙΔΟΠΟΙΗΣΗ! Πριν θέσετε σε λειτουργία οποιονδήποτε εξοπλισμό της
sikkerhedsinstruktionerne i produktets manual og i Manual om sikkerhed Hypertherm, διαβάστε τις οδηγίες ασφαλείας στο εγχειρίδιο του προϊόντος
og overholdelse af krav (80669C), Manual om sikkerhed og overholdelse και στο εγχειρίδιο ασφάλειας και συμμόρφωσης (80669C), στο εγχειρίδιο
af krav for vandstråleskæring (80943C), og Manual om radiofrekvensadvarsel ασφάλειας και συμμόρφωσης του waterjet (80943C) και στο εγχειρίδιο
(80945C), gennemlæses. προειδοποιήσεων για τις ραδιοσυχνότητες (80945C).
Kopier af manualerne kan ledsage produktet i elektroniske og trykte formater. Αντίγραφα των εγχειριδίων μπορεί να συνοδεύουν το προϊόν σε ηλεκτρονική
Du kan også få kopier af manualer, på alle sprog der er til rådighed for hver και έντυπη μορφή. Μπορείτε, επίσης, να λάβετε αντίγραφα των εγχειριδίων
manuel, fra “Dokumentbiblioteket” på www.hypertherm.com. σε όλες τις γλώσσες που διατίθενται για κάθε εγχειρίδιο από την ψηφιακή
βιβλιοθήκη εγγράφων (Documents library) στη διαδικτυακή τοποθεσία
DE (DEUTSCH/GERMAN) www.hypertherm.com.
WARNUNG! Bevor Sie ein Hypertherm-Gerät in Betrieb nehmen, lesen Sie
bitte die Sicherheitsanweisungen in Ihrer Bedienungsanleitung, das Handbuch HU (MAGYAR/HUNGARIAN)
für Sicherheit und Übereinstimmung (80669C), das Handbuch für Sicherheit VIGYÁZAT! Mielőtt bármilyen Hypertherm berendezést üzemeltetne,
und Compliance bei Wasserstrahl-Schneidanlagen (80943C) und das olvassa el a biztonsági információkat a termék kézikönyvében, a Biztonsági
Handbuch für Hochfrequenz-Warnung (80945C). és szabálykövetési kézikönyvben (80669C), a Vízsugaras biztonsági
Bedienungsanleitungen und Handbücher können dem Gerät in elektronischer és szabálykövetési kézikönyvben (80943C) és a Rádiófrekvenciás
Form oder als Druckversion beiliegen. Alle Handbücher und Anleitungen figyelmeztetéseket tartalmazó kézikönyvben (80945C).
können in den jeweils verfügbaren Sprachen auch in der A termékhez a kézikönyv példányai elektronikus és nyomtatott formában
„Dokumente-Bibliothek“ unter www.hypertherm.com heruntergeladen werden. is mellékelve lehetnek. A kézikönyvek példányai (minden nyelven)
a www.hypertherm.com weboldalon a „Documents library”
ES (ESPAÑOL/SPANISH) (Dokumentum könyvtár) részben is beszerezhetők.
¡ADVERTENCIA! Antes de operar cualquier equipo Hypertherm, lea
las instrucciones de seguridad del manual de su producto, del Manual ID (BAHASA INDONESIA/INDONESIAN)
de seguridad y cumplimiento (80669C), del Manual de seguridad PERINGATAN! Sebelum mengoperasikan peralatan Hypertherm, bacalah
y cumplimiento en corte con chorro de agua (80943C) y del Manual petunjuk keselamatan dalam manual produk Anda, Manual Keselamatan dan
de advertencias de radiofrecuencia (80945C). Kepatuhan (80669C), Manual Keselamatan dan Kepatuhan Jet Air (80943C),
Pueden venir copias de los manuales en formato electrónico e impreso dan Manual Peringatan Frekuensi Radio (80945C). Kegagalan mengikuti
junto con el producto. También se pueden obtener copias de los manuales, petunjuk keselamatan dapat menyebabkan cedera pribadi atau kerusakan
en todos los idiomas disponibles para cada manual, de la “Biblioteca pada peralatan.
de documentos” en www.hypertherm.com. Produk mungkin disertai salinan manual dalam format elektronik maupun cetak.
Anda juga dapat memperoleh salinan manual, dalam semua bahasa yang
tersedia untuk setiap manual, dari "Perpustakaan dokumen"
di www.hypertherm.com.
IT (ITALIANO/ITALIAN) RO (ROMÂNĂ/ROMANIAN)
AVVERTENZA! Prima di usare un’attrezzatura Hypertherm, leggere le istruzioni AVERTIZARE! Înainte de utilizarea oricărui echipament Hypertherm, citiți
sulla sicurezza nel manuale del prodotto, nel Manuale sulla sicurezza e la instrucțiunile de siguranță din manualul produsului, manualul de siguranță
conformità (80669C), nel Manuale sulla sicurezza e la conformità Waterjet și conformitate (80669C), manualul de siguranță și conformitate Waterjet
(80943C) e nel Manuale di avvertenze sulla radiofrequenza (80945C). (80943C) și din manualul de avertizare privind radiofrecvența (80945C).
Il prodotto può essere accompagnato da copie elettroniche e cartacee Produsul poate fi însoțit de copii ale manualului în format tipărit și electronic.
del manuale. È anche possibile ottenere copie del manuale, in tutte le lingue De asemenea, dumneavoastră puteţi obţine copii ale manualelor, în toate limbile
disponibili per ogni manuale, dall’“Archivio documenti” all’indirizzo disponibile pentru fiecare manual, din cadrul secţiunii „Bibliotecă documente”
www.hypertherm.com. aflată pe site-ul www.hypertherm.com.

RU (PУССКИЙ/RUSSIAN)
JA ( /JAPANESE)
БЕРЕГИСЬ! Перед работой с любым оборудованием Hypertherm
! Hypertherm ознакомьтесь с инструкциями по безопасности, представленными
(80669C) в руководстве, которое поставляется вместе с продуктом,
(80943C) (80945C) в Руководстве по безопасности и соответствию (80669С),
в Руководстве по безопасности и соответствию для водоструйной
резки (80943C) и Руководстве по предупреждению о радиочастотном
излучении (80945С).
www.hypertherm.com
Копии руководств, которые поставляются вместе с продуктом, могут быть
представлены в электронном и бумажном виде. Копии руководств на всех
KO (한국어 /KOREAN) языках, на которые переведено то или иное руководство, можно также
загрузить в разделе «Библиотека документов» на веб-сайте
경고! Hypertherm 장비를 사용하기 전에 제품 설명서와 안전 및 규정 준수 www.hypertherm.com.
설명서(80669C), 워터젯 안전 및 규정 준수 설명서(80943C) 그리고 무선
주파수 경고 설명서(80945C)에 나와 있는 안전 지침을 읽으십시오. SK (SLOVENČINA/SLOVAK)
전자 형식과 인쇄된 형식으로 설명서 사본이 제품과 함께 제공될 VÝSTRAHA! Pred použitím akéhokoľvek zariadenia od spoločnosti Hypertherm
수 있습니다. www.hypertherm.com 의 'Documents library (문서 라이브러리)' si prečítajte bezpečnostné pokyny v návode na obsluhu vášho zariadenia
에서도 모든 언어로 이용할 수 있는 설명서 사본을 얻을수 있습니다. a v Manuáli o bezpečnosti a súlade s normami (80669C), Manuáli
o bezpečnosti a súlade s normami pre systém rezania vodou (80943C)
NE (NEDERLANDS/DUTCH) a v Manuáli s informáciami o rádiofrekvencii (80945C).
WAARSCHUWING! Lees voordat u Hypertherm-apparatuur gebruikt Kópia návodu, ktorá je dodávaná s produktom, môže mať elektronickú
de veiligheidsinstructies in de producthandleiding, in de Veiligheids- alebo tlačenú podobu. Kópie návodov, vo všetkých dostupných jazykoch,
en nalevingshandleiding (80669C) in de Veiligheids- en nalevingshandleiding sú k dispozícii aj v sekcii z „knižnice Dokumenty“ na www.hypertherm.com.
voor waterstralen (80943C) en in de Waarschuwingshandleiding
radiofrequentie (80945C). SL (SLOVENŠČINA/SLOVENIAN)
De handleidingen kunnen in elektronische en gedrukte vorm met OPOZORILO! Pred uporabo katerekoli Hyperthermove opreme preberite
het product worden meegeleverd. De handleidingen, elke handleiding varnostna navodila v priročniku vašega izdelka, v Priročniku za varnost in
beschikbaar in alle talen, zijn ook verkrijgbaar via de “Documentenbibliotheek” skladnost (80669C), v Priročniku za varnost in skladnost sistemov rezanja
op www.hypertherm.com. z vodnim curkom (80943C) in v Priročniku Opozorilo o radijskih frekvencah
(80945C).
NO (NORSK/NORWEGIAN)
Izdelku so lahko priloženi izvodi priročnikov v elektronski ali tiskani obliki.
ADVARSEL! Før du bruker noe Hypertherm-utstyr, må du lese Izvode priročnikov v vseh razpoložljivih jezikih si lahko prenesete tudi iz knjižnice
sikkerhetsinstruksjonene i produktets håndbok, håndboken om sikkerhet dokumentov “Documents library” na naslovu www.hypertherm.com.
og samsvar (80669C), håndboken om vannjet sikkerhet og samsvar
(80943C), og håndboken om radiofrekvensadvarsler (80945C). SR (SRPSKI/SERBIAN)
Eksemplarer av håndbøkene kan medfølge produktet i elektroniske og trykte UPOZORENJE! Pre rukovanja bilo kojom Hyperthermovom opremom
utgaver. Du kan også få eksemplarer av håndbøkene i alle tilgjengelige språk pročitajte uputstva o bezbednosti u svom priručniku za proizvod,
for hver håndbok fra dokumentbiblioteket på www.hypertherm.com. Priručniku o bezbednosti i usaglašenosti (80669C), Priručniku o bezbednosti
i usaglašenosti Waterjet tehnologije (80943C) i Priručniku sa upozorenjem
PL (POLSKI/POLISH) o radio-frekvenciji (80945C).
OSTRZEŻENIE! Przed rozpoczęciem obsługi jakiegokolwiek systemu Može se dogoditi da kopije priručnika prate proizvod u elektronskom
firmy Hypertherm należy się zapoznać z instrukcjami bezpieczeństwa i štampanom formatu. Takođe možete da pronađete kopije priručnika, na svim
zamieszczonymi w podręczniku produktu, w podręczniku bezpieczeństwa jezicima koji su dostupni za svaki od priručnika, u “Biblioteci dokumenata”
i zgodności (80669C), podręczniku bezpieczeństwa i zgodności systemów (“Documents library”) na www.hypertherm.com.
strumienia wody (80943C) oraz podręczniku z ostrzeżeniem o częstotliwości
radiowej (80945C). SV (SVENSKA/SWEDISH)
Do produktu mogą być dołączone kopie podręczników w formacie VARNING! Läs häftet säkerhetsinformationen i din produkts säkerhets- och
elektronicznym i drukowanym. Kopie podręczników, w każdym udostępnionym efterlevnadsmanual (80669C), säkerhets- och efterlevnadsmanualen för
języku, można również znaleźć w „Bibliotece dokumentów” pod adresem Waterjet (80943C) och varningsmanualen för radiofrekvenser (80945C)
www.hypertherm.com. för viktig säkerhetsinformation innan du använder eller underhåller
Hypertherm-utrustning.
PT (PORTUGUÊS/PORTUGUESE)
Kopior av manualen kan medfölja produkten i elektronisk och tryckform.
ADVERTÊNCIA! Antes de operar qualquer equipamento Hypertherm, Du hittar även kopior av manualerna i alla tillgängliga språk
leia as instruções de segurança no manual do seu produto, no Manual i dokumentbiblioteket (Documents library) på www.hypertherm.com.
de Segurança e de Conformidade (80669C), no Manual de Segurança
e de Conformidade do Waterjet (80943C) e no Manual de Advertência
de radiofrequência (80945C).
Cópias dos manuais podem acompanhar os produtos nos formatos eletrônico
e impresso. Também é possível obter cópias dos manuais em todos os idiomas
disponíveis para cada manual na “Biblioteca de documentos” em
www.hypertherm.com.
TH (ภาษาไทย/THAI) ZH-CN ( /CHINESE SIMPLIFIED)
คําเตือน! กอนการใชงานอุปกรณของ Hypertherm ทั้งหมด โปรดอานคําแนะนําดาน
ความปลอดภัยในคูมือการใชสินคา คูมือดานความปลอดภัยและการปฏิบัติ (80669C) (80943C)
ตาม (80669C), คูมือดานความปลอดภัยและการปฏิบัติตามสําหรับการใชหัวตัดระบบ (80945C)
วอเตอรเจ็ต (80943C) และ คูมือคําเตือนเกี่ยวกับความถี่วิทยุ (80945C)
การไมปฏิบัติตามคําแนะนําดานความปลอดภัยอาจสงผลใหเกิดการบาดเจ็บหรือเกิด
ความเสียหายตออุปกรณ “Documents library”
www.hypertherm.com.
สินคาอาจมีสําเนาคูมือในรูปแบบอิเล็กทรอนิกสและแบบสิ่งพิมพแนบมาดวย นอกจาก
นี้ คุณสามารถขอรับสําเนาคูมือแตละประเภทเปนภาษาตาง ๆ ที่มีใหใชงานไดที่ “คลัง
เอกสาร” ในเว็บไซต www.hypertherm.com ZH-TW (繁 體中文/CHINESE TRADITIONAL)
警告！在操作任何 Hypertherm 設備前，請先閱讀您產品手冊內的安全指
TR (TÜRKÇE/TURKISH) 示，包括 《安全和法規遵從手冊》(80669C) 、《水刀安全和法規遵從手冊》
UYARI! Bir Hypertherm ekipmanını çalıştırmadan önce, ürününüzün kullanım （80943C），以及 《無線電頻率警示訊號手冊》（80945C）。
kılavuzunda, Güvenlik ve Uyumluluk Kılavuzu’nda (80669C), Su Jeti Güvenlik 手冊複本可能以電子和印刷格式隨附產品提供。您也可以在
ve Uyumluluk Kılavuzu’nda (80943C) ve Radyo Frekansı Uyarısı Kılavuzu’nda www.hypertherm.com 的 「文檔資料庫」內獲取所有手冊的多語種複本。
(80945C) yer alan güvenlik talimatlarını okuyun.
Kılavuzların kopyaları, elektronik ve basılı formatta ürünle birlikte verilebilir.
Her biri tüm dillerde yayınlanan kılavuzların kopyalarını www.hypertherm.com
adresindeki “Documents library” (Dosyalar kitaplığı) başlığından da elde
edebilirsiniz.

VI (TIẾ NG VIỆ T/VIETNAMESE)

CẢNH BÁO! Trước khi vận hành bất kỳ thiết bị Hypertherm nào, hãy đọc
các hướng dẫn an toàn trong hướng dẫn sử dụng sản phẩm của bạn,
Sổ tay An toàn và Tuân thủ (80669C), Sổ tay An toàn và Tuân thủ Tia nước
(80943C), và Hướng dẫn Cảnh báo Tần số Vô tuyến (80945C). Không tuân
thủ các hướng dẫn an toàn có thể dẫn đến thương tích cá nhân hoặc hư
hỏng thiết bị.
Bản sao của các hướng dẫn sử dụng có thể đi kèm sản phẩm ở định dạng
điện tử và bản in. Bạn cũng có thể lấy bản sao của các hướng dẫn sử dụng,
thuộc tất cả các ngôn ngữ hiện có cho từng hướng dẫn sử dụng, từ “Thư
viện tài liệu” tại địa chỉ www.hypertherm.com.
 Contents

Electromagnetic Compatibility (EMC) .................................................................................. 21

Introduction........................................................................................................................................................... 21
Installation and use ............................................................................................................................................. 21
Assessment of area ............................................................................................................................................ 21
Methods of reducing emissions....................................................................................................................... 21
Mains supply............................................................................................................................................. 21
Maintenance of cutting equipment.................................................................................................................. 21
Cutting cables...................................................................................................................................................... 21
Equipotential bonding ............................................................................................................................ 21
Earthing of the workpiece ..................................................................................................................... 22
Screening and shielding.................................................................................................................................... 22

Warranty..................................................................................................................................... 23
Attention ................................................................................................................................................................ 23
General.................................................................................................................................................................. 23
Patent indemnity.................................................................................................................................................. 23
Limitation of liability............................................................................................................................................. 23
National and local codes ................................................................................................................................... 23
Liability cap........................................................................................................................................................... 24
Insurance............................................................................................................................................................... 24
Transfer of rights ................................................................................................................................................. 24
Waterjet product warranty coverage.............................................................................................................. 24
Product ...................................................................................................................................................... 24
Parts coverage......................................................................................................................................... 24

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Shrink-wrap License Agreement ............................................................................................25

1 Specifications and Installation .............................................................................................. 27

Overview ............................................................................................................................................................... 27
Data plate.................................................................................................................................................. 28
Upon receipt............................................................................................................................................. 29
Claims ............................................................................................................................................ 29
Installation requirements.................................................................................................................................... 29
Placement of system components .................................................................................................................. 30
Embedded-CNC specifications ...................................................................................................................... 30
Environmental requirements ............................................................................................................................. 30
EDGE Connect (model number 090184)..................................................................................................... 31
Before you begin ..................................................................................................................................... 32
Enclosure ...................................................................................................................................... 32
Monitor........................................................................................................................................... 32
Video cable ................................................................................................................................... 35
USB cable..................................................................................................................................... 35
Ethernet cable .............................................................................................................................. 35
EtherCAT cable ........................................................................................................................... 36
External power supply and power cord.................................................................................. 36
Power button and cable ............................................................................................................ 37
EtherCAT drives .......................................................................................................................... 37
EDGE Connect installation overview.................................................................................................. 38
EDGE Connect dimensions and weight............................................................................................ 39
Mount the EDGE Connect.................................................................................................................... 39
EDGE Connect wall mount....................................................................................................... 39
EDGE Connect DIN rail mount ................................................................................................ 40
Ground the EDGE Connect ................................................................................................................. 40
EDGE Connect connector locations.................................................................................................. 41
EDGE Connect TC (model number 090198).............................................................................................. 42
Before you begin ..................................................................................................................................... 43
Ethernet cable .............................................................................................................................. 43
EtherCAT cable ........................................................................................................................... 43
External power supply and power cord.................................................................................. 44
EtherCAT drives .......................................................................................................................... 44
EDGE Connect TC installation overview........................................................................................... 45
EDGE Connect TC touchscreen specifications.............................................................................. 46
EDGE Connect TC dimensions and weight..................................................................................... 46
Mount the EDGE Connect TC............................................................................................................. 48
EDGE Connect TC bottom mount.......................................................................................... 48
EDGE Connect TC VESA mount............................................................................................ 49

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EDGE Connect TC flush-mount.............................................................................................. 50

Ground the EDGE Connect TC .......................................................................................................... 53
EDGE Connect TC rear I/O panel connector locations ................................................................ 54
Recommended grounding and shielding....................................................................................................... 55
Introduction............................................................................................................................................... 55
Types of grounding ................................................................................................................................. 55
Grounding practices............................................................................................................................... 56
Example grounding diagram with an HPR or MAXPRO200 cutting system............................. 60
Example grounding diagram with an XPR cutting system ............................................................. 61
Symbols and marks ............................................................................................................................................ 62

2 Operate ....................................................................................................................................... 63
Operate Phoenix.................................................................................................................................................. 64
Operate the standard Hypertherm Soft Op Con......................................................................................... 65
Station control tab .................................................................................................................................. 66
Program control ....................................................................................................................................... 66
Manual motion tab................................................................................................................................... 67
Screen capture and live video tab....................................................................................................... 68
Information tab ......................................................................................................................................... 69
Automatically open a custom software operator console.......................................................................... 70
Before you begin ..................................................................................................................................... 70
Modify the EDGE Connect Launcher................................................................................................. 70
Phoenix Help and technical documentation ................................................................................................. 73
Operate the EDGE Connect TC hardware operator console .................................................................. 77
Operate the touchscreen .................................................................................................................................. 77
Touchscreens, drops of water, and unintended motion................................................................. 77
Optional keyboard and mouse ......................................................................................................................... 78

3 Machine Stop Strategies and Table Hardware ....................................................................79

Machine stop strategies .....................................................................................................................................79
How the CNC stops motion..............................................................................................................................80
Program pause/stop (non-urgent stop) ..............................................................................................80
Fast stop/fast deceleration (urgent stop) ...........................................................................................80
Fault ramp ..................................................................................................................................................80
Emergency stop (E-stop) and Fast Stop compared........................................................................82
Fast Stop........................................................................................................................................82
Emergency stop............................................................................................................................82
Enable the cutting machine after a power cycle or stop.............................................................................83
Safety circuit example .........................................................................................................................................84
Drive enable signals.............................................................................................................................................85

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Drive Enable output .................................................................................................................................85

Drive Disabled input ................................................................................................................................85
Hardware overtravel limits..................................................................................................................................85
Software travel limits ...........................................................................................................................................86
Home switches .....................................................................................................................................................87
General recommendations.................................................................................................................................88

4 Configure the EtherCAT Network........................................................................................... 89

Before you begin ................................................................................................................................................. 89
Scan your slave devices .................................................................................................................................... 90
Enable and set up distributed clocks ............................................................................................................. 94
Export your network configuration to the CNC............................................................................................ 98

5 Machine Axes .......................................................................................................................... 101

Overview ............................................................................................................................................................ 101
Axis orientation and positive motion ............................................................................................................ 102
Axis assignments.............................................................................................................................................. 103
4-axis, I-cutting, no Dual Gantry ....................................................................................................... 103
5-axis, I-cutting, with Dual Gantry .................................................................................................... 104
6-axis, 2-station, I-cutting, with Dual Gantry ................................................................................. 104
Machine setups screen................................................................................................................................... 104
Transverse or Rail axis ........................................................................................................................ 105
Using software travel limits ................................................................................................................ 108
Dual Gantry axis.................................................................................................................................... 110

6 Speeds ...................................................................................................................................... 111

Set speeds ........................................................................................................................................................ 111
Set speed ranges (speed breaks).................................................................................................... 111
Acceleration rates ................................................................................................................................ 112
Maximum machine speed................................................................................................................... 113
Set the speed for manual moves ...................................................................................................... 113
Home speeds........................................................................................................................................ 114
Corner speed ........................................................................................................................................ 114
Limited speeds...................................................................................................................................... 114
Trapezoidal motion compared to S-curve motion .................................................................................... 115
S-curve setup........................................................................................................................................ 117
Change the cutting speed ............................................................................................................................. 118
Cutting speed and acceleration affects cut quality...................................................................... 118

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7 I/O – Inputs and Outputs....................................................................................................... 119

Introduction........................................................................................................................................................ 119
Types of I/O....................................................................................................................................................... 119
Fixed function I/O (virtual) .................................................................................................................. 119
How to view fixed function I/O.......................................................................................................... 120
Fixed function I/O for HPRXD plasma power supplies ................................................... 120
Fixed function I/O for the EDGE Connect TC hardware operator console................ 121
General purpose I/O ........................................................................................................................... 121
Numbered I/O ....................................................................................................................................... 121
Assign I/O.......................................................................................................................................................... 122
How Phoenix assigns I/O................................................................................................................... 122
Assign the digital I/O........................................................................................................................... 123
Logic............................................................................................................................................ 124
Torch Collision uses ................................................................................................................ 124
Drive Enables ............................................................................................................................ 124
Initial Feedback Delay ............................................................................................................. 124
Joystick Installed....................................................................................................................... 125
Analog I/O.............................................................................................................................................. 125
Arc voltage................................................................................................................................. 125
Enable speed pots ................................................................................................................... 125
Speed overrides ....................................................................................................................... 126
Assign analog inputs ............................................................................................................... 126
Analog Input Offset 1 – 32.................................................................................................... 127
Analog outputs...................................................................................................................................... 127
Digital I/O definitions........................................................................................................................... 127
Digital inputs.............................................................................................................................. 127
Digital outputs ........................................................................................................................... 131

8 Torch Height Control (THC)................................................................................................... 135

Sensor THC ...................................................................................................................................................... 135
About plasma torch height control................................................................................................... 135
Sensor THC setup............................................................................................................................... 136
Assign the Sensor THC to an axis ............................................................................................................... 137
Set speeds and acceleration......................................................................................................................... 137
Set up Torch Height Disable......................................................................................................................... 138
Define the THC axis......................................................................................................................................... 140
Voltage Gain.......................................................................................................................................... 140
Servo Error Tolerance ......................................................................................................................... 140
Stall Force Tolerance .......................................................................................................................... 140
Encoder Counts per mm (inch) ........................................................................................................ 141
Retry on Transfer Fail .......................................................................................................................... 141

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Slide Length .......................................................................................................................................... 141

Home setting for current-type drives............................................................................................... 142
Tracking Mode ...................................................................................................................................... 142
Home the axis ................................................................................................................................................... 143
Manual .................................................................................................................................................... 143
Automatic ............................................................................................................................................... 143
Set the Sensor THC operating modes ....................................................................................................... 143
Automatic modes ................................................................................................................................. 143
Manual mode......................................................................................................................................... 143
Sample Arc Voltage mode ................................................................................................................. 144
Set Arc Voltage mode......................................................................................................................... 146
Methods for changing the Set Arc Voltage........................................................................ 146
THC voltage offsets................................................................................................................. 146
Change offsets automatically for Sensor THC.................................................................. 147
Increase or decrease arc voltage in Automatic mode ..................................................... 148
Raise and lower cut height in Manual mode.................................................................................. 148
Change arc voltage in the Process screen or cut chart ............................................................. 148
Initial height sense ........................................................................................................................................... 149
IHS sequence ....................................................................................................................................... 149
IHS in Manual mode ............................................................................................................................ 149
Perform a first IHS ............................................................................................................................... 149
Offset IHS .................................................................................................................................. 150
When to disable height control......................................................................................................... 151
THC sequence of operations ........................................................................................................................ 151
Set up a Watch Window................................................................................................................................ 153

9 Station Setup........................................................................................................................... 155

Overview ............................................................................................................................................................ 155
Generic and numbered I/O............................................................................................................................ 156
Generic I/O............................................................................................................................................ 156
Numbered I/O ....................................................................................................................................... 156
Enable station I/O ............................................................................................................................................ 157
Auto Select and Manual Select inputs and Station Enable LED output ................................. 157
Use Manual mode as an override ..................................................................................................... 159
Summary ................................................................................................................................................ 159
THC and cut chart setup on the Station Configuration screen ............................................................ 161
Guidelines for using the Station Configuration screen ............................................................... 162
Conflicting process ......................................................................................................................................... 162
Example of a conflicting process...................................................................................................... 163
How a tool is associated with a station .............................................................................. 163
A conflicting process example that prevents a program from loading..................................... 164

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Troubleshooting a conflicting process error .................................................................................. 165

The settings look correct on the screen below ................................................................. 165
The cause of the error ............................................................................................................. 166
Troubleshooting steps .................................................................................................................................... 166
Remove a station from the Soft Op Con ........................................................................................ 167

10 Plasma Setup........................................................................................................................... 169

Overview ............................................................................................................................................................ 169
Plasma 1 and Plasma 2 .................................................................................................................................. 170
Sample settings for a single-torch cutting system ....................................................................... 170
Sample settings for a multiple-torch cutting system.................................................................... 171
Sample settings for a two-torch cutting system ........................................................................... 173
Plasma cut sequence...................................................................................................................................... 174
Setting up inputs and outputs for plasma .................................................................................................. 177
Fixed function I/O for HPRXD ........................................................................................................... 177
Station I/O for the Soft Op Con ....................................................................................................... 177
Summary: setting up the plasma routine .................................................................................................... 178
I/O, plasma power supply status, and diagnostics information............................................................. 179
Plasma power supply status.............................................................................................................. 179
Remote tools (HPR diagnostics)...................................................................................................... 180
Plasma power supply and gas console I/O ................................................................................... 181
Plasma power supply inputs.................................................................................................. 181
Gas console inputs.................................................................................................................. 182
Plasma power supply outputs ............................................................................................... 183
Gas console outputs ............................................................................................................... 184

11 Phoenix Setup Files................................................................................................................ 185

About setup files .............................................................................................................................................. 185
Setup files from previous versions of Phoenix............................................................................... 186
Save and load the setup file .......................................................................................................................... 186
Save a setup file with a different name ........................................................................................... 187
Load a setup file ................................................................................................................................... 187
Save system files for troubleshooting ......................................................................................................... 188
Save and load default settings...................................................................................................................... 188
Save Default.ini ..................................................................................................................................... 188
Load Default.ini ..................................................................................................................................... 189
Reload factory settings ................................................................................................................................... 190

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12 Local Area Networking........................................................................................................... 191

Connect to a local area network with wireless or Ethernet.................................................................... 191
Notes....................................................................................................................................................... 193
Map a drive ........................................................................................................................................................ 194

13 Back Up and Restore the System ........................................................................................ 197

Introduction........................................................................................................................................................ 197
Backup................................................................................................................................................................ 198
Restore ............................................................................................................................................................... 200

14 Troubleshooting and Diagnostics ........................................................................................ 203

Save system files for troubleshooting ......................................................................................................... 204
Remote Help™ from a technician .................................................................................................................. 205
CNC troubleshooting...................................................................................................................................... 205
CNC messages .................................................................................................................................... 205
CNC information screen..................................................................................................................... 205
General CNC troubleshooting.......................................................................................................... 207
When you push the power button, the CNC does not power ON............................... 207
The power button is illuminated, but the touchscreen or monitor is black ................. 208
The warning message The display settings for this system are not at the optimal values
appears....................................................................................................................................... 209
The monitor displays a burn-in, ghost, or dim outline of a previously displayed image ....
209
Previously mapped local network drives do not show when you try to load a part .. 209
You cannot download part programs over the local network (LAN or wireless)....... 210
The CNC does not recognize a USB device..................................................................... 210
Test the PC board and connectors ................................................................................................. 211
LEDs and test points for EDGE Connect TC.................................................................... 211
Test the USB, EtherCAT, and LAN connectors and hardware operator console..... 213
Hardware operator console for EDGE Connect TC only ............................................... 213
Log data with the oscilloscope ......................................................................................................... 213
Save an oscilloscope file ........................................................................................................ 215
Load an oscilloscope file ........................................................................................................ 215
View an oscilloscope file ........................................................................................................ 216
HPRXD plasma power supply troubleshooting ........................................................................................ 217
HPR error help ...................................................................................................................................... 217
HPR information screens ................................................................................................................... 217
Bypass an HPRXD on the EtherCAT network .............................................................................. 218
Bypass the HPRXD in a single-HPRXD cutting system ................................................. 219
Put the HPRXD back on the network in a single-HPRXD cutting system.................. 220

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Bypass an HPRXD in a multiple-HPRXD cutting system ............................................... 220

Put an HPRXD back on the network in a multiple-HPRXD cutting system................ 222
Status messages.............................................................................................................................................. 224
Plasma cut sequence status messages.......................................................................................... 224
Tool status messages ......................................................................................................................... 225
Dialog box messages: pauses, faults, and errors ..................................................................................... 226
Tool dialog box messages.................................................................................................................. 226
Tool error dialog box example ............................................................................................... 226
Troubleshooting tool errors.................................................................................................... 227
CNC pauses, faults, and errors ........................................................................................................ 227
Troubleshooting CNC pauses, faults, and errors ............................................................. 228
CNC dialog box message examples .................................................................................. 229
CNC fault message reference .......................................................................................................... 231
Fast Stop Active ....................................................................................................................... 231
HPR Fault................................................................................................................................... 231
Cut Gas Lost............................................................................................................................. 232
Cut Sense Lost......................................................................................................................... 232
Invalid Process Requested in Part Program ...................................................................... 233
Remote Pause Active .............................................................................................................. 234
Safety Mat Active ..................................................................................................................... 234
Software Limit Active............................................................................................................... 235
Torch Collision .......................................................................................................................... 235
Field Bus Drives Not Ready................................................................................................... 236
Take HPR# Out for Service? ................................................................................................ 236
CNC error message reference ......................................................................................................... 238
Error 1) Transverse position error......................................................................................... 238
Error 2) Rail Position Error ..................................................................................................... 238
Error 3) Dual Gantry Position Error...................................................................................... 238
Error 4) Rotate Position Error................................................................................................ 239
Error 5) Tilt Position Error....................................................................................................... 239
Error 6) CBH Position Error................................................................................................... 239
Error 7) THC Position Error ................................................................................................... 239
Error 8) Transverse Positive Hardware Overtravel ........................................................... 240
Error 9) Rail Positive Hardware Overtravel ........................................................................ 241
Error 13) Transverse Negative Hardware Overtravel....................................................... 242
Error 14) Rail Negative Hardware Overtravel.................................................................... 243
Error 18) Transverse Positive Software Overtravel .......................................................... 243
Error 19) Rail Positive Software Overtravel ....................................................................... 244
Error 23) Transverse Negative Software Overtravel ........................................................ 244
Error 24) Rail Negative Software Overtravel ..................................................................... 244
Error 28) Tilt Positive Hardware Overtravel ....................................................................... 245

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Error 29) Tilt Negative Hardware Overtravel ..................................................................... 246

Error 30) Tilt Positive Software Overtravel......................................................................... 246
Error 31) Tilt Negative Software Overtravel....................................................................... 247
Error 34) Rotate Positive Software Overtravel.................................................................. 247
Error 35) Rotate Negative Software Overtravel ................................................................ 247
Error 36) Dual Gantry Skew Error........................................................................................ 248
Error 37) Collision Fault.......................................................................................................... 248
Error 38) Excessive Mechanical Skew................................................................................ 249
Error 41) Dual Head Collision Fault..................................................................................... 250
Error 42) Torch Collision ........................................................................................................ 251
Error 44) Hardware Fault or Failure ..................................................................................... 252
Error 45) Dual Transverse Positive Hardware Overtravel............................................... 253
Error 46) Dual Transverse Negative Software Overtravel .............................................. 253
Error 47) Dual Transverse Positive Software Overtravel ................................................ 253
Error 48) Dual Transverse Negative Software Overtravel .............................................. 254
Error 60) Field Bus Configuration Fault.............................................................................. 254
Error 61) Field Bus Device Fault .......................................................................................... 255
Network diagnostic screen ................................................................................................................ 255
Error 62) Field Bus Network Fault........................................................................................ 256
Error 64) Field Bus Slave Fault............................................................................................. 257
Error 66) RTOS Watchdog Fault ......................................................................................... 258
Error 67) PLC application ...................................................................................................... 258
Error 68) PLC............................................................................................................................ 258
HASP warning and error message reference................................................................................ 259
The warning message Use of this control has expired appears ................................... 259
Error 18) HASP key ID not found......................................................................................... 260
Error 19) HASP invalid update data .................................................................................... 260
Error 54) HASP Update Too Old ......................................................................................... 260
Error 55) HASP Update Too New ....................................................................................... 261
Plasma cutting tips .......................................................................................................................................... 262
Cut quality problems ........................................................................................................................... 262
Angularity.................................................................................................................................... 262
Dross........................................................................................................................................... 263
Surface finish............................................................................................................................. 263
Color............................................................................................................................................ 264
Basic steps to improve cut quality ................................................................................................... 264
Step 1: Is the plasma arc cutting in the appropriate direction?.................................... 264
Step 2: Was the correct process selected for the material and thickness?.............. 265
Step 3: Are the consumables worn?................................................................................... 266
Step 4: Is the torch square to the workpiece?.................................................................. 266
Step 5: Is the cut height set at the proper height? .......................................................... 266

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Step 6: Is the cutting speed set too fast or too slow?.................................................... 267
Step 7: Are there problems with the gas delivery system?............................................ 267
Step 8: Is there torch vibration? ........................................................................................... 267
Step 9: Does the table need to be tuned? ........................................................................ 267
Bevel cutting tips.............................................................................................................................................. 268
Types of bevel cuts.............................................................................................................................. 268
I cut.............................................................................................................................................. 268
V cut ............................................................................................................................................ 268
A cut ............................................................................................................................................ 268
Y Top cut.................................................................................................................................... 268
Y Bottom cut ............................................................................................................................. 268
X cut ............................................................................................................................................ 269
K cut ............................................................................................................................................ 269
Bevel cutting tips.................................................................................................................................. 269
Clipped corner .......................................................................................................................... 270
Inconsistent cut quality on a single part surface............................................................... 270
Rounded edges on Y Top cuts ............................................................................................. 271
Part dimensions change within a nest................................................................................. 272
Jagged cut ................................................................................................................................. 273
Incorrect dimension for the land on a Y Top cut............................................................... 274
Change consumables ..................................................................................................................................... 275

15 Part Replacement ................................................................................................................... 279

Required tools................................................................................................................................................... 279
Remove the rear enclosure ............................................................................................................................ 280
Install the rear enclosure ................................................................................................................................ 283
Replace the touchscreen ............................................................................................................................... 285
Replace the embedded-CNC....................................................................................................................... 295
Replace the power distribution or hardware operator console PCB................................................... 299
Replace the power button.............................................................................................................................. 302
Replace the front USB connector................................................................................................................ 303
Replace the start or stop switch assembly ................................................................................................ 306
Replace the potentiometers and harness................................................................................................... 308
Replace the toggle switch ............................................................................................................................. 311
Replace the joystick......................................................................................................................................... 314
Replace the hardware operator console wiring harness ........................................................................ 320
Replace the rear I/O panel............................................................................................................................. 326
Replace the rear USB connector ................................................................................................................. 328
Replace the Ethernet or EtherCAT connector .......................................................................................... 330

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16 Parts.......................................................................................................................................... 333
Internal EtherCAT cables ............................................................................................................................... 333
Touchscreen cables ........................................................................................................................................ 333
Enclosure and hardware................................................................................................................................. 334
Front panel and rear I/O panel parts ........................................................................................................... 334
Internal parts...................................................................................................................................................... 335
Operator console parts................................................................................................................................... 335
Optional accessories ...................................................................................................................................... 336
Wireless antenna extension cables ................................................................................................. 336
Ethernet and EtherCAT bulkhead connector................................................................................. 336
Mounting options.................................................................................................................................. 336
USB with instruction manuals ........................................................................................................... 336
EtherCAT test PCB ............................................................................................................................. 336
External EtherCAT cables .............................................................................................................................. 337
EtherCAT drives and I/O modules ............................................................................................................... 338

17 Wiring Diagrams ..................................................................................................................... 339

EDGE Connect CNC connection diagram (Sheet 1 of 1)......................................................... 341
EDGE Connect TC CNC connection diagram (Sheet 1 of 3).................................................. 342
EDGE Connect TC CNC connection diagram (Sheet 2 of 3).................................................. 343
EDGE Connect TC CNC connection diagram (Sheet 3 of 3).................................................. 344

20 809340 Installation and Setup Manual EDGE Connect

 Electromagnetic Compatibility (EMC)

Introduction Methods of reducing emissions

Hypertherm’s CE-marked equipment is built in compliance with standard Mains supply
EN60974-10. The equipment should be installed and used in
accordance with the information below to achieve electromagnetic Cutting equipment must be connected to the mains supply according to
compatibility. the manufacturer’s recommendations. If interference occurs, it may be
necessary to take additional precautions such as filtering of the mains
The limits required by EN60974-10 may not be adequate to completely supply.
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 Consideration should be given to shielding the supply cable of
use other measures to further reduce interference. permanently installed cutting equipment, in metallic conduit or
equivalent. Shielding should be electrically continuous throughout its
This cutting equipment is designed for use only in an industrial length. The shielding should be connected to the cutting mains supply so
environment. that good electrical contact is maintained between the conduit and the
cutting power source enclosure.
Installation and use
Maintenance of cutting equipment
The user is responsible for installing and using the plasma equipment
according to the manufacturer’s instructions. The cutting equipment must be routinely maintained according to the
manufacturer’s recommendations. All access and service doors and
If electromagnetic disturbances are detected then it shall be the
covers should be closed and properly fastened when the cutting
responsibility of the user to resolve the situation with the technical
equipment is in operation. The cutting equipment should not be modified
assistance of the manufacturer. In some cases this remedial action may in any way, except as set forth in and in accordance with the
be as simple as earthing the cutting circuit, see Earthing of the
manufacturer’s written instructions. For example, the spark gaps of arc
workpiece. In other cases, it could involve constructing an
striking and stabilizing devices should be adjusted and maintained
electromagnetic screen enclosing the power source and the work according to the manufacturer’s recommendations.
complete with associated input filters. In all cases, electromagnetic
disturbances must be reduced to the point where they are no longer
troublesome. Cutting cables
The cutting cables should be kept as short as possible and should be
Assessment of area positioned close together, running at or close to the floor level.

Before installing the equipment, the user shall make an assessment of Equipotential bonding
potential electromagnetic problems in the surrounding area. The
following shall be taken into account: Bonding of all metallic components in the cutting installation and
adjacent to it should be considered.
a. Other supply cables, control cables, signaling and telephone
cables; above, below and adjacent to the cutting equipment. However, metallic components bonded to the workpiece will increase
b. Radio and television transmitters and receivers. the risk that the operator could receive a shock by touching these
metallic components and the electrode (nozzle for laser heads) at the
c. Computer and other control equipment. same time.
d. Safety critical equipment, for example guarding of industrial
equipment. The operator should be insulated from all such bonded metallic
components.
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.

Safety and compliance 21

Electromagnetic Compatibility (EMC)

Earthing of the workpiece

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

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

Screening and shielding

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

22 Safety and compliance

 Warranty

Attention The warranty set forth above is exclusive and is in lieu of all other
warranties, express, implied, statutory, or otherwise with respect to the
Genuine Hypertherm parts are the factory-recommended replacement Products or as to the results which may be obtained therefrom, and all
parts for your Hypertherm system. Any damage or injury caused by the implied warranties or conditions of quality or of merchantability or fitness
use of other than genuine Hypertherm parts may not be covered by the for a particular purpose or against infringement. The foregoing shall
Hypertherm warranty, and will constitute misuse of the Hypertherm constitute the sole and exclusive remedy for any breach by Hypertherm
Product. of its warranty.

You are solely responsible for the safe use of the Product. Hypertherm Distributors/OEMs may offer different or additional warranties, but
does not and cannot make any guarantee or warranty regarding the safe Distributors/OEMs are not authorized to give any additional warranty
use of the product in your environment. protection to you or make any representation to you purporting to be
binding upon Hypertherm.

General
Patent indemnity
Hypertherm, Inc. warrants that its Products shall be free from defects in
materials and workmanship for the specific periods of time set forth Except only in cases of products not manufactured by Hypertherm or
herein and as follows: if Hypertherm is notified of a defect (i) with respect manufactured by a person other than Hypertherm not in strict conformity
to the plasma power supply within a period of two (2) years from the date with Hypertherm’s specifications and in cases of designs, processes,
of its delivery to you, with the exception of Powermax brand power formulae, or combinations not developed or purported to be developed
supplies, which shall be within a period of three (3) years from the date of by Hypertherm, Hypertherm will have the right to defend or settle, at its
delivery to you, and (ii) with respect to the torch and leads within a period own expense, any suit or proceeding brought against you alleging that
of one (1) year from its date of delivery to you, with the exception of the the use of the Hypertherm product, alone and not in combination with
HPRXD short torch with integrated lead, which shall be within a period of any other product not supplied by Hypertherm, infringes any patent of
six (6) months from the date of delivery to you, and with respect to torch any third party. You shall notify Hypertherm promptly upon learning of any
lifter assemblies within a period of one (1) year from its date of delivery to action or threatened action in connection with any such alleged
you, and with respect to Automation products one (1) year from its date infringement (and in any event no longer than fourteen (14) days after
of delivery to you, with the exception of the EDGE Connect CNC, learning of any action or threat of action), and Hypertherm’s obligation to
EDGE Connect T CNC, EDGE Connect TC CNC, EDGE Pro CNC, defend shall be conditioned upon Hypertherm’s sole control of, and the
EDGE Pro Ti CNC, MicroEDGE Pro CNC, and ArcGlide THC, which indemnified party’s cooperation and assistance in, the defense of the
shall be within a period of two (2) years from the date of delivery to you, claim.
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
Limitation of liability
a period of one (1) year from its date of delivery to you. In no event shall Hypertherm be liable to any person or entity for
All third-party engines, engine accessories, alternators, and alternator any incidental, consequential direct, indirect, punitive or
accessories are covered by the respective manufacturers’ warranties and exemplary damages (including but not limited to lost profits)
not covered by this warranty. regardless of whether such liability is based on breach of
contract, tort, strict liability, breach of warranty, failure of
This warranty shall not apply to any Powermax brand power supplies that essential purpose, or otherwise, and even if advised of the
have been used with phase converters. In addition, Hypertherm does not possibility of such damages. Hypertherm shall not be liable for
warranty systems that have been damaged as a result of poor power any losses to Distributor based on down time, lost production or
quality, whether from phase converters or incoming line power. This lost profits. It is the intention of the Distributor and Hypertherm
warranty shall not apply to any product which has been incorrectly that this provision be construed by a court as being the
installed, modified, or otherwise damaged. broadest limitation of liability consistent with applicable law.

Hypertherm provides repair, replacement or adjustment of the Product as

the sole and exclusive remedy, if and only if the warranty set forth herein National and local codes
properly is invoked and applies. Hypertherm, at its sole option, shall
repair, replace, or adjust, free of charge, any defective Products covered National and local codes governing plumbing and electrical installation
by this warranty which shall be returned with Hypertherm’s prior shall take precedence over any instructions contained in this manual.
authorization (which shall not be unreasonably withheld), properly In no event shall Hypertherm be liable for injury to persons or property
packed, to Hypertherm’s place of business in Hanover, New Hampshire, damage by reason of any code violation or poor work practices.
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.

Safety and compliance 23

Warranty

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

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

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

Waterjet product warranty coverage

Product Parts coverage
HyPrecision pumps 27 months from the ship date, or 24 months
from the date of proven installation, or
4,000 hours, whichever occurs first

PowerDredge 15 months from the ship date or 12 months

abrasive removal from the date of proven installation,
system whichever occurs first

EcoSift abrasive 15 months from the ship date or 12 months

recycling system from the date of proven installation,
whichever occurs first

Abrasive metering 15 months from the ship date or 12 months

devices from the date of proven installation,
whichever occurs first

On/off valve air 15 months from the ship date or 12 months

actuators from the date of proven installation,
whichever occurs first

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

filter and compliance with Hypertherm’s
water quality requirements

Consumable parts are not covered by this warranty. Consumable parts

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

24 Safety and compliance

 Shrink-wrap License Agreement

ENTERING INTO THE LICENSE AGREEMENT SET FORTH BELOW (THE “LICENSE AGREEMENT”) GIVES YOU
THE RIGHT TO USE THE HYPERTHERM TECHNOLOGY AND RELATED SOFTWARE AND EMBODIED THEREIN
WITH HYPERTHERM PLASMA SYSTEMS.

PLEASE READ THE LICENSE AGREEMENT CAREFULLY BEFORE USING THE SOFTWARE.

YOUR RIGHT TO USE THE HYPERTHERM TECHNOLOGY AND RELATED SOFTWARE EMBODIED THEREIN IS
SUBJECT TO YOUR AGREEMENT TO BE BOUND BY THE TERMS AND CONDITIONS OF THE LICENSE
AGREEMENT. BY ACTIVATING YOUR CONTROL PLATFORM AND/OR RELATED SOFTWARE PLATFORM, YOU
ACKNOWLEDGE YOUR ACCEPTANCE OF THE LICENSE AGREEMENT AND REPRESENT THAT YOU ARE
AUTHORIZED TO ENTER INTO THE LICENSE AGREEMENT ON BEHALF OF LICENSEE. IF YOU DO NOT AGREE
TO THESE TERMS AND CONDITIONS, HYPERTHERM DOES NOT GRANT YOU THE RIGHT TO USE THE
HYPERTHERM TECHNOLOGY OR RELATED SOFTWARE.

1. “Designated Hypertherm Patents” shall mean United States Patent Nos. 8,338,739, 8,354,610, 8,354,609,
8,541,711, 8,710,395, and 8,436,270, including foreign equivalents, and any patents issuing therefrom; “Hypertherm
Plasma Systems” shall mean Hypertherm HPR XD plasma systems, XPR plasma systems, or systems designated as
True Hole enabled; “Hypertherm Technology” shall mean Hypertherm’s proprietary hole cutting technology, including
know-how, specifications, inventions, methods, procedures, algorithms, software, programs, works of authorship and
other information, documentation and materials for use in programming and operating an automated high
temperature thermal cutting system; “Controller Platform” shall mean Hypertherm computer numerical controller and/
or Hypertherm software platform supplied with this license; and “End User Customer(s)” shall mean an entity
licensed to use the Hypertherm Technology for such entity’s own internal business purposes and not for distribution
to others.
2. The End User Customer shall be granted a non-exclusive, non-transferable, personal license, without the right to
sublicense, to use the Hypertherm Technology, for internal business purposes only, solely as incorporated within the
Controller Platform and solely for use in conjunction with Hypertherm Plasma Systems.
3. The End User Customer shall be granted a non-exclusive, non-transferable, personal, royalty-free license, without the
right to sublicense, under the Designated Hypertherm Patents solely to the extent necessary to enable the End User
Customer to exercise the rights granted under Paragraph 2, above. The License Agreement shall provide that, except
for the rights expressly granted to the End User Customer in the License Agreement, the license under the
Designated Hypertherm Patents shall not be deemed to grant any license or immunity for combining the Hypertherm
Technology with other items or for the use of such combination.
4. The licenses granted to the End User Customer under Paragraphs 2 and 3, above, shall expressly be made subject
to the following limitations and restrictions, and the End User Customer’s agrees that it shall not (and shall not permit
any third party to): (a) use or permit the use of the Hypertherm Technology in conjunction with any high temperature
thermal cutting systems other than Hypertherm Plasma Systems; (b) remove, alter or obscure any copyright,
trademark or other proprietary or restrictive notice or legend on or within the Hypertherm Technology; (c) disclose,
sublicense, distribute or otherwise make available the Hypertherm Technology to any third party or permit others to
use it; (d) provide timesharing, service bureau, data processing or other services to a third party whereby such third
party would obtain the benefits of the Hypertherm Technology for its own end-user purposes through the End User
Customer; (e) decompile, disassemble, or otherwise reverse engineer or attempt to deconstruct or discover any
source code or underlying ideas or algorithms of the Hypertherm Technology by any means whatsoever; (f) assign,
rent, lease, sell or otherwise transfer the Hypertherm Technology; or (g) modify or alter the Hypertherm Technology in
any manner whatsoever or create derivative works thereof.
5. The License Agreement shall provide that nothing therein shall be construed as granting the End User Customer any
right or license under any intellectual property right of Hypertherm or any of its licensors or suppliers by implication,
estoppel or otherwise, except as expressly set forth in the License Agreement.

Safety and Compliance 25

Shrink-wrap License Agreement

6. The License Agreement shall provide that Hypertherm shall retain sole and exclusive ownership of the Hypertherm
Technology and that the End User Customer shall obtain no rights in the Hypertherm Technology, except for those
expressly set forth in the sublicense agreement.
7. The License Agreement shall give Hypertherm the right to terminate the agreement effective immediately upon
written notice if the End User Customer breaches any provision of the License Agreement and fails to cure such
breach within five (5) days after receiving written notice thereof from Hypertherm.
8. HYPERTHERM, ITS LICENSORS AND SUPPLIERS MAKE NO REPRESENTATIONS OR WARRANTIES,
EXPRESS OR IMPLIED, WITH RESPECT TO THE HYPERTHERM TECHNOLOGY OR RELATED SOFTWARE
EMBODIED THEREIN, AND DISCLAIM ALL IMPLIED WARRANTIES, INCLUDING, WITHOUT LIMITATION,
THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
WITHOUT LIMITING THE FOREGOING, NEITHER HYPERTHERM NOR ANY OF ITS LICENSORS OR
SUPPLIERS MAKES ANY REPRESENTATION OR WARRANTY REGARDING THE FUNCTIONALITY,
RELIABILITY OR PERFORMANCE OF THE HYPERTHERM TECHNOLOGY OR RELATED SOFTWARE
EMBODIED THEREIN, OR THE RESULTS TO BE OBTAINED THROUGH THE USE OF THE HYPERTHERM
TECHNOLOGY OR RELATED SOFTWARE, OR THAT THE OPERATION OF SUCH HYPERTHERM
TECHNOLOGY OR RELATED SOFTWARE WILL BE UNINTERRUPTED OR ERROR-FREE.
9. TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW, IN NO EVENT SHALL HYPERTHERM, ITS
LICENSORS OR SUPPLIERS BE LIABLE FOR ANY INDIRECT, EXEMPLARY, PUNITIVE, CONSEQUENTIAL,
INCIDENTAL OR SPECIAL DAMAGES, INCLUDING LOST PROFITS, ARISING OUT OF OR IN CONNECTION
WITH THE USE OF THE HYPERTHERM TECHNOLOGY OR RELATED SOFTWARE EMBODIED THEREIN,
EVEN IF SUCH PARTY HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. THE LIMITATION
STATED IN THIS SECTION SHALL APPLY REGARDLESS OF THE FORM OF ACTION, WHETHER THE
ASSERTED LIABILITY OR DAMAGES ARE BASED ON CONTRACT (INCLUDING, BUT NOT LIMITED TO,
BREACH OF WARRANTY), TORT (INCLUDING, BUT NOT LIMITED TO, NEGLIGENCE), STATUTE, OR ANY
OTHER LEGAL OR EQUITABLE THEORY.

26 Safety and Compliance

 Specifications and Installation

Overview

The EDGE Connect is a computer numerical controller (CNC) designed as a shape cutting
controller. EDGE Connect CNCs use Hypertherm’s Phoenix® software and EtherCAT®
communication for motion and cutting control.

There are two models of the EDGE Connect CNC: the EDGE Connect and the
EDGE Connect TC.

EDGE Connect EDGE Connect TC

Model number 090184 Model number 090198*

Embedded-CNC only Embedded-CNC, 495.3 mm/19.5 inch
touchscreen, and hardware operator
console

* Model number 090198 (495.3 mm/19.5 inch touchscreen) replaced model number 090185
(469.9 mm/18.5 inch touchscreen).

EDGE Connect Installation and Setup Manual 809340 27

 1 Specifications and Installation

Data plate
The data plate shows the CNC’s part number and serial number. If you contact Hypertherm
Technical Service, they ask for this information. You can find the data plate on the bottom of the
EDGE Connect or on the rear of the EDGE Connect TC.

Figure 1

2
1 090###

3 ##########

1 Part number 3 Serial number (YYMM######, where YY is the

2 Part number bar code year and MM is the month of manufacture)
4 Serial number bar code

28 809340 Installation and Setup Manual EDGE Connect

 Specifications and Installation 1

Upon receipt
 Make sure that you received all items on your order in good condition. Contact your
distributor if any parts are damaged or missing.
 EDGE Connect/EDGE Connect TC
 HASP software key (installed)
 USB memory stick with product information
 Wireless antennas
 External power supply
 Input power cord (United States IEC)
 Pluggable terminal block (EDGE Connect only)
 Other optional items that appear on your order
 Inspect the items for damage that may have occurred during shipment. If you find evidence
of damage, see Claims below. All communications regarding this equipment must include
the model number and serial number.
 Record your product information on the inside front cover of this manual, then use the
instructions there to register your product’s serial number at www.hypertherm.com.
 Before you set up this equipment, read the safety information included with your equipment.
Failure to follow safety instructions can result in personal injury or in damage to equipment.

Claims
 Claims for damage during shipment – If your equipment was damaged during shipment, file
a claim with the carrier. You can contact Hypertherm for a copy of the bill of lading. 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 component is missing or defective,
contact your Hypertherm distributor. If you need additional assistance, call the nearest
Hypertherm office listed in the front of this manual.

Installation requirements

All installation and service of the electrical systems must obey national and local electrical codes. A
qualified person must do this work.

Contact the nearest Hypertherm Technical Service team listed in the front of this manual, or your
authorized Hypertherm distributor with any technical questions.

EDGE Connect Installation and Setup Manual 809340 29

 1 Specifications and Installation

Placement of system components

 Put all system components into position prior to making electrical, gas, and interface
connections.
 Ground all system components to earth. See Recommended grounding and shielding on
page 55 for details.

Embedded-CNC specifications

Processor Intel® Celeron® J1900, Quad Core

Operating system Windows® 10 embedded
RAM 4 GB
Hard drive Solid-state, SATA drive, greater than or equal to120 GB
Wireless Complies with 802.11G and 802.11N standards

Environmental requirements

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

Humidity 95% maximum relative humidity
Ingress protection EDGE Connect IP2X
Protect the equipment from exposure to excessive moisture.
Ingress protection EDGE Connect TC IP23
Protect the equipment from exposure to excessive moisture.
Altitude 2,000 m (6,561 ft) maximum
Pollution Pollution Degree 2

 You must install the EDGE Connect in an enclosure to protect it from the
environment. For enclosure recommendations, see Enclosure on page 32.

30 809340 Installation and Setup Manual EDGE Connect

 Specifications and Installation 1

EDGE Connect (model number 090184)

Figure 2 – EDGE Connect system diagram

19

5 3
7
4 2 10
6
15

6 13
10
12
7 9 9

11 14
3 17 18
8 16

1 Monitor 11 EtherCAT cable***

2 DVI-D cable* 12 Terminal block power-in†
3 USB cable or device** 13 Terminal block
4 HASP software key 14 Power button
5 HDMI cable* 15 Metal enclosure
6 Wireless extensions 16 Drives and motors††
7 Wireless antennas 17 I/O module
8 Ethernet cable 18 Plasma power supply***
9 Bulkhead connector 19 External power supply and input power cord**
10 Chassis ground

* Choose HDMI or DVI-D.

** If you use a USB hub, use only 1 USB hub.

*** If you want to connect a Powermax® or MAXPRO® to an EDGE Connect CNC, use a discrete connection
through the drive I/O or an I/O module on the network.
† Connect the input power to the terminal block or barrel connector. Do not use either for power out.
†† Make sure that you can remove power from the drives separately from the CNC so that you can troubleshoot
network faults or errors if necessary. Refer to the drive manufacturer's documentation for instructions on drive
installation.

EDGE Connect Installation and Setup Manual 809340 31

 1 Specifications and Installation

Before you begin

Enclosure
Make an enclosure for your CNC. You must install the EDGE Connect inside an enclosure. The
enclosure is customer supplied and must meet the following specifications.
 The enclosure must be metal.
 The enclosure must meet all local and national codes.
 For the Ethernet and EtherCAT connections, you must use bulkhead connectors bonded to
the enclosure to prevent noise. (See Ethernet and EtherCAT bulkhead connector on
page 336.)

Monitor
Choose a monitor for your CNC. A touchscreen is suggested but not required. The monitor is
customer supplied and must support the requirements listed in Table 1.

Table 1 – Required display settings

Monitor setting Requirement Notes

Screen resolution 1366 X 768 If you must choose a monitor with a higher
native screen resolution, make sure that the
monitor supports the 16:9 aspect ratio and
lower resolutions including 1366 X 768.
Aspect ratio 16:9
Refresh rate 60 Hz A 60 Hz refresh rate is not optimal for all
(recommendation) monitors. Make sure that you select a
monitor that works well with a 60 Hz refresh
rate.
Touchscreen Minimum diagonal
dimension: 469.9 mm
(18.5 in)
Single-touch touchscreen
Connection HDMI or DVI-D See Video cable on page 35.

Phoenix and the Soft Op Con must be fully visible on the screen. A screen resolution of
1366 X 768 and an aspect ratio of 16:9 support this requirement.

32 809340 Installation and Setup Manual EDGE Connect

 Specifications and Installation 1
Check the screen resolutions that the selected monitor supports

1. Connect a mouse to the CNC.

2. Close all the EDGE Connect software on the CNC.

a. Click anywhere in the Main screen of Phoenix, and then press Alt+F4 to exit Phoenix.
b. Click anywhere in the upper part of the Soft Op Con, and then press Alt+F4 to exit the
upper part of the Soft Op Con.
c. Click anywhere in the lower part of the Soft Op Con, and then press Alt+F4 to exit the lower
part of the Soft Op Con.

3. Right-click on the Windows desktop, and then click Graphics Properties.

4. Click Display.

5. Compare the available options with the requirements in page 32.

Set the required display settings for the selected monitor

1. If the selected monitor can support the requirements, continue from step 5 above.

2. On the Display screen, make the following selections:

 Resolution: 1366 X 768
 Refresh rate: 60 Hz
 Scaling: Maintain Display Scaling

EDGE Connect Installation and Setup Manual 809340 33

 1 Specifications and Installation

3. Click Apply.

4. After Windows applies the new settings, the message Do you want to keep these settings?
appears. Click Yes.

5. Close the Display screen.

Troubleshoot common monitor display issues

Table 2

Display issue Cause Suggested Action

Phoenix and the Soft Op Con The monitor has: Select a monitor that either:
are not fully visible • A native resolution that is • Has a native full-screen resolution of
lower than 1366 X 768 1366 X 768
or or
• A 4:3 aspect ratio • Supports a higher resolution and a 16:9
aspect ratio, but also supports the
Maintain Display Scaling option when a
resolution of 1366 X 768 is selected
• Phoenix and the The monitor has a resolution • Select the Maintain Display Scaling
Soft Op Con do not fill the that is higher than option in the monitor’s display settings,
entire screen 1366 X 768 if supported
or • If the Maintain Display Scaling option is
• Phoenix and the not supported at 60 Hz, try each of the
Soft Op Con are centered other refresh rates to see if one of them
with black borders filling supports Maintain Display Scaling
the outside portions of the • If Maintain Display Scaling is not
screen supported at any refresh rate, then
select the Center Image option
or
• Select a monitor that either has a native
full-screen resolution of 1366 X 768 or
supports a higher resolution and a 16:9
aspect ratio, but also supports the
Maintain Display Scaling option when a
resolution of 1366 X 768 is selected

 To troubleshoot screen burn-in issues, see The monitor displays a burn-in,

ghost, or dim outline of a previously displayed image on page 209.

 See also The warning message The display settings for this system are
not at the optimal values appears on page 209.

34 809340 Installation and Setup Manual EDGE Connect

 Specifications and Installation 1

Video cable
Choose one of the following video cables to connect your CNC to the monitor. This cable is
customer supplied.

HDMI cable Maximum length: 5 m (16.4 ft)

DVI-D cable Maximum length: 5 m (16.4 ft)

USB cable
This cable is customer supplied.

USB cable Maximum length: 5 m (16.4 ft)

Ethernet cable

 If you plan to use wireless, you do not need an Ethernet cable for your
LAN connection.

This cable is customer supplied. Choose an Ethernet cable with the following specifications.

Specification Cat5e, F/UTP type cable, braid and foil shielding minimum
Maximum length 61 m (200 ft)

EDGE Connect Installation and Setup Manual 809340 35

 1 Specifications and Installation

EtherCAT cable
You need an internal and an external EtherCAT cable. Hypertherm sells EtherCAT cables. See Parts
on page 333.

If you supply your own cables, choose EtherCAT cables that follow the Beckhoff® specification.

Type Cat5e, 2-pair, 4-wire, double-shielded

Wire Construction: Stranded tinned wire
Diameter: 0.75 mm (7 X 0.25 mm), 22 AWG
Insulation: Polyethylene, 1.5 mm (0.06 inch) diameter
Core Construction: Filler as central element
Layer 1: 4 wires, 2 pair
Sequence of colors: White, yellow, blue, orange
Layer 2: Plastic tape overlapped
Inner jacket: Thermoplastic copolymer, 3.9 mm (0.04 inch) diameter
Aluminum laminated foil overlapped
Shield: Braided, tinned copper wires, 0.13 mm (0.005 inch)
diameter, coverage about 85%, 4.7 mm (0.19 inch) diameter
Jacket Material: Polyurethane
Wall thickness: 0.9 mm (0.04 inch)
Outer diameter: 6.5 mm (0.26 inch) ± 0.2 mm (0.008 inch)
Maximum length 61 m (200 ft)

External power supply and power cord

Hypertherm’s power supply is 5 A at 12 VDC or 60 W. It can be used to power the EDGE Connect
and the EDGE Connect TC. If you buy your own external power supply and cord, choose a power
supply with the following specifications.

Input voltage 100 VAC to 240 VAC at 50 Hz/60 Hz

Output voltage 12 VDC ± 5%
External power supply type AC to DC switching
Minimum power supply capacity 36 W
External power supply to CNC connector Switchcraft® 760K, barrel type
Screw lock (use only locking connectors)
5.5 mm (0.22 inch) outer diameter
2.5 mm (0.1 inch) inner diameter
9.5 mm (0.37 inch) long

Alternatively, you can supply power to the EDGE Connect with the green terminal block. See
Figure 3.

36 809340 Installation and Setup Manual EDGE Connect

 Specifications and Installation 1
Figure 3

V-V+ PWR
1

DC 12V

CPU
PWR
PWR

9
COMMON
+12V

6
6

3
8
4 7

1 Connector on the EDGE Connect 6 Power

2 Terminal block (included)* 7 Metal enclosure wall
3 Common 8 Chassis ground
4 +12 V 9 Power button
5 Alternative power to the EDGE Connect

* Terminal block can take 1.31 mm2 – 0.08 mm2 (16 AWG – 28 AWG) wires.

Power button and cable

Connect the power button to the terminal block. See Figure 3 on page 37.

Power button Single-pole, single-throw (SPST), Normally Open, momentary

switch with gold-plated contacts
Cable Maximum length: 5 m (16 ft)
Minimum 0.33 mm2 (22 AWG)
Shielded twisted pair

EtherCAT drives
Install all the drives before you install your CNC. For a list of supported EtherCAT drives and I/O
modules, see the EtherCAT Devices Supported by EDGE Connect CNCs Application Note
(809660). Technical documentation is available at www.hypertherm.com/docs.

EDGE Connect Installation and Setup Manual 809340 37

 1 Specifications and Installation

EDGE Connect installation overview

These are the general steps to install the EDGE Connect. See Figure 2 on
page 31 for an example of how to install a system. For more details, see Wiring
Diagrams on page 339.

1. Mount the EDGE Connect inside of an enclosure.

 For enclosure requirements see Enclosure on page 32.
 For mounting dimensions see Mount the EDGE Connect on page 39.

2. Install the wireless extensions and wireless antennas.

 Use an RP-SMA female to RP-SMA male extension cable so that the

antennas can be on the exterior of the enclosure.

3. Ground the EDGE Connect. See Ground the EDGE Connect on page 40.

4. Connect a monitor to the EDGE Connect.

 For monitor requirements see Monitor on page 32.
 For cable requirements see Video cable on page 35 and USB cable on page 35.

 Turn off the CNC when not in use to prevent retained charge in the LCD
crystals.

5. Install the bulkhead connectors into the enclosure for the LAN Ethernet and EtherCAT cables.
The bulkhead connectors must be bonded to the enclosure to prevent noise.

6. Connect the LAN Ethernet cable and EtherCAT cable to the EDGE Connect.
 For LAN Ethernet cable requirements see Ethernet cable on page 35.
 For EtherCAT cable requirements see EtherCAT cable on page 36.

7. Connect a power button to the EDGE Connect.

 For power button and cable requirements see Power button and cable on page 37.

8. Connect the power to the EDGE Connect.

 Use the external power supply. See External power supply and power cord on page 36.
 If necessary, use the pluggable terminal block. See Figure 3 on page 37.

9. Connect a USB keyboard and USB mouse to the CNC to make software setup easier. This
step is optional but strongly recommended.

10. Push the power button.

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 Specifications and Installation 1

EDGE Connect dimensions and weight

133.8 mm
(5.27in.)

43.1 mm
(1.70 in.)

94.2 mm
(3.71 in.)

1.2 kg 130.8 mm
(2.65 lb) (5.15 in.)

Mount the EDGE Connect

The EDGE Connect must be mounted inside an enclosure to protect it from the environment.

The EDGE Connect can be mounted with wall brackets, a DIN rail bracket, or a VESA bracket.
Hypertherm sells wall brackets and a DIN rail bracket. See Mounting options on page 336.

EDGE Connect wall mount

7.37 mm 26.0 mm
(0.29 in.) (1.02 in.)

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 1 Specifications and Installation

EDGE Connect DIN rail mount

7.37 mm 26.0 mm
(0.29 in.) (1.02 in.

Ground the EDGE Connect

See Recommended grounding and shielding on page 55 for more information.

The ground wire is customer supplied. The minimum ground wire size is 1.3 mm2 (16 AWG).

1. Remove the nut.

6 mm (0.25 in.)
stud with nut

2. Install the ground terminal.

3. Install the nut.

4. Connect the ground wire to the metal enclosure.

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 Specifications and Installation 1

EDGE Connect connector locations

2 3

1 1

4
8
7

6
9

1 Wireless antenna connector RP-SMA connector type

2 HDMI connector Supports 1366 X 768 at 60 Hz
3 USB connector 4 hi-speed USB
4 Female RJ-45 connector For LAN, 10/100/1000 Mbps
5 Chassis ground
6 Female DVI-D connector Supports 1366 X 768 at 60 Hz
7 Female RJ-45 connector For EtherCAT, 10/100/1000 Mbps
8 Terminal block connector For power-in, if the barrel connector is not used, and for a momentary
switch
9 Female barrel connector 2.5 mm (0.1 inch) X 5.5 mm (0.22 inch),12 VDC

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 1 Specifications and Installation

EDGE Connect TC (model number 090198)

Figure 4 – EDGE Connect TC system diagram

3 8 9
4

1 External power supply and input power cord 6 I/O module

2 Wireless antennas 7 Plasma power supply*
3 LAN Ethernet cable 8 USB device***
4 EtherCAT cable* 9 EMI chassis ground
5 Drives and motors**

* If you want to connect a Powermax or MAXPRO to an EDGE Connect CNC, use a discrete connection
through the drive I/O or an I/O module on the network.
** Make sure that you can remove power from the drives separately from the CNC so that you can troubleshoot
network faults or errors if necessary. Refer to the drive manufacturer's documentation for instructions on drive
installation.
*** If you use a USB hub, use only 1 USB hub.

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 Specifications and Installation 1

Before you begin

Ethernet cable

 If you plan to use wireless, you do not need an Ethernet cable for your
LAN connection.

This cable is customer supplied. Choose an Ethernet cable with the following specifications.

Specification Cat5e, F/UTP type cable, braid and foil shielding minimum
Maximum length 61 m (200 ft)

EtherCAT cable
Hypertherm sells EtherCAT cables, see External EtherCAT cables on page 337.

If you supply your own cables, choose EtherCAT cables that follow the Beckhoff® specification.

Type Cat5e, 2-pair, 4-wire, double-shielded

Wire Construction: Stranded tinned wire
Diameter: 0.75 mm (7 X 0.25 mm), 22 AWG
Insulation: Polyethylene, 1.5 mm (0.06 inch) diameter
Core Construction: Filler as central element
Layer 1: 4 wires, 2 pair
Sequence of colors: White, yellow, blue, orange
Layer 2: Plastic tape overlapped
Inner jacket: Thermoplastic copolymer, 3.9 mm (0.04 inch) diameter
Aluminum laminated foil overlapped
Shield: Braided, tinned copper wires, 0.13 mm (0.005 inch)
diameter, coverage about 85%, 4.7 mm (0.19 inch) diameter
Jacket Material: Polyurethane
Wall thickness: 0.9 mm (0.04 inch)
Outer diameter: 6.5 mm (0.26 inch) ± 0.2 mm (0.008 inch)
Maximum length 61 m (200 ft)

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 1 Specifications and Installation

External power supply and power cord

Hypertherm’s power supply is 5 A at 12 VDC or 60 W. It can be used to power the EDGE Connect
and the EDGE Connect TC. If you choose to buy your own external power supply and cord, use the
following specifications.

Input voltage 100 VAC to 240 VAC at 50 Hz/60 Hz

Output voltage 12 VDC ± 5%
External power supply type AC to DC switching
Minimum power supply capacity 60 W
External power supply to CNC connector Switchcraft® 760K, barrel type
Screw lock (use only locking connectors)
5.5 mm (0.22 inch) outer diameter
2.5 mm (0.1 inch) inner diameter
9.5 mm (0.37 inch) long

EtherCAT drives
Install all the drives before you install your CNC. For a list of supported EtherCAT drives and I/O
modules, see the EtherCAT Devices Supported by EDGE Connect CNCs Application Note
(809660). Technical documentation is available at www.hypertherm.com/docs.

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 Specifications and Installation 1

EDGE Connect TC installation overview

These are the general steps to install the EDGE Connect TC. See
Figure 4 on page 42 for an example of how to install this system.
For more details, see Wiring Diagrams on page 339.

1. Mount the EDGE Connect TC.

 For mounting dimensions see Mount the EDGE Connect
TC on page 48.

2. Install the wireless extensions, if necessary, and wireless

antennas.

3. Ground the EDGE Connect TC. See Ground the

EDGE Connect TC on page 53.

4. Connect the LAN Ethernet cable and EtherCAT cable to the EDGE Connect TC.
 For LAN Ethernet cable requirements see Ethernet cable on page 43.
 For EtherCAT cable requirements see EtherCAT cable on page 43.

5. Connect the power to the EDGE Connect TC. For power supply requirements, see External
power supply and power cord on page 44.

6. Connect a USB keyboard and USB mouse to the CNC to make software setup easier. This
step is optional but strongly recommended.

7. Push the power button.

 Turn off the CNC when not in use to prevent retained charge in the LCD
crystals.

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 1 Specifications and Installation

EDGE Connect TC touchscreen specifications

Model number Size of screen Specifications
090198 495.3 mm (19.5 inches) • Projected capacitive touch (PCAP)
090185 469.9 mm (18.5 inches) • 16:9 aspect ratio
• 1366 X 768 resolution

 For more information about touchscreen resolution, see Monitor on

page 32.

EDGE Connect TC dimensions and weight

Figure 5 – Model number 090198 (495.3 mm/19.5 in. touchscreen)

96.3 mm
560.3 mm
(3.79 in.)
(22.06 in.)

495.3 mm
(19.5 in.)

411.0 mm
(16.18 in.)

52.6 mm 131.4 mm
10.7 kg
(2.07 in.) (5.17 in.)
(23.6 lb)

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 Specifications and Installation 1
Figure 6 – Model number 090185 (469.9 mm/18.5 in. touchscreen)
96.3 mm
530.9 mm
(3.79 in.)
(20.90 in.)

469.9 mm
(18.5 in.)

399.5 mm
(15.73 in.)

63.7 mm 131.4 mm
9.5 kg
(2.51 in.) (5.17 in.)
(21.0 lb)

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 1 Specifications and Installation

Mount the EDGE Connect TC

You must mount the CNC.

The EDGE Connect TC can be mounted from the bottom on a flat surface, with a VESA bracket, or
with flush-mount brackets. Hypertherm sells mounting brackets. See Mounting options on
page 336.

EDGE Connect TC bottom mount

440 mm
(17.32 in.)

19.8 mm
(0.78 in.)

61.8 mm
(2.43 in.) 60.0 mm
(2.36 in.)

137.2 mm
For access to EtherCAT and (5.40 in.) M6 X 1 mm threads
12 VDC, for custom operator Maximum fastener depth is
consoles 10 mm (0.40 in.)

The mounting pattern and dimensions are the same for model number 090198 (495.3 mm/19.5 in. touchscreen) and
090185 (469.9 mm/18.5 in. touchscreen).

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 Specifications and Installation 1

EDGE Connect TC VESA mount

Hypertherm does not sell a VESA bracket. Use the dimensions below to buy a compatible bracket.
M4 X 0.7 threads 100 mm
Maximum fastener (3.94 in.)
depth is 10 mm
(0.40 in.)

100 mm
183.8 mm
(3.94 in.)
(7.24 in.)

The mounting pattern and dimensions are the same for model number 090198 (495.3 mm/19.5 in. touchscreen) and
090185 (469.9 mm/18.5 in. touchscreen).

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 1 Specifications and Installation

EDGE Connect TC flush-mount

Hypertherm sells a flush-mount bracket with screws. See Mounting options on page 336.

Secondary enclosure

 The maximum panel thickness is 10 mm (0.4 inch).

1. Select M4, M5, or M6 screws.

2. Use a CNC to cut the rectangle hole and screw holes. See Figure 8 on page 52 for dimensions.

 The rectangle hole dimensions allow 0.51 mm (0.02 inch) nominal

clearance all around. You can adjust this clearance.

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 Specifications and Installation 1
3. Use the brackets and screws to mount the EDGE Connect TC in the panel.

Figure 7 – Dimensions for model number 090198 (495.3 mm/19.5 in. touchscreen)

411.50 mm
561.3 mm
(16.20 in.)
(22.10 in.)
Radius 5.3 mm
(0.21 in.)

M6
360 mm
(14.17 in.)
M5
330 mm
(12.99 in.)
M4
300 mm
(11.81 in.)

20.20 mm
(0.79 in.)
586 mm 35.20 mm
(23.07 in.) (1.39 in.)
50.20 mm
Secondary enclosure (1.98 in.)

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 1 Specifications and Installation

Figure 8 – Dimensions for model number 090185 (469.9 mm/18.5 in. touchscreen)

400.5 mm
531.9 mm
(15.77 in.)
(20.94 in.)
Radius 5.3 mm
(0.21 in.)

M6
360 mm
(14.17 in.)

M5
330 mm
(12.99 in.)
M4
300 mm
(11.81 in.)

Secondary enclosure

560 mm
(22.05 in.)

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 Specifications and Installation 1

Ground the EDGE Connect TC

See Recommended grounding and shielding on page 55 for more information.

The ground wire is customer supplied. The minimum ground wire size is 1.3 mm2 (16 AWG).

1. Remove the screw from the rear of the CNC.

2. Put the ground wire terminal on the screw.

3. Tighten the screw.

4. Connect the ground wire to the EMI chassis ground.

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 1 Specifications and Installation

EDGE Connect TC rear I/O panel connector locations

3 4 5 6

1 Wireless antenna connector RP-SMA connector type

2 Female power-in connector 2.5 mm X 5.5 mm,12 VDC
3 Female RJ-45 connector For LAN, 10/100/1000 Mbps
4 Female RJ-45 connector For EtherCAT, 10/100/1000 Mbps
5 USB connector Hi-speed USB
6 EMI chassis ground M6 thread insert

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 Specifications and Installation 1

Recommended grounding and shielding

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

 The grounding practices in this section have been used on many

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

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

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

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

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

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 1 Specifications and Installation

Grounding practices
1. Unless noted, for HPR or MAXPRO200 cutting systems, use cables with a minimum gauge of
13.3 mm2 (6 AWG) (047040) for the EMI ground cables shown in the Example grounding
diagram with an HPR or MAXPRO200 cutting system on page 60. Unless noted, for XPR
cutting systems, use cables with a minimum gauge of 21.2 mm2 (4 AWG) (047031) for the EMI
ground cables shown in the Example grounding diagram with an XPR cutting system on
page 61.

2. The cutting table is used for the common, or star, EMI ground point and should have threaded
studs welded to the table with a copper bus bar mounted on them. A separate bus bar should
be mounted on the gantry as close to each motor as possible. If there are motors at each end of
the gantry, run a separate EMI ground cable from the far motor to the gantry bus bar. The gantry
bus bar should have a separate, heavy EMI ground cable 21.2 mm2 (4 AWG; 047031) to the
table bus bar. The EMI ground cables for the torch lifter and the RHF or combined ignition/gas
connect console must each run separately to the table ground bus.

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

4. A ground rod (a PE ground) that meets all applicable local and national electric codes must be
installed within 6 m (20 ft) of the cutting table. For HPR or MAXPRO200 cutting systems, the
PE ground must be connected to the cutting table ground bus bar using a minimum 13.3 mm2
(6 AWG) green and yellow grounding cable (047121). For XPR cutting systems, the PE ground
must be connected to the cutting table ground bus bar using a minimum 21.2 mm2 (4 AWG)
grounding cable (047031). Consult an electrician in your location to make sure that your
grounding meets all local and national electric codes.

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

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

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

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

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 Specifications and Installation 1
9. For a system with a RHF console or combined ignition/gas connect console, Hypertherm
recommends that you mount this console as close as possible to the torch. This console also
must have a separate ground cable that connects directly to the cutting table ground bus bar.

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

11. For HPR or MAXPRO200 cutting systems, the metal braided shield on the torch lead must be
connected firmly to the ignition/gas connect console and to the torch. It is recommended to be
electrically insulated from any metal and from any contact with the floor or building. The torch
lead can be run in a plastic cable tray or track, or covered with a plastic or leather sheath.

12. For XPR cutting systems, the coupler on the pilot arc and coolant hose set assembly must be
connected firmly to the gas connect console and torch connect console collars. Make sure to
tighten the clamp. The collar on the torch lead must be connected firmly to the torch sleeve.
Make sure to tighten the clamp. Connect a ground lead (10 AWG) to the flat terminal on the
torch mounting sleeve.

13. 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.

14. 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.

15. 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.

16. 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.

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 1 Specifications and Installation

The following picture shows an example of a cutting table ground bus with an HPR or
MAXPRO200 cutting system. The components shown here may differ from your system.

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

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

1 2 3 4 5 6 7 8
1 Gantry ground bus
2 Ground rod
3 Plasma system lead (+)
4 Gas connect console
5 CNC enclosure
6 Torch holder
7 Plasma system chassis
8 Torch connect console

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 Specifications and Installation 1
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.

1 Cable to the cutting table ground bus

2 Ground cables from components on the
gantry

1 2

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 1 Specifications and Installation

Example grounding diagram with an HPR or MAXPRO200 cutting system

6 7 8 9 10

5
12

11

Chassis and RFI ground

3 13
AC earth ground (PE)

1 Cutting table 8, 9 System-specific component such as metering

2 Gantry console, gas console, or selection console

3 Plasma system 10 CNC chassis

4 Table ground bus bar 11 Torch height control module

(ArcGlide, Command THC)
5 Gantry ground bus bar
12 System-specific component such as a cooler or
6 Torch height control lifter (ArcGlide, Sensor THC, chiller
Sensor PHC, or other)
13 DC power ground
7 RHF console (not on all systems). Connect to
table ground bus bar.

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 Specifications and Installation 1

Example grounding diagram with an XPR cutting system

6 7 8

10

Chassis and EMI ground 11

Service ground
3

PE earth ground

1 Cutting table 8 CNC controller

2 Gantry 9 Torch height control module
3 Plasma system 10 Gas connect console. Connect to table ground
4 Table ground bus bar bus bar.*

5 Gantry ground bus bar 11 DC power ground (work)

* The ignition console is integrated into the gas connect
6 Torch height control lifter
console for XPR cutting systems.
7 Torch connect console

 This example is based on practices in North America. Other regions can

have different local or national electrical codes. Hypertherm recommends
that you consult your local and national electrical codes to make sure that
the grounding and shielding practices that you use satisfy the
requirements for your location.

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 1 Specifications and Installation

Symbols and marks

Your product may have one or more of the following marks on or near the data plate. Because of 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 comply with European Directives. Applicable directives may include the European
Low Voltage Directive, the European Electromagnetic Compatibility (EMC) Directive, the Radio
Equipment Directive (RED), and the Restriction of Hazardous Substances (RoHS) Directive.
See the European CE Declaration of Conformity for details.
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.
RCM mark
CE versions of products with a RCM mark comply with the EMC and safety regulations required
for sale in Australia and New Zealand.
CCC mark
s
The China Compulsory Certification (CCC) mark indicates that the product has been tested and
found compliant with product safety regulations required for sale in China.

UkrSEPRO mark
The CE versions of 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.

RoHS mark
The RoHS mark indicates that the product meets the requirements of the European Restriction of
Hazardous Substances (RoHS) Directive.

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 Operate

When you turn on the CNC, the Phoenix software and the software operator console (Soft Op Con)
open. Before using Phoenix, you must click OK on a dialog window to agree to Hypertherm’s Terms
of Use.

Figure 9

Phoenix Soft Op Con

Phoenix is the core software interface for operating the CNC, and is common across all Hypertherm
CNCs. The Soft Op Con is a fully integrated part of Phoenix. The standard Hypertherm
Soft Op Con, shown in Figure 9, comes with the EDGE Connect and EDGE Connect TC CNCs.

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2 Operate

Cutting system manufacturers can create their own custom software operator consoles using the
Phoenix application programmer interface (API). If your cutting system has a custom software
operator console, contact your cutting system manufacturer or see their documentation for more
information. See also Automatically open a custom software operator console on page 70.

Operate Phoenix
1

In addition to the information in this manual, the Phoenix Help 1 provides details on how to operate
the Phoenix software. Phoenix Help is available for each screen in Phoenix. For more information,
see Phoenix Help and technical documentation on page 73.

The buttons 2 in Phoenix screens are called soft keys.

Some soft keys go to particular screens, and some soft keys do a particular action. The soft keys
that show on a screen change based on installed components, enabled features, Phoenix setup
options, passwords, and user levels (beginner, intermediate, or advanced).

 This manual assumes the CNC is in advanced user level mode and shows
all features.

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 Operate 2

Operate the standard Hypertherm Soft Op Con

The Soft Op Con can replace a hardware operator console. With an EDGE Connect TC, the
Soft Op Con and the hardware operator console can be used together. For example, pressing Start
in the Soft Op Con is the same as pressing the Start button on the hardware operator console.

 Cutting system manufacturers can create their own custom software

operator consoles using the Phoenix application programmer interface
(API). If your cutting system has a custom software operator console,
contact your cutting system manufacturer or see their documentation for
more information.

1 2 3 4

1 Station control tab (shown) 4 Information tab

2 Manual motion tab 5 Program control (always shows)
3 Screen capture and live video tab

The following sections explain each part of the Soft Op Con.

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2 Operate

Station control tab

1 2 3 4 5

1 Station number 3 Disable station key

• As defined on the Station Configuration • Press to disable the station (green when
screen (stations 1 – 8) or the Digital I/O selected)
screen (stations 9 – 20)
4 Manual mode key
2 Station status • Press to operate the station in manual
• Enabled (green) mode (green when selected)
• Disabled (red) 5 Program (automatic) mode key
• Press to operate the station in program
mode (green when selected)

Program control

2 3

1 Program speed (if speed pots are enabled on 2 Start cutting key
the Analog I/O screen) • Press to start cutting
• Slide left for slower program speed
3 Stop cutting key
• Slide right for faster program speed
• Press to stop cutting

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Manual motion tab

These soft keys control all of the stations that are currently enabled.

1 Move speed (if speed pots are enabled on the Analog I/O screen)
• Slide left for slower move speed
• Slide right for faster move speed

2 Latch manual keys key

• Press to turn ON latch manual keys (if enabled in the Special Setups screen)
• Press again to turn OFF latch manual keys

3 Directional jog keys

• Press an arrow key to move in that direction (if latch manual keys is enabled and ON)
• Press and hold an arrow key to move in that direction (if latch manual keys is OFF)

4 Raise torch key

• Press and hold to raise the torch or tool

5 Lower torch key

• Press and hold to lower the torch or tool

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2 Operate

Screen capture and live video tab

2 6

3 7

(In use) 4 8

1 Screen capture and live video* view

This area shows the current screen capture or live video.*

2 Select video source

If two or more video cameras are installed, choose a camera in the drop-down menu.

3
Start or Pause live video

4 Capture the CNC screen, including Phoenix and the Soft Op Con.

This button appears green while in use.

5 Clear screen capture/ Stop live video

6 Refresh video camera options

7 Enlarge image or video in a new window

• Click and drag the new window, such as for display on an external monitor (if installed).
• To close the new window, click on the X in the upper-right corner of the window.

8 Save screen capture

Open the Save As menu and save your screenshot as a file. Videos are not recorded on the CNC.

* Live video is supported if you have one or more supported USB video cameras installed. Video cameras are supplied by your
cutting system manufacturer.

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Information tab

1 Soft Op Con version

• Shows the version of the Soft Op Con on the
CNC

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Automatically open a custom software operator console

Cutting system manufacturers can create their own custom software operator consoles using the
Phoenix application programmer interface (API). By default, the EDGE Connect Launcher
automatically opens the standard Hypertherm Soft Op Con when an operator turns on the CNC. To
automatically open the custom software operator console instead, modify the EDGE Connect
Launcher.

Before you begin

 Make sure that the executable (.exe) files for the custom software operator console
application are saved in the C:\Phoenix folder on the CNC. Typically there is one .exe file
for the upper part of the Soft Op Con and one .exe file for the lower part of the
Soft Op Con.
 Connect a USB keyboard and USB mouse to the CNC.

Modify the EDGE Connect Launcher

1. Close all the EDGE Connect software on the CNC.
a. Click anywhere in the Main screen of Phoenix, and then press Alt+F4 to exit Phoenix.
b. Click anywhere in the upper part of the Hypertherm Soft Op Con, and then press Alt+F4 to
exit the upper part of the Hypertherm Soft Op Con.
c. Click anywhere in the lower part of the Hypertherm Soft Op Con, and then press Alt+F4 to
exit the lower part of the Hypertherm Soft Op Con.

2. Click the Windows Start button and then click File Explorer.

3. In the C:\Phoenix folder, double-click the steps.json file.

 The steps.json file should automatically open in Notepad. If it does not,

open Notepad and then open the steps.json file.

4. To replace the upper part of the Hypertherm Soft Op Con, do the following in the steps.json file:

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Figure 10

 Only delete the specified characters. Do NOT delete quotation marks,

commas, brackets, or other existing characters from the file.

a. Next to StepName, delete SoftOpCon.

b. Type the name of the upper part of the custom software operator console.
c. Next to StepDesc, delete Starting Hypertherm Soft Op Con.
d. Type the text you want to appear while the custom software operator console opens.
e. Next to StepPath, delete C:\\Phoenix\\SoftOpCon.exe.
f. Type the absolute path of the executable (.exe) file for the upper part of the custom software
operator console. For example: C:\\Phoenix\\CustomSoftOpCon.exe.

5. To replace the lower part of the Hypertherm Soft Op Con, do the following in the steps.json file:

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Figure 11

 Only delete the specified characters. Do NOT delete quotation marks,

commas, brackets, or other existing characters from the file.

a. Next to StepName, delete MinReqOpCon.

b. Type the name of the lower part of the custom software operator console.
c. Next to StepDesc, delete Starting Hypertherm Soft Op Con.
d. Type the text you want to appear while the custom software operator console opens.
a. Next to StepPath, delete C:\\Phoenix\\MinReqOpCon.exe.
b. Type the absolute path of the executable (.exe) file for the lower part of the custom software
operator console. For example: C:\\Phoenix\\CustomMinReqOpCon.exe.

6. On the File menu in Notepad, click Save and then close the steps.json file.

7. Click the Windows Start button and then click EDGE Connect Launcher to open Phoenix and
the custom Soft Op Con.

 To get support using your custom Soft Op Con, contact your cutting
system manufacturer.

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Phoenix Help and technical documentation

Phoenix Help gives details on how to operate the Phoenix software. Phoenix
Help is available for each screen in Phoenix.

Choose the Help soft key to see information about each screen.

 To close the Help window, press the X in the upper right corner.

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Hypertherm also provides tips and solutions for common issues to help
improve cut quality.

Choose the Cutting Tips soft key for this information.

 To close the cutting tips, choose the OK soft key.

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In addition, Hypertherm provides technical documentation for the CNC and
any other installed Hypertherm components of your cutting system.

Choose the Technical Documentation soft key to get this documentation.

Figure 12

The EDGE Connect Installation and Setup Manual opens automatically.

Soft keys for all the technical documentation available for installed components appear at the
bottom of the screen. For example, Figure 12 shows an EDGE Connect Manual soft key and an
HPR Manual soft key.

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To see the contents of a manual, choose the Show Bookmarks soft key. Choose a topic in the list
to go to that page in the manual.

 To do a full-text search, press Ctrl + F.

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Operate the EDGE Connect TC hardware operator console

The EDGE Connect TC comes with a hardware operator console.

1 2 3 4 5 6 7 8 9

1 Power button 6 Program speed potentiometer

2 USB connector cover with chain 7 Raise or lower station
3 Female USB connector 8 Manual speed potentiometer
4 Start button (green) 9 Joy stick
5 Stop button (red)

Operate the touchscreen

The EDGE Connect supports a touchscreen. The EDGE Connect TC comes with a touchscreen.
Touch the window controls and fields to enter data into the software. Any field that requires data
input automatically shows an on-screen keypad when you tap it twice.

Touchscreens, drops of water, and unintended motion

Drops of water can be a safety concern if you install the EDGE Connect on a water table. If water
gets onto the touchscreen, the drops can activate a jog key and cause unintended motion on the
table. Unintended motion can cause dangerous conditions for the operator and other people,
damage to machinery, or faults in cutting. To prevent unintended motion:
 Dry your hands completely before you use the touchscreen.
 Install the CNC so that the touchscreen has protection from water splashes.
 If water could get on the touchscreen, do not display the jog keys in the Watch Window or
the software operator console (Soft Op Con).

 Hypertherm recommends enabling the Ready to Move? dialog if there are

any concerns that water could get onto the EDGE Connect touchscreen.
The Ready to Move? dialog can be enabled on the Special Setups
screen (Setups > Password > Special Setups).

For additional information, contact your nearest Hypertherm office listed in the front of this manual.

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Optional keyboard and mouse

You can use a USB-connected keyboard and mouse to enter information and navigate the
CNC software.

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 Machine Stop Strategies and Table Hardware

Machine stop strategies

Phoenix provides several options to ramp down motion to stop the cutting system in the case of a
fault or error condition or an emergency. The option you choose depends on the mechanical design
of the cutting system and your national and local electrical and safety codes. Consult your
regulatory authority to make sure that your cutting system meets all codes.

Use the following information to implement the machine stop strategies that meet the needs of your
cutting system and the electrical and safety codes for your location.
 How the CNC stops motion
 Types of stops: Program stop/pause, Fast stop, and Fault ramp
 Safety circuit example
 About drive enable signals
 About the Drive Enable output and Drive Disabled input
 How the CNC enables and disables the drives
 Inputs and outputs provided by the CNC

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How the CNC stops motion

Program pause/stop (non-urgent stop)

A non-urgent stop is used to pause or stop cutting or trialing. The CNC brings the machine to a
stop using the acceleration rate set for the program speed or manual move speed at which the
cutting system is moving.

Fast stop/fast deceleration (urgent stop)

Fast stop brings all drives to an abrupt stop when a fault occurs and then disables the drives. A fast
stop occurs when an operator activates the fast stop input or under these fault conditions:

Torch Collision (if Fast Decel is selected on the I/O setup screen)
 X and Y overtravel inputs are activated
 Software overtravel limits are activated (if Fast Decel is selected)

Fast stop should be used when safety is not a factor. The deceleration rate is entered on the
Speeds screen in the Fast Deceleration field. The table’s home position (if homing is used) and
program position information are retained.

Figure 13 – Fast stop/fast deceleration

Drive Enable
output ON

Servo command Fast Decel Rate

voltage = n V
(motion) Drive Enable output OFF
Home position (if homing used)
is retained
OFF or 0 V
Fast Stop input turns ON

Servo command voltage to 0

Time
(motion stopped)

Fault ramp
Fault Ramp brings all drives to an abrupt stop and then disables the drives when one of these faults
occur:
 Torch Collision (if Fault Ramp is selected on the I/O setup screen)
 X and Y overtravel inputs are activated
 Software overtravel limits are activated (if Fault Ramp is selected)

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 Machine Stop Strategies and Table Hardware 3
The deceleration rate uses the Fault Ramp Time entered on the Axis screens and disables the drives
when the Fault Ramp time expires. The table’s home position (if homing is used) is not retained and
the table will need to be homed. An exception is a torch collision, which does not require homing
again.

To meet immediate-disable safety standards, the Fault Ramp Time must be set to 0 seconds. When
the Front Panel E-Stop input is activated, the drives will be disabled immediately. With no resistance
from the motors, there is a potential for the table gantry to coast or move uncontrollably. How far the
cutting machine coasts depends on the gantry weight, mechanics, the speed of the gantry when the
Front Panel E-Stop input is activated, and the amount of friction present.

If a coasting gantry is a concern, adjust the Fault Ramp Time value to bring the gantry to a controlled
stop before the drives are disabled. The available range for Fault Ramp Time is between 0.1 and 2
seconds.

In general, larger gantries require a longer Fault Ramp Time to stop the cutting system safely.
Shorter Fault Ramp Times result in faster, or immediate, stop times which can cause damage to the
cutting machine and the drive mechanics. Controlling the gantry to a stop may not meet certain
safety regulations and may not meet other local codes or standards. Consult local safety regulations
for a complete understanding of the requirements for your system.

The CNC is capable of running with software overtravel limits that are based on position. When
enabled, this feature lets you select Fault or Fast Decel when active. Fault operates as hardware
switches with immediate fault. Fast Decel uses the fast deceleration value to ramp down motion.

Figure 14 – Fault Ramp

Drive Enable
output ON

Fault Ramp Time

Servo command
0.1 – 2 seconds
voltage = n V
(motion)

Drive Enable output OFF

Home position (if homing used) and
program position NOT retained
OFF or 0 V
Hardware overtravel switch
turns ON
Servo command voltage to 0
Time (motion stopped)

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Emergency stop (E-stop) and Fast Stop compared

Fast Stop

Use the Fast Stop input when you want an urgent stop. DO NOT use the Fast Stop input for an
E-stop. Connect the Fast Stop input to a separate switch on the operator console. When this input
activates, the CNC decelerates motion for 1 second using the Fast Deceleration Rate on the
Speeds screen, then turns off the individual drive enable signals and the Drive Enable output. The
CNC retains position information so that you can restart the cutting job after clearing the condition
that caused you to stop the system.

 If the Fast Stop input is removed in less than 1 second, the drives may
remain enabled.

Emergency stop

An emergency stop, or E-stop, is a physical switch on the cutting system or on a CNC custom
operator console. The design and implementation of an E-stop switch and circuit depends on
national and local electrical and safety codes.

The EDGE Connect/EDGE Connect TC CNC provides an input called Front Panel E-Stop for use
when designing an E-stop circuit. When this input activates, the CNC turns off the individual drive
enable signals and the Drive Enable output. The CNC also erases all position information from
memory and requires that you re-home the cutting system. The CNC displays the status message
Emergency Stop Active when the Front Panel E-stop input activates.

In Phoenix, you can enter a fault ramp time for each axis. The Fault Ramp Time delays the CNC from
turning off the Drive Enable output so that power is maintained to the drives briefly (0.1 to 2
seconds) to stop the gantry without damage to the mechanics.

Normally local safety codes require AC power to be removed immediately from the drives. In this
case, enter 0 for the fault ramp time for each axis.

CAUTION
Using a 0-second Fault Ramp Time could result in the gantry coasting, which can damage the
cutting machine and the drive mechanics. Controlling the gantry to a stop may not meet certain
safety codes and may not meet other local codes or standards. Consult local safety regulations
for a complete understanding of the requirements for your system.

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Enable the cutting machine after a power cycle or stop

After you turn ON the cutting machine and after an emergency or urgent stop, one or more error
messages like the following appears.

These error messages are remaining from the interruption in EtherCAT network communications
when the CNC was turned off or motion stopped. You need to re-enable the drives. Choose
Manual to close each message. Phoenix continues to start the EtherCAT network.

If the error messages continue to appear, another method may be necessary. This is because how
you re-enable the cutting machine depends on the wiring of the drives, the machine’s safety circuit,
the machine’s reset mechanisms, the disable input assigned in the CNC, and the timing of the
CNC’s enable logic.

The following is another example sequence of re-enabling the drives. (The state of the machine is:
E-stop depressed, no AC power to the drives, and the disable input is active to the CNC.) Turn ON
the CNC and wait for the network to establish communications.

Deactivate the disable input to the CNC (Drive Disabled, Front Panel E-stop, or Fast Stop). Often
this is accomplished by a reset mechanism or push-button, depending on the operator console and
the drive box safety circuit.

After the input is deactivated, the CNC attempts to re-enable the drives for up to 2 seconds. After
2 seconds, the CNC stops trying. The drives must be in stand-by mode or the attempt fails after
2 seconds. If the CNC doesn’t succeed in re-enabling the drives automatically, you can re-enable
the drives manually by choosing the Setups > Enable Control soft key.

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Safety circuit example

The following drawing shows a simplified example of the components and I/O of a cutting system
safety circuit.

 The drawing is an example only. There are other ways to create a safety
circuit. For instance, this example does not use the Safe Torque Off (STO)
that is available on certain drives.

The CNC follows this sequence of operations:

 Power to the drives requires:
 Front Panel E-stop input or Fast Stop input must be OFF, and
 Drive Enable output must be ON, then
 AC power can flow to the drives through the main contactor. A switch connects the
main contactor to the safety circuit.

Figure 15 – Safety circuit logic example

AC power to drives

E-Stop
push button switch
Normally Closed

Front Panel E-stop (input to CNC)

Drive Disabled (input to CNC)

Drive Enable (output from CNC)

Power On/Reset
Momentary switch,
Normally Open
Customer-supplied components for Main contactor
safety circuit
(within dotted lines)

When the E-stop push button is engaged, the Drive Disabled input turns ON and the Drive Enable
output turns OFF. As long as Drive Disabled is ON, AC power is removed from the drives and no
motion can occur. Use both of these inputs.

The Front Panel E-stop input indicates the E-stop switch is engaged. Drive Disabled indicates the
safety circuit has not been reset. You have to re-enable with a push-button reset that turns off the
Drive Disable input and maintains that status until the Drive Enable output becomes active.

After the stop condition is cleared, the Power On/Reset switch is used to restore the I/O and power
to the drives.

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Drive enable signals

When the CNC turns ON, with no safety inputs active (Drive Disabled, Fast Stop, or Front Panel
E-stop), it immediately enables the drives.

Each axis has an axis enable signal. Phoenix activates this signal when it turns ON the Drive
Enable # status signal where the # is the axis number. When the drives are wired in series, these
signals activate or deactivate at the same time. When the drives are wired in parallel, the signals
activate and deactivate in succession. After the Drive Enable bit is activated for each axis in the
cutting system, the CNC turns ON the Drive Enable output.

In the Setups > I/O screen, select whether the drive enable signals should be activated in series or
independently. If a fault or error occurs, drives in series all complete their ramp times before the
drives are disabled. Drives that are wired in parallel or independently each disable at the end of the
Fault Ramp Time.

Drive Enable output

A Drive Enable output must be assigned in the CNC and wired into the cutting system safety circuit.
This output turns off after the individual drive enable signals turn off. When you require a controlled
stop to the cutting system where motion ramps down before the drives are disabled, you want to
include the Drive Enable output as part of your safety circuit logic and drive wiring scheme.

 A 2-second delay is required before the Drive Enable output turns on. The
operator may need to press and hold the reset switch for 2 seconds.

Drive Disabled input

Wire this input to the drive box safety circuit. The CNC doesn’t know if a drive is disabled unless the
Drive Disabled input is wired into the safety circuit. If a safety condition occurs, the Drive Disabled
input opens (it is Normally Closed) and the CNC cannot enable the drives until the Drive Disabled
input is closed again.

In a cutting system using an EDGE Connect CNC, messaging on the network tells the CNC
whether or not the drives are enabled. If one or more drives are not enabled then the CNC changes
to Control Disabled state. When the issue is resolved, the operator can toggle the Enable Control
soft key in the Setups screen. This allows the CNC to re-enable the drives.

Hardware overtravel limits

Select whether the cutting system will be using hardware overtravel switches. If hardware overtravel
switches are used, the CNC will disable feedback and display an error message if the inputs
become active. It is recommended that hardware overtravel switches be installed.

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Software travel limits

If Software Overtravels are enabled, the user is prompted for the minimum and maximum travel of
the cutting machine.

A software travel limit (also called a software overtravel) is a position on the axis that can be reached
before the system contacts a hardware limit switch or hard stop. Figure 16 on page 86 shows
measurements from an example system with a gantry that has 154 inches (3,912 mm) of travel on
the Transverse axis between the overtravel switches.

 The gantry travel distance of 154 inches (3,912 mm) also equals the
Table Size X dimension on the Machine Setups screen (Setups >
Password > Machine Setups).

 For software travel limits to work correctly, the cutting system must first be
homed so that the CNC can determine the absolute home position.

Figure 16

2 4 Gantry 5 3

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 Machine Stop Strategies and Table Hardware 3

1 Gantry distance between hardware overtravel 3 X+ overtravel switch at 154 inches

switches 154 inches (3,912 mm) (3,912 mm) (when the Absolute Home
position is 0 mm [0 inches])
2 X- overtravel switch at 0 mm (0 inches) (this
equals the Absolute Home position on the X 4 Software minimum travel limit at 3 inches
axis setup screen). Add a hard stop to the left (76 mm) to stop motion before contact with
of 2 . There needs to be enough space to stop the hardware overtravel switch.
without breaking your hard stop. 5 Software maximum travel limit at 151 inches
(3,835 mm) to stop motion before contact with
the hardware overtravel switch.

Home switches

The Home parameter is used to activate use of the Home feature. Depending on configuration, the
table may be Homed to either a designated Home Switch or an Overtravel Switch.

The Home feature is used to set a known absolute physical position location on the cutting table.
This is used for referencing future manual Go to Home and other motion commands. This is
generally performed through activation of a home switch positioned on the appropriate axis, giving it
a known physical location.

When you enter a homing command, the CNC moves the axis toward the home switches at the Fast
Home Speed until the switches activate. Once the switches activate, motion stops and then the axis
moves in the opposite direction of the switch at the Slow Home Speed. The moment that the switch
deactivates, the CNC resets the axis position to the absolute home position. Motion then continues
for the Home Offset distance. When motion stops, the position is saved as the Home reference.
 The Absolute Home Position defines the position of the axis when the Home Limit Switch
turns off or Marker Pulse is detected.
 The Home Offset Distance allows the user to set an offset distance from the Home Limit
Switch.
 Home Direction determines which direction the axes will travel during phase one of the
homing sequence.
 The Axes Home Position is the position of the axes when homing is complete.
 Use Marker Pulse, when enabled, assigns the absolute home position at the instant the
marker pulse is detected. It is recommended that the Marker Pulse be used for optimal
homing repeatability.
 The Dual Gantry Home switch offset value needs to change when the home switch is moved
or replaced. Phoenix aligns the Rail and Dual Gantry axis based on the old Dual Gantry
Home switch offset value. When you zero the switch offset value to measure the new switch
offset value, Phoenix returns the wrong measured value because the original switch offset
value is still being applied. There are 2 ways to fix this issue.
 Zero the switch offset value and shutdown and re-start Phoenix.
 Zero the switch offset value, disable and re-enable the control and then measure and
enter the new switch offset value. A simple solution in Phoenix is to disable and then
re-enable the axis each time the Dual Gantry Home switch offset value changes.

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General recommendations

Follow these recommendations for ease of setup and best performance:

 Dedicate a single drive to each axis in the cutting system.
 Do not mix EtherCAT CoE and SoE drives on the same EtherCAT network.
 Connect the axis limit switches (also called overtravel switches) to the drive I/O, not to an
inline I/O module. The drive and the CNC together provide the capabilities for the best
possible machine deceleration in the event of a machine stop.
 When you choose Go to Home or attempt motion, a Ready to Move? message prompts you
to confirm that you are ready to start motion. You can disable the Ready to Move? message
in Special Setups.

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 Configure the EtherCAT Network

Hypertherm EtherCAT Studio is an EtherCAT network configuration tool. It includes an EtherCAT

master and a library of EtherCAT slave information files for supported devices.

To configure the network, you use Hypertherm EtherCAT Studio to do the following:

1. Scan the slave devices to collect information about the network.

2. Enable and set up distributed clocks to synchronize communications.

3. Save the network information as a file and export it to the CNC.

Before you begin

 Connect a USB keyboard and USB mouse to the CNC.

 Make sure that the cutting system is ready for motion:
 All the slave devices are installed, configured, connected to the CNC with an EtherCAT
cable, and energized.
 The motors are connected to the drives.

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Scan your slave devices

1. Turn ON the CNC.

After Phoenix opens, it begins to start the EtherCAT network. The following message appears.

2. Choose Cancel to stop network start-up.

3. Click anywhere in the Main screen of Phoenix, and then press Alt+F4 to exit Phoenix.

4. Click anywhere in the upper part of Soft Op Con, and then press Alt+F4 to exit the upper part of
Soft Op Con.

5. Click anywhere in the lower part of Soft Op Con, and then press Alt+F4 to exit the lower part of
Soft Op Con.

6. In the notification area of the Windows task bar, right-click the INtime icon and then click
Start NodeA.

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 Configure the EtherCAT Network 4
7. Click the Windows Start button and then click Master Server (INtime).

8. To make sure that INtime Server is running, click the Windows Start button and then click
Master Server (INtime) again.
The following message appears.

9. Click the Windows Start button and then click HT EtherCAT Studio.

Hypertherm EtherCAT Studio appears. See Figure 17 on page 92.

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 4 Configure the EtherCAT Network

Figure 17 – Hypertherm EtherCAT Studio

10. Make sure that Master 1 is selected in the folder list on the left and that the Master tab is on
top.

11. In Host name under 1. Connection settings for master server, click the arrow to select
192.168.50.50:5000. See Figure 18.
Hypertherm EtherCAT Studio connects to the master.
In Network card under 2. Master parameters, ie1g0 appears.

Figure 18 – Master settings

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 Configure the EtherCAT Network 4
12. In the folder list on the left, right-click Master 1 and then click Scan configuration.

Hypertherm EtherCAT Studio scans the slave devices on your network, and then shows a list of
your slave devices.

Figure 19 – List of slave devices

 As shown in the example in Figure 19, if you have an EDGE Connect

TC, the operator console PCB (229827) is always the first slave device.

 The HPR EtherCAT plasma interface PCBs (229829) are always the last
slave devices (when installed as instructed).

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 4 Configure the EtherCAT Network

Enable and set up distributed clocks

1. Make sure that Master 1 is selected in the folder list on the left, and then click the Distributed
Clocks tab.

2. Make the following selections. See Figure 20.

 Enable Distributed Clocks
 Slave is Reference Clock
 Independent mode
 Set master time to Reference Clock
 Enable propagation delay compensation

Figure 20 – Distributed Clocks tab

 Hypertherm EtherCAT Studio automatically selects the first slave device

that is capable of being the reference clock as the reference clock.

 You will set the Sync shift time later. For now, leave the default value in
this field.

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 Configure the EtherCAT Network 4
3. In the folder list on the left, right-click Master 1 and then click Attach Master.
Look at the status bar at the bottom of the screen to monitor this process.
Continue to the next step when the symbol to the left of Master 1 is green and the status is
Ready.

 If Hypertherm EtherCAT Studio cannot attach the master, examine each

slave device for errors. If you still do not know the cause of the problem,
remove all the slave devices from the network except for the first slave
device. Then go back to step 1 on page 89 (see Scan your slave devices)
and repeat these instructions. Continue adding one slave device at a time
and repeating these instructions until you find the slave device that is
causing the problem.

4. Make sure Master 1 is selected in the folder list on the left and then click the State tab.
See Figure 21 on page 96.

5. Click Operational.
Current state changes from INIT to OPERATIONAL.

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 4 Configure the EtherCAT Network

Figure 21 – State tab

6. Click the Statistics tab. Monitor the number in Slaves response time for 15 to 30 seconds,
and record the highest response time you see.

7. Select the State tab and click INIT. Current state changes from OPERATIONAL to INIT.

8. In the folder list on the left, right-click Master 1 and then click Detach Master.

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 Configure the EtherCAT Network 4
9. When Hypertherm EtherCAT Studio asks you if you want to stop the master, click Yes.

10. Click the Distributed Clocks tab. In Sync shift time, type the response time noted in step 6 on
page 96 multiplied by 110% (1.10) and rounded up or down as necessary.
For example, assume the response time noted in step 6 was 72. 72 multiplied by 1.10 is 79.2.
Round that down to 79, and type 79 in Sync shift time.

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 4 Configure the EtherCAT Network

Export your network configuration to the CNC

1. In the folder list on the left, right-click Master 1, then click Export, and then click Export Master
Configuration KPA.

2. In the Save As window, make sure you are in the C:\Phoenix folder. See Figure 22.

3. In the list of files, click Phoenix.xml. Make sure that Save as type is EtherCAT Network
Information (ENI) files (*.xml).

4. Click Save.

5. Click Yes to overwrite the existing XML file.

The EtherCAT network is now configured.

Figure 22 – Save As window

6. On the File menu, click Exit to close Hypertherm EtherCAT Studio.

7. When Hypertherm EtherCAT Studio asks you if you want to stop the master, click Yes.

8. When Hypertherm EtherCAT Studio asks you if you want to save your project file, click Yes.

 Saving the project file is optional but strongly recommended, as a

troubleshooting aid.

9. In the Save As window, make sure you are in the C:\Phoenix folder.

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 Configure the EtherCAT Network 4
10. In File name, type Phoenix.ecsn. Make sure that Save as type is EtherCAT Studio project
files (*.ecsn).

11. Click Save.

12. Click the Windows Start button and then click EDGE Connect Launcher to restart Phoenix.

After Phoenix opens, it begins to start the EtherCAT network. The following message appears.

This message shows the progress of network startup as it continues from Init to
Pre-Operational to Safe-Operational to Operational.
One or more error messages like the following may appear.

Click Manual to close each message. Phoenix continues to start the EtherCAT network. These
error messages are remaining from when you canceled network startup (see step 2 on
page 90).

 If you continue to see error messages, disconnect the slave devices from
power and then reconnect them to power. Then click Manual to restart
the network.

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 4 Configure the EtherCAT Network

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 Machine Axes

Overview

Phoenix has several screens that let you define your cutting system. The screens are accessed with
the Machine Setups password provided by Hypertherm.

Access the screens by choosing > > .

This section describes setting up your cutting system, including:

 Defining axis orientation and positive motion
 Identifying Transverse, Rail, and Dual Gantry axes on the cutting system (for Sensor THC
axis setup see Torch Height Control (THC) on page 135)

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5 Machine Axes

Axis orientation and positive motion

Gantry-table cutting systems are based on the Cartesian coordinate system. Phoenix requires you
to define the X axis and positive motion relative to the table’s 0,0 position (absolute home position).
In the Cartesian coordinate system, the X+ and Y+ motion is represented like this:
Y+

X- X+
0,0

Y-

Axes assignments on the Machine screen are sequential, beginning with the first axis (X).

The X axis is the first axis Phoenix needs to know about. In a standard orientation, the X axis is along
the gantry. Phoenix calls the axis along the gantry the Transverse axis. The Y axis is always
perpendicular to the X axis. In Phoenix, the Rail axis is perpendicular to the Transverse. In a standard
orientation the Y axis is along the rail. When a cutting system has a second rail motor, you select the
Dual Gantry axis on the Machine Setups screen in Phoenix.

Figure 23 shows a cutting table where X is assigned to the gantry, also called Transverse, and Y is
assigned to the Rail.

Figure 23

Gantry Rail
(Transverse axis)
+Y

Rail

-X

0, 0
-Y

+X

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 Machine Axes 5
The Sensor THC, integrated into many Hypertherm CNCs, is also an axis on the CNC. The
Sensor THC axis, or lifter axis, is called a Z axis. Its positive direction is always up (skyward) and its
negative direction is always down (earthward). Its Z position increases in the positive direction for
motion in the downward direction. If the Sensor THC is not used, an axis is not assigned to the
CNC and Z-axis motion is not calculated.

+Z +Y

-X
-Z
0, 0
-Y

+X

Axis assignments

Hypertherm CNCs use fixed axis assignments for all axis types except the Sensor THC. The tables
below show a sample of possible configurations. with the axis number and assignment that the
CNC uses for up to 6 axes, and the common letter identifiers for the axes.

 All cutting systems require both Transverse and Rail axes, but you can
assign either to X or Y.

 A Dual Gantry axis is parallel to the Rail axis (think of it as a “Rail 2” axis).
In a Dual Gantry cutting system, the second Rail axis is powered by its
own motor using the same command signal as the Rail axis.

4-axis, I-cutting, no Dual Gantry

Axis number Axis assignment

1 Transverse or Rail (X or Y)

2 Rail or Transverse (Y or X)

3 Sensor THC (Z)

4 Transverse 2

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5 Machine Axes

5-axis, I-cutting, with Dual Gantry

Axis number Axis assignment

1 Transverse or Rail (X or Y)

2 Rail or Transverse (Y or X)

3 Dual Gantry (W)

4 Sensor THC (Z)

5 Transverse 2

6-axis, 2-station, I-cutting, with Dual Gantry

Axis number Axis assignment

1 Transverse or Rail (X or Y)

2 Rail or Transverse (Y or X)

3 Dual Gantry (W)

4 Sensor THC 1 (Z)

5 Transverse 2

6 Sensor THC 2

Machine setups screen

Use the Machine Setups screen to define the axis assignments, machine motion direction, and table
size.

To open the Machine Setups screen, choose > > .

 The Machine Setups screen includes Sensor THC settings. For more
information about those settings and Sensor THC axis setup, see Torch
Height Control (THC) on page 135.

1. Choose the X axis as the Transverse or Rail axis . The default

setting is Transverse.

2. Choose the Up Direction to define the machine motion

when the up arrow soft key is pressed on the Soft Op Con when the CNC is in manual
mode. This choice also defines the machine motion when the joystick on the EDGE Connect TC
hardware operator console is moved in the up direction when the CNC is in manual mode.

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 Machine Axes 5

3. Choose the Right Direction to define the machine motion when the

right arrow soft key is pressed on the Soft Op Con when the CNC is in manual mode.
This choice also defines the machine motion when the joystick on the EDGE Connect TC
hardware operator console is moved in the right direction when the CNC is in manual mode.

4. Choose the X and Y Motor/Encoder mode .

Select Swapped to swap the X and Y axis encoder signals internally.

5. Choose Yes or No for Dual Gantry Installed . If yes is

selected, the Dual Gantry will be assigned to axis 3 and the Z axis will be axis 4.

6. Enter the size of your cutting table. Enter the distance between the X overtravel switches and
the Y overtravel switches. The X and Y dimensions represent the cutting area of the table and
limit the workpiece size dimensions set in the Cutting screen.

7. Choose Yes or No for Key Press Logging . Choose Yes to record

key press and other related information in a daily log file. Service technicians use this log to
review events before a fault. When logging is enabled, the log file is saved to the hard drive so it
can be retrieved by transfer to a USB memory stick. Usually this parameter is set to No.

Transverse or Rail axis

The settings on the Transverse and Rail screens are identical.

The CNC comes with both an advanced position and velocity servo loop. The following parameters
are available to help configure the servo loops for your specific drive and mechanical system.

To get to the Transverse or Rail screens:

1. Choose > > > > or

2. Enter the Servo Error Tolerance .

Servo error, also called following error, is the difference between the commanded axis position
and the actual axis position as calculated by the drive. The servo error tolerance is the upper
limit of the amount of following error allowed before the CNC faults.
The amount of servo error tolerance depends on the cutting machine mechanics. Setting the
servo error tolerance too low could cause the CNC to fault repeatedly. Setting it too high may

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5 Machine Axes

allow inaccurate motion or result in mechanical damage. Set the servo error tolerance to a value
higher than the steady-state following error that is reported by the drive.

3. Enter the Encoder Counts per mm (inch) .

Encoder counts are a position scaling factor used by Phoenix. Refer to the drive manufacturer
documentation for specific scaling information required by the drive.
In general, to determine the encoder counts per mm (inch), you need to know the following:
 Counts per revolution of the motor
 Gear ratio
 Distance of travel in one revolution of the pinion gear
 Diameter of the pinion gear when it engages the rack
The formula you use is shown below:

x x 1
encoder counts motor revolutions pinion revolution
x encoder counts
X X x pinion =
1 1 per mm (inch)
circumference
motor revolution pinion revolution
X Π (pitch)

Below is an example using the following sample data:

 Kollmorgen AKD drive with 65,536 encoder counts per revolution of the motor
 10:1 gear ratio
 150 mm (5.91 in.) pitch

65,536 10 1
encoder counts motor revolutions pinion revolution 4,369.067 (110,890.017)
X X =
1 1 150 mm (5.91 in.) encoder counts per mm (inch)
motor revolution pinion revolution pitch

 This is just an example. Refer to the drive manufacturer documentation for

specific scaling information required by the drive. Some drive-specific
information is also available in Hypertherm Application Notes. Technical
documentation is available at www.hypertherm.com/docs.

4. Choose Yes or No for Use Hardware Overtravels to

select whether the cutting system will be using hardware overtravel switches. If hardware
overtravel switches are used, the CNC disables feedback and shows an error message if the
inputs become active. We recommend that hardware overtravel switches be installed.

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 Machine Axes 5

5. Enter Backlash Compensation to offset or compensate for

any backlash in the mechanics of the drive system. The maximum value for backlash
compensation is 12.7 mm (0.5 inch).

6. Enter the Fault Ramp Time to set the motion deceleration time
after a fault occurs. At the end of the Fault Ramp Time the drives will be disabled.

7. Choose a Home parameter . This parameter is used to activate the

Home feature. Depending on your configuration, the table may be homed to either a designated
home switch or an overtravel switch.
The Home feature is used to set a known absolute physical position location on the cutting table
that is used for referencing future manual Go to Home and other motion commands. This is
generally performed through activation of a home switch positioned on the appropriate axis,
giving it a known physical location.
When you home an individual axis or all axes, the CNC moves the axis toward the home
switches at the Fast Home Speed until the switches activate. Once the switches activate,
motion stops and then the axis moves in the opposite direction of the switch at the Slow Home
Speed. The moment that the switch deactivates, the CNC sets the axis position equal to the
Absolute Home Position.

8. Enter the Absolute Home Position to define the position of

the axis when the Home Limit Switch turns OFF or Marker Pulse is detected.

9. Enter the Home Offset Distance . This parameter allows you

to set an offset distance from the Home Limit Switch or an offset from the marker pulse.

10. Choose a Home Direction to determine which direction the

axes will travel during phase one of the homing sequence.

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5 Machine Axes

11. Choose to disable or enable software travel limits. The CNC is capable of running with software
travel limits that are based on position.

a. Choose No to disable this feature .

b. Choose Fault or Fast Decel to enable this feature. Fault performs a Fault Ramp to ramp
down motion. The Fault Ramp Time is set on the Axis screen. Fast Decel uses the Fast
Deceleration rate set on the Speeds screen to ramp down motion. If Software Overtravels
are enabled, enter the maximum and minimum travel from the cutting machine’s final home
position.

Using software travel limits

A software travel limit (also called a software overtravel) is a position on the axis that can be reached
before the system contacts a hardware limit switch or hard stop. Figure 24 on page 109 shows
measurements from an example system with a gantry that has 154 inches (3,912 mm) of travel on
the Transverse axis between the overtravel switches.

 The gantry travel distance of 154 inches (3,912 mm) also equals the
Table Size X dimension on the Machine Setups screen (Setups >
Password > Machine Setups).

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 Machine Axes 5
Figure 24 – Example measurements

Add a hard stop to

the left of 2. Allow
enough space to
Gantry
stop without 2 4 5 3
breaking your hard
stop.

1 The gantry distance between the hardware overtravel switches is 3,912 mm (154 inches).

2 The X- overtravel switch at 0.

3 The X+ overtravel switch at 3,912 mm (154 inches).

4 The software minimum travel limit is at 76 mm (3 inches) to stop motion before contact with the
hardware overtravel switch.

5 The software maximum travel limit is at 3,835 mm (151 inches) to stop motion before contact with the
hardware overtravel switch.

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 5 Machine Axes

Dual Gantry axis

1. Choose > > > > .

The Dual Gantry axis is commanded as a separate axis on the CNC that mirrors the output of the
main Rail axis. Additionally, performance of the Dual Gantry axis is compared to the main Rail axis
and additional output command is given to keep the axis in position.

The definitions for the setup parameters are the same as for the Transverse/Rail Axes. However, the
number of selections are reduced because features for overtravels and homing do not apply.

1. Enter the Skew Error Tolerance to set the amount of position

error allowed between the master and slave gantry drive axes prior to an error.

 This value should match the value used for the Rail for proper operation.

2. Enter the Encoder Counts per mm (inch) . See step 3 on

page 106 for more information.

3. Enter the Backlash Compensation to offset or

compensate for any backlash in the mechanics of the drive system. The maximum value for
backlash compensation is 12.7 mm (0.5 inch).

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 Speeds

Set speeds

The CNC is capable of operating over a wide range of speeds, depending on the drives, motors,
gearboxes, and mechanics of the system.

The Speeds setup screen is where you set machine speeds for the operating modes.

To get to the speeds screen choose > > .

Set speed ranges (speed breaks)

Enter parameters for the Speed 0 to settings.

These parameters specify speed ranges (or breaks) and customize the acceleration rates for these
speeds. When a speed range that is lower than the maximum speed is entered, a new range setting
is created. You can set a maximum of 5 speed ranges.

To reduce the number of speed ranges, enter the maximum speed in the highest range and the
additional range fields will be removed from the screen.

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 6 Speeds

Acceleration rates
1. Enter parameters for the Acceleration Rate settings.These parameters determine both the
acceleration and deceleration rate for all motion.

All mechanical systems have different acceleration and deceleration rates to move the cutting
device smoothly. The higher the acceleration rate, the faster the machine will get up to speed
and decelerate. Higher acceleration rates will be able to reach optimal cut speeds faster,
resulting in better cut quality. The lower the acceleration rate, the slower the machine will get up
to speed and decelerate.
It is important to use the optimal acceleration for your cutting table’s mechanical design and
drive/motor capability. Excessive acceleration settings can cause issues with the performance
of the cutting system.
Enter a value in mGs for the desired acceleration rate. 1 mG is approximately 0.386 inches per
second2. The drive, motor, gears, mass, and overall table design affect the acceleration
capability. We recommend that for the initial tuning of a new design that you start at 10 mG
before proceeding to your final acceleration values.

2. Enter parameters for the Peak S Curve Acceleration fields. This parameter appears when
S Curve Acceleration (at the lower right on the Speeds screen) is set to Yes.

For more information, see Trapezoidal motion compared to S-curve motion on page 115.

3. Enter a parameter for Fast Deceleration Rate .

This parameter is activated by the Fast Stop, Software Overtravel, or Torch Collision inputs and
specifies in mGs how quickly the system will stop when the Fast Stop input is active. Generally,
this value is much higher than the acceleration rate.
1 mG is approximately 0.386 inches per second2.

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Maximum machine speed

Enter a parameter for the Maximum Machine Speed . This

parameter limits the range of all subsequent speed entries. In addition, it scales the speedometer in
the Watch Window.

Calculate the maximum machine speed using the following formula.

32,767 60,000
X
(max. encoder counts per ms) (ms per minute) Maximum machine speed
=
Encoder counts per mm (inch) per minute

 The maximum encoder counts per ms in Phoenix is fixed at 32,767.

 For more information about calculating encoder counts per mm (inch), see
step 3 on page 106.

For example, assume the encoder counts per inch are 1,000,000.

32,767 X 60,000
= 1,966 inches per minute
1,000,000

You would enter 1,966 in the Maximum Machine Speed parameter.

 To use a higher machine speed, you must reduce the encoder counts per
mm (inch) by reducing the position scaling in the drive.

Set the speed for manual moves

Choose the Change Move Speed soft key to cycle through the 4 move speeds that
are available: Maximum Machine Speed, High Jog Speed, Medium Jog Speed, and Low Jog Speed.

1. Enter a parameter for the High Jog Speed . This parameter

defines the maximum speed you can select for jog speed.

2. Enter a parameter for the Medium Jog Speed .

This parameter defines the medium speed you can select for manual motion.

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 6 Speeds

3. Enter a parameter for the Low Jog Speed . This parameter

defines the lowest speed you can select for manual motion.

4. Select Yes or No for Limited Speed If Not Homed . If

you select Yes, and the machine has not been homed, machine motion is limited to the value
entered for Limited Machine Speed. See Limited speeds.

Home speeds

1. Enter a parameter for the Fast Home Speed . This

parameter defines the speed that the CNC uses during the first phase of the homing sequence.
During the first phase, the master station moves toward the home limit switches at the Fast
Home speed and decelerates to a stop when the home input is activated.

2. Enter a parameter for the Slow Home Speed .

This parameter defines the speed that the CNC uses during the second phase of the homing
sequence. During the second phase, the master station reverses direction and moves at the
slow home speed until the home input turns off. If marker pulse is used, motion continues until
marker pulse occurs (or the home input turns off). Then the axis position is reset to the Absolute
Home position and motion continues at the slow home speed, and the master station travels the
Home Offset distance and comes to a stop. The position when homing is complete is the home
position for that axis.

Corner speed

Enter a parameter for the Minimum Corner Speed .

This parameter defines the minimum speed to use when negotiating corners. Corner speed is set by
the centripetal limiting algorithms that use the program speed and the acceleration rate set for this
speed range. For normal operations, this parameter should be set to zero to let the centripetal
limiting algorithm determine the speed based on the acceleration rate.

Limited speeds

1. Enter a parameter for the Limited Machine Speed .

This parameter defines the maximum machine speed when the Limited Speed input is active.
This is commonly used to set a reduced machine speed for increased safety during machine
testing or maintenance. If this value is set to 0, no motion will occur before homing (if homing is
configured), and no motion will occur if the Limited Speed input is on.

2. Enter a parameter for the Creep Speed . The Creep

Speed percentage defines what percentage of the machine cut speed is used when creeping.
Generally, creep speed is 25% of the cut speed.

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 Speeds 6

Trapezoidal motion compared to S-curve motion

During trapezoidal motion, the CNC sends a command to the drive systems to accelerate
immediately to the desired machine acceleration, as determined in the machine setups. This is the
fastest way of reaching the maximum acceleration rate and achieving the desired cut speed.
However, this rapid change in acceleration produces “jerk” in the motion of the table that can affect
cut quality. With trapezoidal motion, jerk is always greatest when the table is beginning to accelerate
or decelerate at the beginning or end of a cut.

S-curve motion is a feature of Phoenix that allows smoother motion during acceleration than
traditional, or trapezoidal, motion.

Figure 25 – Trapezoidal motion

Jerk
Jerk
Velocity

Jerk

Time (ms)

During S-curve motion, the CNC sends acceleration commands to the drive system in increments
until the system reaches the maximum acceleration rate. The S-curve commands smooth out
acceleration and reduce jerk for a given acceleration rate. This could allow the table to reach higher
acceleration rates if jerk was the limiting factor when using trapezoidal motion.

Figure 26 – S-curve motion

Velocity

Time (ms)

The typical implementation of S-curve motion uses the same peak acceleration as trapezoidal
acceleration and results in smoother acceleration. However, this implementation takes more time to
reach the desired acceleration rate and more time to complete a specific motion.

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 6 Speeds

In Phoenix, S-curve uses the same average acceleration rate that was selected for trapezoidal
acceleration but uses a peak acceleration that is 50% higher than the average acceleration setting.
Increasing the peak acceleration allows S-curve acceleration to execute a segment in the same
amount of time as trapezoidal acceleration.

As an example, if 40 mG average acceleration has been selected for trapezoidal motion, when
S-curve motion is turned on, the table still accelerates at an average rate of 40 mG but the peak
rate of acceleration will reach 60 mG.
Acceleration (mG)

70

60

50

40

30

20

10

0
40 80 120 160 200 240 Time 40 80 120 160 200 240
(ms)
Trapezoidal motion S-curve motion

With a higher peak acceleration, S-curve allows the table to achieve the desired cut speed, with
reduced jerk, in the same amount of time as trapezoidal motion.

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 Speeds 6

S-curve setup

CAUTION!

Verify that the cutting table is capable of a 50% increase in acceleration before s-curve is
enabled to avoid damage to mechanical components on the table.

S-curve acceleration is enabled with a single parameter on the >

screen (S Curve Acceleration).

The Acceleration Rate parameter determines the average rate of acceleration for both S-curve and
trapezoidal motion. When you choose S Curve Acceleration, the Peak S Curve Acceleration
parameter shows on the screen. This parameter is for information only, and shows the maximum
acceleration used during the beginning of a cut. As described previously, this represents a rate of
acceleration that is 50% greater than the average rate of acceleration.

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 6 Speeds

Change the cutting speed

The cut speed field on a cut chart screen sets the cutting speed (also known as the feed rate) for
the material type and material thickness.
 If you change the default cut speed for a provided cut chart (like an HPR process) the new
value will be shown in blue.
 Double-tap on the Speed field. An on-screen keyboard shows, and you can enter a new
speed value.
 If speed pots are not enabled, the Increase Speed and Decrease Speed soft keys show
on the cutting screen.
 Choose the Increase Speed soft key to increase the current cut speed by 3%.
 Choose the Decrease Speed soft key to decrease the current cut speed by 3%.
 Keyboard operation: To change the current cut speed while cutting a part, press the Enter
key once to highlight the current cut speed. Then enter the new cut speed, and press Enter
again.

Cutting speed and acceleration affects cut quality

Here are some troubleshooting tips for cutting speed.
 High-speed dross occurs when the cutting speed is too fast and the arc lags behind.
 Reduce the cutting speed.
 Low-speed dross occurs when the cutting speed is too slow and the arc shoots ahead.
 Increase the cutting speed.
 Top spatter occurs when the cutting speed is too fast.
 Reduce the cutting speed.
 Low-speed dross that occurs at the beginning or end of a cut segment can be caused by
acceleration levels being too low.
 Increase the acceleration rate.

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 I/O – Inputs and Outputs

Introduction

Phoenix supports up to 512 digital inputs and 512 digital outputs, and 32 analog inputs and
32 analog outputs.

General purpose I/O is 1 – 512. Station I/O is automatically assigned when you configure a station
in the Station Configuration screen, and starts at 129 and above.

Use the plan you have created for your cutting system to assign I/O. See Assign I/O on page 122.

Types of I/O

 Definitions for some of the most common I/O are available at the end of
this section. See Digital I/O definitions on page 127.

Fixed function I/O (virtual)

Phoenix assigns fixed function I/O automatically. Fixed function I/O for an HPRXD plasma power
supply is assigned when you choose an HPRXD as the cutting tool on the Station Configuration
screen. Generally, fixed function I/O for the HPRXD is not shown as assigned I/O on the Digital I/O
setup screen and does not appear on the I/O Diagnostics screen. But you can see the fixed
function I/O that assigns a station for the Soft Op Con on the Digital I/O setup screen and the I/O
Diagnostics screen. This I/O includes Auto Select 1 (2, 3, 4), Manual Select1 (2, 3, 4), Station
Enable LED 1 (2, 3, 4), and Station Enable 1 (2, 3, 4).

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7 I/O – Inputs and Outputs

How to view fixed function I/O

 To see the fixed function I/O that defines a station for the Soft Op Con on the Diagnostics
I/O screen, choose Setups>Diagnostics>IO.
 They start at 128. The HPRXD fixed function I/O is not shown.
 To see the fixed function I/O that defines a station for the Soft Op Con on the Digital I/O
screen, choose Setups>Machine Setups>Digital IO.
 They start at 128. The HPRXD fixed function I/O is not shown.
 To see both the fixed function I/O that defines a station for the Soft Op Con and the HPRXD
fixed function I/O in the HPR Supply Watch Window or in the Oscilloscope, set up a Watch
Window or choose Setups>Diagnostics>Oscilloscope.
 The I/O start at 512.

Fixed function I/O for HPRXD plasma power supplies

 When you have multiple HPRXDs the I/O will be numbered

(HPR Cut Sense 1, HPR Cut Sense 2, and so on.)

Digital inputs

HPR Cut Sense

HPR Not Ready For Start

HPR Nozzle Contact Sense

HPR Process Ready

Digital outputs

HPR Cut Control

HPR Hold Ignition

HPR Pierce Control

HPR Nozzle Contact Enable

HPR Remote On

 There is also a fixed function analog input: HPR Arc Voltage. This input is
automatically assigned when you set up a Sensor THC on the Machine
Setups screen (Setups > Password > Machine Setups).

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 I/O – Inputs and Outputs 7

Fixed function I/O for the EDGE Connect TC hardware operator console

Digital inputs

Op-Panel Joystick Up

Op-Panel Joystick Down

Op-Panel Joystick Left

Op-Panel Joystick Right

Op-Panel Forward On Path

Op-Panel Backward On Path

Op-Panel Start

Op-Panel Stop

Op-Panel Raise Tool

Op-Panel Lower Tool

Op-Panel DIP Option 1 (not used)

Op-Panel DIP Option 2 (not used)

Op-Panel DIP Option 3 (not used)

Op-Panel DIP Option 4 (not used)

Analog inputs

Op-Panel Cut Speed Pot

Op-Panel Jog Speed Pot

General purpose I/O

Use general purpose I/O for any cutting process to control cutting machine hardware such as
overtravel switches, and to control a single cutting station.

Numbered I/O
Use numbered I/O to identify stations when the cutting system uses an operator console (with
either a single torch or multiple torches) or has multiple stations. For example, assign the outputs
Station Enable 1 and Cut Control 1 to station 1, Station Enable 2 and Cut Control 2 to station 2.
The input and output names only appear after you have tools assigned in the Station Configuration
screen. See Station Setup on page 155.

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7 I/O – Inputs and Outputs

Assign I/O

How Phoenix assigns I/O

An EtherCAT network can be configured with multiple slave devices that have various numbers of
I/O available. Phoenix assigns I/O in order from 1 – 512, starting with the first slave device
connected on the network. When you use the EDGE Connect TC, the PCB for the factory-installed
hardware operator console is slave 1 on the EtherCAT network and uses virtual I/O. When you use
the EDGE Connect CNC, slave 1 is the first device connected on the EtherCAT network. The
HPRXD EtherCAT plasma interface PCB must be the last slave on the network and it uses fixed
function I/O.

The following example includes:

 Four drives, each with 7 digital inputs, 2 digital outputs, 1analog input, and 1 analog output
 One I/O module that has 4 digital inputs
 One HPRXD plasma power supply with a voltage divider card (VDC3)

I/O assignment starts with the first drive physically connected to the network and continues from
there.

Slave 1
Hardware operator console PCB
(fixed function I/O)

Slave 7
HPRXD
EtherCAT Plasma
Slave 2 Slave 3 Slave 4 Slave 5 Slave 6 Interface PCB
I/O I/O I/O I/O I/O (fixed function I/O)
1–7 8 – 14 15 – 21 22 – 28 29 – 32

I/O expansion
4 drives and 4 motors
module
(table I/O)

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 I/O – Inputs and Outputs 7

Assign the digital I/O

1. From the Main screen, choose > > > .

 Use a mouse to make it easier to scroll through the list of I/O.

 The Inputs window on the Digital I/O screen shows the inputs in groups
of 32.

2. Select the input number from the list on the left.

3. Select the name of the input function from the list on the right. Select Spare if the name of the
function is not shown in the list.

2 3 4

4. To assign the input for use with the PLC Connect programmable logic control, select the PLC
box to the right of the input name selection window.

5. Select the output number from the list on the left.

6. Select the name of the output function from the list on the right.

7. To assign the output for use with PLC Connect, select the PLC box to the right of the output
name selection window.

8. Continue this process until you have assigned all of the digital I/O needed for the cutting
system.

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Logic
The value in this field represents I/O in the range selected that are set to Normally Closed. When
Input Logic is set to zero (0), an active input is shown with a green lamp in the Diagnostics Inputs
screen. The same process is used for output logic.
 Select an input in the input selection box and press the space key, or double-click to select
the logic state for an input.

Input selection box

Torch Collision uses

Select the type of response that you want when the Torch Collision input is active. You can select a
Fast Decel value or the Fault Ramp time that has been selected for the individual axis.

Drive Enables
The Drive Enables selection determines how the CNC responds to drive faults. If you select
Independent, each drive is disabled as soon as its axis fault ramp time is finished. If you select
Series, all axes must complete their individual fault ramp times before the drives are disabled.

Initial Feedback Delay

Initial Feedback Delay allows the drive system to become fully enabled before the CNC enables
the digital drives. The typical setting for digital drives is 0.

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Joystick Installed
The joystick for the EDGE Connect TC is automatically enabled. If you are adding your own
operator console you must enable the joystick on the Digital I/O screen as shown below.

Analog I/O
If each drive in the network supports 1 analog input, then analog input 1 is on drive 1, analog input 2
is on drive 2, and so on. An I/O module follows in physical order after the drives (but before the
plasma power supply). If there are 4 drives on the network, for example, then the I/O module analog
inputs start at 5.

Arc voltage
If you are using an HPRXD, Arc Voltage is automatically available and assigned as fixed on the
machine screen. If you are using a Manual Gas Plasma system you need to assign Arc Voltage to an
analog input on the Machine Setups screen along with the Sensor THC axis assignment.

Enable speed pots

The EDGE Connect TC has a factory-installed hardware operator console with 2 speed pots, which
are automatically enabled. If you have an EDGE Connect CNC to which you are adding your own
hardware operator console, you must enable the speed pots on the Analog I/O screen and assign
them to analog inputs.

1. From the Main screen, choose > > > .

2. Select Yes to enable the speed pots. See Figure 27 on page 126.

 Also, you must enable speed pots to use the sliding speed control on the
Soft Op Con.

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Speed overrides
The speed override ranges control the speed pot setting when the knob is turned completely
counterclockwise or clockwise. Instead of 0% (fully counterclockwise) to 100% (fully clockwise), the
speed pot range can be set at 70% of the programmed cut speed (fully counterclockwise) to 130%
(fully clockwise) of the programmed cut speed.

Figure 27

Assign analog inputs

1. From the Main screen, choose > > > .

2. Select the input name from the Inputs list.

 If you have an EDGE Connect TC, analog 1 and analog 2 inputs are not
available for use. They are automatically assigned to the speed pots in the
hardware operator console.

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3. Select the input number from the Installed on list.

 To assign the analog I/O for use with PLC Connect, select the PLC box to
the right of the I/O name selection window.

Analog Input Offset 1 – 32

The Analog Input Offset corrects for any imbalance in or zeroes the incoming analog voltage to the
CNC. The CNC constantly applies this offset to the incoming analog signal. The offset is subtracted
from the incoming voltage and the CNC shows the voltage after this offset is subtracted.

Analog outputs
Phoenix provides analog outputs for controlling gas regulators in an oxyfuel cutting machine. Select
the gas channel and assign an analog output and maximum pressure for it. The channels are listed in
groups. Each channel in each group should be selected and matched with an analog output. Then
Phoenix transfers these channels and pressures to the Oxyfuel Process screen.

Digital I/O definitions

Digital inputs

Arc Error Counter 1 through 8 – Used as part of consumable data tracking, this input triggers a
counter on the Change Consumable screen. A Plasma Enable input must be mapped to
enable this input.

Cut Select – This input turns on the Cut Control and/or Cut Control outputs 1 – 20 while the
switch remains in the ON position. The cut select input is primarily used with an oxyfuel
hardware operator console to activate the cut and preheat channels, so the operator can
adjust the regulators. However, the input will turn on the Cut Control and/or Cut Control
outputs 1 – 20 for any cutting tool on any enabled station. Cut Select can also be used to
test plasma torches by allowing the operator to bypass the CNC to fire the torch. It is the
OEM's responsibility to wire this input correctly. Hypertherm recommends using a momentary
switch so that an operator doesn't leave the input on.

Cut/Mark Sense 1 through 4 – Verifies that the plasma torch or marker tool has established the
arc for the selected process. This indicates to the CNC that motion can begin.

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Cut Sense – Indicates that the plasma arc has transferred to the work piece. If the Arc On
Feedback setup parameter is ON, machine motion begins at the activation of this input.

Drive Disabled – Causes the CNC to stop all motion and generate a fault message. Position
information is lost.

Enable Plasma 1 through 8 – Formerly used for tracking consumable data for the specified
plasma torch. The Station Select input now supports this input.

Fast Stop – Used as an urgent stop input command to the CNC. When the Fast Stop input
becomes active, the CNC decelerates motion using the Fast Deceleration Rate on the
Speeds screen and shows the Pause screen. One second after the input becomes active, the
Drive Enable output from the CNC turns OFF and disables motion. Position information and
I/O points are maintained while the input is active. This allows the operator to recover the last
position after the input has been cleared.

Fume Extraction Sense – Confirms that an external fume extraction system on the cutting table is
operational before beginning the cut. An option to override appears if the input has not been
satisfied at the time of the cut.

 Use this input only when an external device, not the CNC, controls the
fume extraction system. If the CNC controls the fume extraction system,
use the Fume Extraction Control output instead. See page 132 for more
information on that output. Do not use the Fume Extraction Sense input
and the Fume Extraction Control output at the same time.

High Preheat Select – This input turns on the Preheat Control and/or the High Preheat Control
outputs 1 – 20. With this input ON, high pressure fuel gas will be delivered to the torch and
can be manually adjusted.

Limit Speed Input – Limits the machine speed for safety during machine testing and maintenance.
When this input is active, motion is limited to the user-defined Limited Machine Speed
selected in the Speeds screen.

Limit Switch – Indicates that the machine has traveled to its full positive travel of an axis. If
hardware overtravels are enabled and this input activates, the CNC stops all motion and
generates a fault message. Motion is not re-enabled until the switch deactivates.

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Low Preheat Select – This input turns on the Low Preheat output and/or the Low Preheat Control
outputs 1 – 20 while the input remains in the ON position. With this input on, low pressure
fuel gas will be delivered to the torch and can be manually adjusted.

Lower Torch / Lower All Torches – This input can be a toggle switch that turns on the Torch Down
output. The Torch Down output signals the oxyfuel torch lifter to lower the torch.

Manual Ignition Select – This input turns on the Ignition output and/or the Torch Ignition outputs
1 – 20. The Ignition output remains on while the input is ON. This input can be used to
manually turn on the igniters.

Marker Select 1 and 2 – Select which marker process logic is used by the CNC. These inputs are
generally run by external switches.

Nozzle Contact Sense – Used during Sensor THC initial height sense (IHS) to detect the location
of the cut surface. This input is returned to the CNC through the external voltage divider card.

Pierce Complete – Plasma Select 1 and 2 – Select which plasma process logic is used by the
CNC. These inputs are generally run by external switches.

Program Inhibit – Forces the CNC to command the motion output to a zero (0) speed. This is
generally used as a dwell to pause motion during a tool change or as a pause from a PLC
interface.

Raise/Lower Torch – Operates multiple Sensor THCs when multiple Sensor THCs are
commanded by the CNC as separate axes. The Torch Raise and Torch Lower commands can
be issued with soft keys or through these external inputs to the CNC.

Remote Pause – Stops all CNC motion and shows the Pause screen. No motion is allowed until
this input deactivates.

Remote Start – Begins the selected program cycle as if the Start button on the CNC had been
pressed.

Rotate +/- – Used for manual jog commands for the Rotate axis.

Rotate Home – Indicates that the machine has traveled to its Rotate axis home position. When the
Rotate axis is homed, it moves in the specified home direction at the Fast Home Speed until
the input activates. Then the Rotate axis decelerates to a stop, and then moves in the
opposite direction at the Slow Home Speed until the switch deactivates.

Sensor THC Enable – Formerly indicated which Sensor THCs are active when multiple Sensor
THCs are commanded by the CNC as separate axes. The Station Select input now supports
this input.

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Spare – Activates through the part program. If a spare input is located in the part program, the
CNC pauses the process until the input state is detected. The spare inputs can be
implemented with specific EIA “O” and “M” codes that indicate the input number and
function. For more information, refer to the EDGE® Connect Programmer Reference
(809550).

Station Select Input – Indicates which Sensor THC is active when multiple Sensor THCs are
commanded by the CNC as separate axes. Also tracks consumable data for the specified
plasma or oxy torch. Stations 1 – 8 are designated for plasma; stations 9 – 20 are
designated for oxyfuel.

Test Lifter – Performs a test IHS function with a Sensor THC.

THC Automatic – Used as an external input to switch the Sensor THC between automatic and
manual operation.

THC Home – Indicates that the machine has traveled to its Z axis home position. If the Z axis Use
Home Limit Switch parameter is set to Yes and a homing function is performed, the Z axis
moves in the specified home direction at the fast home speed until the input activates. The
Z axis then decelerates to a stop and moves in the opposite direction at the slow home speed
until the switch deactivates. After the switch deactivates, the Z axis decelerates to a stop or, if
the Use Marker Pulse parameter is set to Yes, continues until the encoder marker pulse is
detected.

Tool Cycle Active – Activates from a PLC to pause motion until the input turns OFF. Used when a
PLC is controlling other tool cycles such as drilling and tapping. After the input turns OFF, the
program motion resumes.

Torch Collision – Used on torch systems with breakaway mounts. If a torch makes contact with the
workpiece or an obstacle that causes the breakaway mount to release, an input for the mount
is sent to the CNC indicating that a torch collision has occurred. The Pause screen appears.
While the input is active, the Cut output is turned OFF and manual motion is enabled,
allowing the operator to raise, lower, and move the torch position to clear the fault.
Position information, motion command, and I/O points are maintained and allow the operator
to return to the cut path and resume cutting. This feature uses the Fast Stop Deceleration
rate. Manual raise inputs can be used.

Torch Down Sense – Indicates that the torch is in the full down position.

Torch Up Sense – Indicates that the torch is in the full up position.

Tracer on Path – Used with the Teach Trace feature and indicates that the tracing system has
detected the template line.

X Home – Indicates that the machine has traveled to its X axis home position. If the X axis Use
Home Limit Switch parameter is set to Yes and a homing function is performed, the X axis
moves in the specified home direction at the fast home speed until the input activates. The

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X axis then decelerates to a stop and moves in the opposite direction at the slow home speed
until the switch deactivates. After the switch deactivates, the X axis decelerates to a stop or, if
the Use Marker Pulse parameter is set to Yes, continues until the encoder marker pulse is
detected.

X Overtravel – Indicates that the machine has traveled to its full positive travel on an X axis. If
hardware overtravels are enabled and this input activates, the CNC stops all motion and
generates a fault message. Motion is not re-enabled until the switch deactivates.

X + Overtravel – Indicates that the machine has traveled to its full positive travel on the X axis. If
hardware overtravels are enabled and this input activates, the CNC stops all motion,
generates a fault message, and only allows manual motion in the X axis negative direction.

X - Overtravel – Indicates that the machine has traveled to its full negative travel on the X axis. If
hardware overtravels are enabled and this input activates, the CNC stops all motion,
generates a fault message, and only allows manual motion in the X axis positive direction.

Y Home – Indicates that the machine has traveled to its Y axis home position. If the Y axis Use
Home Limit Switch parameter is set to Yes and a homing function is performed, the Y axis
moves in the specified home direction at the fast home speed until the input activates. The
Y axis then decelerates to a stop and moves in the opposite direction at the slow home speed
until the switch deactivates. After the switch deactivates, the Y axis decelerates to a stop or, if
the Use Marker Pulse parameter is set to Yes, continues until the encoder marker pulse is
detected.

Y Overtravel – Indicates that the machine has traveled to its full positive travel on the Y axis. If
hardware overtravels are enabled and this input activates, the CNC stops all motion and
generates a fault message. Motion is not re-enabled until the switch deactivates.

Y + Overtravel – Indicates that the machine has traveled to its full positive travel on the Y axis. If
hardware overtravels are enabled and this input activates, the CNC stops all motion,
generates a fault message, and only allows manual motion in the Y axis negative direction.

Y - Overtravel – Indicates that the machine has traveled to its full negative travel on the Y axis. If
hardware overtravels are enabled and this input activates, the CNC stops all motion,
generates a fault message, and only allows manual motion in the Y axis positive direction.

Digital outputs

Change Consumable – Activates when a consumable on the Change Consumable screen has
reached its preset maximum. Generally, this output is tied to an external indicator light or
audible alarm to prompt the system operator to change the appropriate consumable. The
affected consumable data must be reset on the Change Consumable screen to clear the
output.

Cut Control – Starts the plasma system in plasma mode, or enables the cutting oxygen in oxyfuel
mode. This output can also be used to activate a marking device.

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Drive Enable – Used to enable the drives during normal functions and to disable the drives during
fault conditions.

Error During Program – Activates when an Error or Fault occurs that pauses the machine or the
part program. This output can be tied to an external indicator light or audible alarm to tell the
operator when the cutting system is paused due to an Error or Fault condition.

Fume Extraction Control – When you assign this output, a Fume Extraction Delay timer appears
on the I/O screen. The timer allows the fume extraction equipment to run for a period of time
at the end of the part program when the CNC shows the Main screen. This output turns ON
at the start of a cut, at the start of a rip cut, or when resuming a cut after pausing the program.
Assuming the starting and ending positions in the part program are the same, this output
turns OFF when the timer expires at the end of the part program. If the starting and ending
positions in the part program are different, then this output turns OFF when the timer expires
after the operator acknowledges the Ready to Start? prompt. This output also turns OFF
when the operator pauses the part program.

 Use this output only when the CNC, not an external device, controls the
fume extraction system. If an external device controls the fume extraction
system, use the Fume Extraction Sense input instead. See page 128 for
more information on that input. Do not use the Fume Extraction Control
output and the Fume Extraction Sense input at the same time.

Hold Ignition – Part of the Sensor THC operation to hold ignition of the plasma power supply. This
output can be tied back to the CNC through the external voltage divider card or direct to the
plasma power supply depending on configuration.

Key Press Indicator – Activates when a key is pressed on the CNC.

Marker Control – Activates the marker tool during the marking process. The marker tool activates
through the combination of Marker Enable and Cut Control outputs. Options are shown and
can be configured on the Marker Setup screen for the desired process timing and operational
results.

Marker / Marker Enable – Activates an external marking device. It can only be activated by the
appropriate M code in the part program. For more information, refer to the EDGE® Connect
Programmer Reference (809550).

Marker Enables – Used for external logic. The appropriate output(s) is on during marking, based
on the Marker Select inputs.

Motion Indicator – Activates when the CNC is commanding machine motion.

Nozzle Contact Enable – Activates during Sensor THC IHS. This input is tied back to the CNC
through the external voltage divider card. This output can also be used to switch an external
drive system to low output mode (if equipped) during IHS for stall force workpiece sensing.

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Peck Drill Cycle – Activates with an M94 code in the part program. It activates an input in a PLC
that is controlling a tool cycle.

Pierce Control – Used by the plasma cut logic to send an output to the torch during the pierce.
This output is on for the duration of the Pierce Time selected on the Plasma Process screen.

Plasma Enable – Used for external logic. The appropriate output(s) is on during plasma cutting,
based on the Plasma Select inputs.

Plasma Select – Activates when the CNC is in the plasma cutting mode.

Program Running – Active anytime the CNC is operating within a part program.

Spare – Activates through the part program. If a spare output is located in the part program, the
CNC turns ON the output as directed. The Spare outputs can be implemented with specific
EIA W and M codes that indicate the output number and function. For more information, refer
to the EDGE® Connect Programmer Reference (809550).

Station Clamp 1 – 19 – Part of the Automated Torch Spacing feature. The Station Clamp is used
to clamp the selected torch station to the Transverse axis for standard cutting.

Station Enable 1 – 20 – Activates any function specific to a torch station and is controlled through
M37T and M38T codes within a part program. These codes generally enable a torch station
for use. Usually, stations 1 – 8 are configured with plasma and stations 9 – 20 are configured
with oxyfuel or other types of fuel. (Plasma can only be configured on stations 1 – 8.)

Station Lock 1 – 19 – Is part of the Automated Torch Spacing feature. The station lock locks the
unused torch station to the gantry or beam when the torch is not in use.

Station Mirror 1 – 19 – Part of the Automated Torch Spacing feature. The station mirror is used to
clamp the selected torch station to the Transverse axis for mirrored cutting.

Tap Cycle – Activates with an M95 code in the part program. It activates an input in a PLC that is
controlling a tool cycle.

Tool Change – Activates with an M96 code in the part program. It activates an input in a PLC that
is controlling a tool change.

Torch Down – Lowers the cutting torch. In plasma mode, this activates for the Torch Down Time in
plasma mode.

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Torch Height Disable – Disables the automatic torch height control in plasma mode. Torch Height
Disabled is activated when the cut speed drops to the Torch Height Disabled Speed and
remains active until the cut speed is greater than the Torch Height Disabled Speed. Torch
Height Disabled remains active for a specified distance even when the cutting speed drops
below the Torch Height Disable speed if a value has been entered for Distance Before THD
Speed on the Speeds screen in Phoenix. Torch Height Disabled also remains active when the
cutting speed is greater than the Torch Height Disabled Speed if a value has been entered for
Distance After THD Speed on the Speeds screen in Phoenix. For more information see Set
up Torch Height Disable on page 138.

Torch Up – Raises the cutting torch. In plasma mode, this activates for the Torch Up Time.

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Sensor THC

Hypertherm CNCs support an integrated Z axis called the Sensor THC that provides linear motion
and automatic voltage tracking. The built-in electronics in the CNC can be used with the
Sensor THC lifter and drives supplied by table manufacturers and system integrators.

The settings provided in the following sections apply to the Sensor THC lifter and to drives supplied
by table manufacturers and system integrators. The settings can often be used for lifters from other
manufacturers.

About plasma torch height control

A circuit board inside the plasma power supply (the VDC3 voltage divider card) measures the
voltage drop across the plasma arc. This measurement is the raw arc voltage and can range from
0 VDC to 400 VDC. The circuit board then reduces this measurement into an analog signal
(-10 VDC to 10 VDC) that is sent to the CNC. This signal represents the actual arc voltage when
cutting.

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In the CNC, each plasma process has an arc voltage set point, called the Set Arc Voltage, for a
given material thickness, cut height, cut speed, gas type, and current. When cutting starts, the CNC
tracks the actual voltage drop across the arc and compares it to the Set Arc Voltage. When the
actual arc voltage is higher or lower than the Set Arc Voltage, the CNC commands the lifter to move
the torch down or up.
 When the actual arc voltage is higher than the arc voltage set point, the torch moves down.
 When the arc voltage is lower than the set point, the torch moves up.
 The higher the arc voltage set point, the higher the cut height.

3
5
4

1 Torch

2 Electrode

3 Workpiece

4 Plasma arc

5 Voltage drop is measured over the plasma arc between the electrode and the workpiece

Sensor THC setup

 Set up the Sensor THC before you select a cutting tool in the Station
Configuration screen or you will not see Sensor THC as a selection when
assigning the cutting tool.

Setting up the Sensor THC on the CNC requires the following:

 Choose the number of Sensor THCs installed on the cutting system, and assign each THC
to an axis.
 Set speeds and acceleration values for the Sensor THC axis.
 Enter encoder information, servo error tolerance, stall force tolerance, and other information
about the THC axis.
 Select the Sensor THC as a lifter on a station.

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Assign the Sensor THC to an axis

1. Choose > > .

2. Choose the number of Sensor THCs installed .

3. For each Sensor THC:

a. Choose from THC1, THC2, and so on, to identify the torch height control .

b. Choose the axis for the THC .

The THC can be assigned to Axis 3 and higher. The CNC uses Axes 1 and 2 for Transverse
or Rail. Dual Gantry is assigned to Axis 3 if one is used. If Dual Gantry is not being used,
then the Sensor THC can be assigned to Axis 3.
If you assign an HPR in the Station Configuration screen, the input for arc voltage (shown
as Analog 1 above) will automatically change to Fixed. If you are using a generic plasma
cutting tool, you will need to assign an analog input for arc voltage.

Set speeds and acceleration

After you select the Sensor THC on the Machine screen, set the speed and acceleration settings.

 The values shown are recommended initial settings. You may need to
change these values based on the mechanics of your cutting system.

1. Choose .

2. Enter the THC Acceleration Rate .

3. Enter the Maximum THC Speed (10,160 mmpm).

4. Enter the THC Jog Speed (5,080 mmpm).

5. Enter the THC Home / Fast IHS Speed

(1,270 mmpm).

6. Enter the THC Slow IHS Speed (127 mmpm).

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Set up Torch Height Disable

The Torch Height Disable feature activates the Torch Height Disable output. This disables the
automatic adjustment of the automated torch height control system. This is done to prevent diving or
crashing of the torch in corners, holes, or other part features that require the cutting system to slow
down to preserve cut quality or system mechanics.

The CNC activates the Torch Height Disable output based on the values of the following
parameters:
 Torch Height Disable Speed
 Distance Before THD Speed
 Distance After THD Speed

When any one of these conditions is met, the Torch Height Disable feature is implemented. The
definition of a corner is based on the tangent angle in the Special Setups screen and the value of
the Torch Height Disable Speed.

1. Choose .

2. Enter a parameter for the Torch Height Disable Speed

. Specifies the percentage of the program cut

speed at which the CNC disables the height control. For example, when the cutting system is
slowed to cut a part feature such as a corner, the arc voltage increases, which causes the torch
to lower toward the workpiece. When the cutting system slows down to this percentage of the
cut speed, the CNC disables THC voltage tracking.

3. Enter a parameter for the Distance Before THD Speed

. This distance is active whenever the program

cut speed drops below the Torch Height Disable Speed, or segments intersect at an angle
greater than the Tangent Angle. Specifies the distance before turning a corner at which the
CNCs disables the torch height control.

4. Enter a parameter for the Distance After THD Speed .

Specifies the distance after turning a corner to enable voltage tracking for torch height control.
Distance After THD Speed is active whenever the speed drops below the Torch Height Disable
Speed, or segments intersect at an angle greater than the Tangent Angle.

5. To set the Tangent Angle, choose > > .

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6. Enter a parameter for the Tangent Angle . This parameter specifies the
degree of the tangent angle for motion control. Segments within a part that intersect at angles
greater than the selected tangent angle will decelerate to zero or the minimum corner speed.
Segments within a part that intersect at angles less than or equal to the selected tangent angle
do not decelerate unless the next segment is a speed-limited arc.

In the following illustration, the Torch Height Disable output is activated based on the values of the
setup parameters.

Parameter Value

Torch Height Disable Speed Percentage value 90%

Distance Before THC Speed value 12.7 mm (0.5 inches)

Distance After THC Speed value 12.7 mm (0.5 inches)

Tangent Angle Value 20 degrees

For these values, the Torch Height Disable output is active 12.7 mm (0.5 inches) before and
12.7 mm (0.5 inches) after each 90 degree corner. This output is also active as the cutting tool
accelerates after a pierce. It remains active until the cut speed is greater than the Torch Height

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Disable Speed. Finally, because the arc intersects at greater than the 20-degree tangent angle, the
Torch Height Disable output is activated for 12.7 mm (0.5 inches) before and after the beginning of
the arc, and is activated for 12.7 mm (0.5 inches) before and after the end of the arc.

Define the THC axis

On the Machine Setups screen, choose > .

Voltage Gain

This gain is used when the THC operates with a closed-loop arc voltage control. Adjust this value
after you find the appropriate value for Speed Gain.

If this value is set too high, the lifter position during closed-loop arc voltage control becomes
unstable and prone to oscillation. If this value is too low, the arc voltage control can become slow
and inaccurate. Test voltage gain by repeatedly performing a test cut under closed-loop arc voltage
control, and make sure that the THC quickly and accurately reaches the set arc voltage.

To optimize this gain, raise this value until there is a very slight oscillation during a cut, and then
reduce the setting by 1 or 2.

The voltage gain range for Normal mode is 0 to 500 volts.

Servo Error Tolerance

Servo error, also called following error, is the difference between the commanded motor position
and the actual motor position as calculated by the drive. The servo error tolerance is the upper limit
of the amount of following error allowed before the CNC faults.

The amount of servo error tolerance depends on the cutting machine mechanics. Setting the servo
error tolerance too low could cause the CNC to fault repeatedly. Setting it too high may allow
inaccurate motion or result in mechanical damage. Set the servo error tolerance to a value higher
than the steady-state following error which is reported by the drive.

Range: 0 mm to 127 mm (5 inches)

Stall Force Tolerance

Stall force is a method of detecting the workpiece during initial height sense. Use stall force when
cutting underwater or in other conditions in which ohmic contact is not feasible. Stall force
tolerance is the maximum amount of following error on the THC axis. The CNC starts monitoring the
THC axis following error when it reaches the Start IHS Height. The following error accumulates

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when the torch tip contacts the workpiece and the lifter continues downward movement but is
stopped by the workpiece. When the following error exceeds the stall force tolerance value, the
CNC knows the position of the workpiece and motion reverses. Motion stops when the amount of
reverse travel of the THC equals the Transfer Height.

In general, stall force tolerance should be set to twice the following error observed during Fast IHS
speed.

Range: 0 mm to 127 mm (5 inches)

Encoder Counts per mm (inch)

Encoder counts are a position scaling factor used by Phoenix. Refer to the drive manufacturer
documentation for specific scaling information required by the THC drive.

In general, to determine encoder counts per mm (inch) for a THC drive, you need to know the
following:
 Counts per revolution of the motor
 Gear ratio
 Distance of travel in one revolution of the lead screw

An example of the equation you use is shown below:

65,536 1
counts lead screw revolution 13,107.20 (332,670.05)
X =
1 encoder counts per mm (inch)
5 mm (0.197 in.)
motor revolution

Range: Positive, non-zero values up to 39,379.08 counts/mm (1,000,000 counts/inch)

Retry on Transfer Fail

When IHS completes, the torch attempts ignition, the CNC starts a 10-second timer, waits for the
Cut/Mark Sense input (or Cut Sense # input) to turn on, and shows the status message Waiting For
Arc On. If the input does not activate within 10 seconds, the ignition process stops, the torch
retracts, and the IHS starts again with another attempt to ignite the torch. The CNC repeats this
sequence twice.

Slide Length

The slide length is the amount of travel of the lifter. The CNC uses the slide length when changing
speeds during the IHS. The CNC subtracts 5.08 mm (0.2 inches) from the slide length to make
sure the lifter does not contact a hard stop when homing.

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Home setting for current-type drives

1. Choose the method you want to use to home the torch from the list.

2. Set the Current Limit % to the maximum current

output for the operation of the lifter motor.
Range: 0.001 to 100

3. Set the Home Current Limit % to the maximum

current during the homing sequence to stall and detect
the top of the slide. Set Homing Current Limit to 50%
of drive capacity.
Range: 0.001 to 100

4. Set the IHS Current Limit % to the maximum current

during IHS to stall and detect the workpiece.
Range: 0.001 to 100

 See Home the axis on page 143 for more information.

Tracking Mode
The CNC uses voltage tracking to lock on to the actual arc voltage and compare it to the Set Arc
Voltage. You can choose individual tracking mode settings for Plasma 1, Plasma 2, Marker 1, and
Marker 2. Do not use Special tracking mode with the Sensor THC. Special tracking mode is only
used for extreme material tracking situations.

1. For almost all applications we strongly recommend that you set tracking mode to Normal.
Voltage tracking in Normal mode locks on within 2 volts of the Set Arc Voltage value. Adjust
voltage gain to increase lifter responsiveness. In Normal mode, arc voltage accuracy is +/- 1.0
arc volt.
Recommended settings: For the Sensor THC, choose Plasma 1 or 2 as the process, then
choose Normal for tracking mode. Set Average Voltage Over to 25 msec.

2. Use Average Voltage Over to set the arc voltage sampling rate. Phoenix records the arc
voltage every millisecond and averages the arc voltage over the number of milliseconds entered.
The average value is compared to the voltage set point and then the command to the lifter is
calculated.

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Home the axis

Manual

1. On the Main screen choose .

2. Choose .

3. Choose .

Automatic
If the Home Torch Height Control status message is enabled in Special Setups, then Phoenix
automatically prompts you to home the THC axis when you turn ON the CNC and before motion
begins.

Set the Sensor THC operating modes

Automatic modes
In all of the automatic modes, the THC performs an initial height sense (IHS), then retracts to the
Transfer Height. After torch ignition, the plasma arc transfers to the workpiece, then the torch moves
to the Pierce Height for the duration of the Pierce Time. During this pre-cutting sequence, the torch
height control is disabled and the CNC is not tracking the arc voltage. When the Pierce Time
elapses, motion begins and the CNC begins tracking arc voltage after the AVC (Automatic Voltage
Control) Delay time elapses and the cutting speed is equal to the program speed.

Manual mode
This mode is recommended for rip cuts, for calibrating arc voltage, or for cuts where cut quality is
not a primary concern. Manual mode does not use arc voltage tracking or provide any automatic
movement of the lifter. You can move the lifter only with the UP and DOWN soft keys on the
EDGE Connect Soft Op Con, the toggle switch on the EDGE Connect TC hardware operator
console, or by activating the Raise Torch # or Lower Torch # inputs. Using one of these methods,
position the torch at the height above the workpiece you want to use as a cut height.

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8 Torch Height Control (THC)

To set the mode:

1. Choose > .

2. Select Manual or Automatic for the operating mode on the Plasma Process screen.

Sample Arc Voltage mode

Use Sample Arc Voltage mode as much as possible to achieve a consistent cut quality over the life
of the consumables. When cutting begins, the CNC takes several samples of the arc voltage and
averages these samples. It then uses the sample average as the Set Arc Voltage instead of the
value in the Process screen, and compares the sample to the actual arc voltage. If the actual voltage
is higher than the sample value, the torch moves down. If the actual arc voltage is lower than the
sample value, the torch moves up.

The advantage of Sample Arc Voltage mode is that the voltage sample is the result of many
readings of the actual arc voltage under steady-state cutting conditions at the correct speed and
cut height for the active cut process. Instead of you having to change the Set Arc Voltage as the
consumables begin to wear, the CNC re-calculates the voltage sample for each cut in the program
and corrects the torch height automatically to maintain the ideal cut height for the process over the
life of the consumables.

If the arc voltage sample suddenly changes, the CNC will stop cutting and show a warning. For
example, if the sample average was 100 V and on the next sample, the CNC recorded a sample of
115 V. An increase of 15 V indicates that material or slag could be interfering with the arc. The CNC
stops so that you can correct the issue, and you can resume cutting by pressing Start.

Sample arc voltage should be used for “I” cutting and bevel cutting.

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 Torch Height Control (THC) 8
Figure 28

1 3
4
2

1 Plasma arc from a new electrode

2 Cut height from cut chart

3 The plasma arc lengthens as the electrode wears and the arc voltage increases.

4 When the cut height increases because of electrode wear, the CNC lowers the torch to maintain
consistent cut height. When not using Sample Arc Voltage, the torch moves closer and closer to
the workpiece as the electrode wears.

To use Sample Arc Voltage mode:

 Make the following selections on the Plasma Process screen.

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Set Arc Voltage mode

This mode is recommended for cutting or marking thin material at low cut height, workpieces that
are dirty, rusty, oiled or painted, or cutting on a water table or with water injection. When cutting
begins, the CNC uses the Set Arc Voltage value from the cut chart and compares it to the actual arc
voltage. If the actual voltage is higher than the Set Arc Voltage, the torch moves down. If the actual
arc voltage is lower than the Set Arc Voltage, the torch moves up. In Set Arc Voltage mode, you can
change the Set Arc Voltage while cutting, or apply voltage offsets for each station in the cutting
system.

To use Set Arc Voltage mode:

 On the Plasma Process screen, choose Automatic for Height Control and Off for Sample
Voltage to use Set Arc Voltage mode.

Methods for changing the Set Arc Voltage

When Sample Voltage is OFF, changing the Set Arc Voltage moves the torch up or down. The
CNC reads the Set Arc Voltage parameter (also called the arc voltage set point) from the Plasma
Process screen (which is set by the cut chart). Some methods for changing the Set Arc Voltage
include:
 Issue a G59 V600 Fvalue command in the part program for Plasma 1 where the value is the
new Set Arc Voltage. (Use G59 V625 Fvalue to change the Set Arc Voltage for Plasma 2).
 Enter THC voltage offsets.
 When Automatic is selected for Height Control, press the Increase Arc Voltage or
Decrease Arc Voltage soft keys on the Main screen while the system is cutting.
 When Manual is selected for Height Control, press the Raise Manual Cut Height or
Lower Manual Cut Height soft keys on the Main screen while the system is cutting.
 Change the Set Arc Voltage in the Process screen or cut chart.

THC voltage offsets

THC Voltage Offsets provide a method for changing the Set Arc Voltage value called for in the cut
chart. When you enter a positive voltage offset, the CNC adds the voltage offset to the Set Arc
Voltage. When you enter a negative voltage offset, the CNC subtracts the voltage offset from the
Set Arc Voltage. Voltage offsets are used only when the torch height control is in Automatic mode
with Sample Arc Voltage turned off. Sample Arc Voltage mode does not use the THC Voltage
Offsets.

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 Torch Height Control (THC) 8

Choose to view the THC Voltage Offsets on the Cutting screen. Offset 1 applies to
Station 1, Offset 2 applies to Station 2, and so on.

The THC voltage offsets are saved to the system setup file and are used with every cutting job, even
if you change the process, load a different cut chart, or change the consumables. The THC voltage
offset value will remain at a value unless you change it.

To reset a voltage offset to zero, choose Setup to open the Cutting screen and change the THC
voltage offset
 When using Sample Arc Voltage mode, set the THC voltage offset to zero
 After you load new consumables, set the THC voltage offset to zero.

The CNC allows only one arc voltage set point, even when your cutting system has more than one
torch. You can use the voltage offset to change the height of an individual torch in a multi-torch
system by adding additional voltage to the arc voltage set point for that torch.

Change offsets automatically for Sensor THC

For the Sensor THC, the THC voltage offsets can be changed automatically and continually by
entering a value for the Volts / Minute parameter on the Change Consumable screen (on the Main
screen, choose the Change Consumable soft key). The amount to enter depends on each system’s
consumable use history. For more information see Change consumables on page 275.

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8 Torch Height Control (THC)

If you entered a value for Volts / Minute, when you change consumables, reset the THC Voltage
Offset to zero to allow the CNC to gradually increase the offset using the Volts / Minute parameter.
Otherwise, the THC Voltage Offset could be too large and cause torch movement or cut quality
issues when applied to the Set Arc Voltage when you are cutting with new consumables.

 When using Sample Arc Voltage mode, set the Volts / Minute to 0.

Increase or decrease arc voltage in Automatic mode

After cutting begins in Automatic mode, the CNC shows Increase Arc Voltage and Decrease Arc
Voltage soft keys on the Main screen. Press these keys to change the arc voltage while cutting.

These keys increase or decrease the Set Arc Voltage parameter by 0.5 V per soft key press.

 Sometimes the voltage offset or Set Arc Voltage parameters change by

more than 0.5 V depending on the length of the key press.

Raise and lower cut height in Manual mode

After cutting begins in Manual mode, the CNC shows Raise Manual Cut Height and Lower
Manual Cut Height soft keys on the Main screen.

These soft keys change the cut height by 0.2 mm (0.01 inch) per soft key press. These soft keys
also affect the THC voltage offset by 0.5 V per soft key press.

 Raise and Lower only change the voltage offset when the system is
cutting. When the system is not cutting, Raise and Lower move the lifter
up and down.

Change arc voltage in the Process screen or cut chart

 If you want a voltage change for a single cutting job, change the Set Arc Voltage in the
Process screen or on the process Watch Window (if Set Arc Voltage is included on the
Watch Window).
 To change the Set Arc Voltage for a process, change the value in the cut chart and save it
as a custom cut chart.

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Initial height sense

Phoenix uses a sequence called initial height sense, or IHS, for detecting the workpiece. A first IHS
detects the height of the workpiece so that the CNC can calculate the torch-to-work distance. The
CNC uses the torch-to-work distance for all subsequent IHSs, which it can perform using much
faster speeds since the height of the workpiece is known.

IHS sequence
The IHS begins at the Start IHS Height set in the Process screen. When the torch (or external
sensor if using Offset IHS) reaches this distance above the workpiece, the following actions occur:
 Speed slows from Maximum THC Speed to Fast IHS Speed.
 THC Torque Limit and Nozzle Contact Enable outputs turn on.
 The CNC monitors the Nozzle Contact Sense input. This input activates when the torch (or
an external sensor for Offset IHS) touches the workpiece, so the CNC knows the height of
the workpiece.
 In case the Nozzle Contact Sense input does not activate, the CNC also monitors the axis
following error, which the CNC compares to the stall force. When the following error
exceeds the stall force, the CNC knows the height of workpiece.
 After sensing the workpiece, the torch (or sensor) retracts at the Slow IHS speed to the
Transfer Height.
 When using Nozzle Contact Sense to sense the workpiece, the CNC measures the
Transfer Height from the point the Nozzle Contact Sense turns off during the retract.
 When using Stall Force to sense the workpiece, the CNC measures the Transfer Height
from the point where the following error exceeded the Stall Force.

IHS in Manual mode

The THC must be in Manual mode. If IHS in Manual is ON, IHS and the sequence of operations is
automatic but the torch height is not controlled by measured arc voltage. If IHS in Manual is OFF, all
operations are controlled manually.

Perform a first IHS

1. Choose or press F11 on the Main screen to home the THC axis.

2. Choose .

3. Choose .

4. Choose OK twice to return to the Main screen.

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8 Torch Height Control (THC)

5. Choose . The THC performs the initial height sense starting 12.7 mm (0.5 inches)
from the THC axis home position.

Sensor THC moves 12.7 mm (0.5 inches) from the THC axis home position at the maximum speed,
then changes to the Fast IHS Speed until it reaches the IHS Start Height (set on the Process
screen). The THC changes to the Slow IHS Speed until it detects the workpiece. It then raises to
the Transfer Height (also set in the Process screen).

 Sensor THC’s speeds are set in the Setups > Machine Setups > Speeds
screen.

Offset IHS
Offset IHS enables an external sensor (or probe) to detect the workpiece and perform an initial
height sense. Offset IHS is useful when cutting a pre-pierced workpiece to prevent the torch from
performing an IHS on a pierce point.

 The sensing device and the mechanism to control the device are
determined by the OEM.

To set up Offset IHS in Phoenix:

1. Select Setups > Process to go the Sensor THC - Plasma 1 or 2 Process screen.

2. Set the Offset IHS parameter to On.

3. Review the IHS Start Height value. To use the default value, make sure that the value’s
checkbox is selected.

 This height must be a distance above the workpiece that will allow the
sensor to fully extend. For example, if the sensor extends 50mm below the
shield of the torch, the IHS Start Height must be greater than 50mm.

4. Click OK to save your settings.

5. On the Cutting screen (select Main > Setups > Cutting), set the offset values for Marker
Offset 9.

 The Z value is the difference in height between the torch and the external
sensor. This distance is determined by the OEM who installs the external
sensor. This value should be less than the IHS Start Height (set in step 3).

When Offset IHS is performed, the torch moves to the position of Marker Offset 9, performs the
IHS according to the IHS sequence on page 149, and returns to the pierce location.

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 Torch Height Control (THC) 8

When to disable height control

The THC Disabled status bit turns ON when the CNC disables the torch height control, usually as it
approaches a corner in a part and slows down to cut the corner. The reason is that when the speed
slows down, the arc voltage increases. This causes the torch to lower in order to reach the arc
voltage set point. The torch will continue to lower until there is a collision with the workpiece, which
causes a fault. To prevent the collision and fault, you can program the speeds for the torch height
control so that the THC disables when the cutting speed slows down.

THC sequence of operations

The diagram on the next page shows the heights and timers used by THCs during cutting in
Automatic mode. See the following notes for the diagram below:

 For 15 : The voltage tracking begins using the average of samples: one sample per cut up to
6 samples.

 For 16 : The THC tracks arc voltage as long as AVC is not disabled by an M50, auto-kerf, or
due to the torch height disable settings in Phoenix.

 For 17 : Momentarily stops tracking until either the actual arc voltage comes back to its
previous reading (before kerf was detected) or kerf re-acquire time expires.

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152

8
1 2 23 24

Torch Height Control (THC)

12 14 15 17 18 19

9 10

3 11
8
21
5
13 16
20 22
4 Workpiece

6 7

1 Torch path 8 Pierce height 15 AVC sampling (see note) 22 Stop time
809340

2 M07 Command – cut on 9 Pierce delay 16 AVC begins (see note) 23 Retract complete
Installation and Setup Manual

3 IHS start height 10 Creep time 17 Auto kerf detect (see note) 24 Retract height
(does not affect THC states)

4 Tip touch 11 Puddle jump height 18 Torch height disable CNC cut control active (not shown)
(ohmic contact/stall force)

5 Transfer height 12 Cut height delay 19 Cut off time (this example assumes Plasma torch active (not shown)
(-) cut off time)

6 Cut control 13 Cut height 20 Arc off time (this limits the nuisance Cutting X/Y motion (not shown)
trip arc lost at end of cut. Max 2 sec.)
EDGE Connect

7 Arc transfers 14 AVC delay 21 M07 Command – cut off AVC active (voltage tracking state)
(not shown)
 Torch Height Control (THC) 8

Set up a Watch Window

An example Watch Window for the Sensor THC is shown below:

To set up this Watch Window:

1. Choose > .

2. Choose System Errors from the Upper Location list .

3. Choose Input / Output from the Middle Location list .

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8 Torch Height Control (THC)

4. The Status list appears below the Inputs and Outputs lists. Select the following status bits and
I/O from the lists.
Nozzle Contact Sense
This input activates during IHS when the torch detects the workpiece.
Nozzle Contact Enable
This output activates during the IHS and while cutting if Nozzle Contact is on.
THC Locked On
This status bit turns ON when the arc voltage is within +/- 2 V of the set point.
THC Tracking Voltage
This status bit turns ON when the torch height control is using Automatic Voltage Control
(AVC). When ON, the CNC makes adjustments to the position of the THC by comparing actual
arc voltage to the set arc voltage. The torch height control adjusts the cutting height based on
the arc voltage.
If the 50 V default tracking voltage is exceeded, the THC will not track voltage. This can happen,
for example, with an incorrect Pierce Height or Cut Height setting.
THC Disabled
This status bit turns ON when the CNC disables the torch height control, usually as it
approaches a corner in a part (or a small radius, hole, or pierce), the cutting system slows down,
and the actual cutting speed is slower than the program speed. This bit is controlled by the
Torch Height Disable Speed along with the Distance Before and Distance After settings on the
Speeds screen, and by the M50 (Torch Height Disable) and M51 (Torch Height Enable) codes
in a part program.
THC Kerf Detected
This status bit turns ON when the THC detects a rapid rise in the measured arc voltage, which
indicates that the torch is cutting across a previously cut kerf. This bit is controlled by the Auto
Kerf Detect and Auto Kerf Detect Voltage parameters. Auto Kerf Detect must be active and the
THC must be in Automatic mode. When kerf is detected, the CNC temporarily disables the
AVC and prevents the torch from diving into the workpiece.

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Overview

Hypertherm CNCs define a station as a physical tool on the cutting system along with its lifter (if
one is used). The tool can be a plasma torch, marker, or oxyfuel torch. Regardless of the tool, the
CNC provides many of the same options for setup and operation of the stations.

The CNC supports multiple stations on a single cutting system. For the CNC to operate each
cutting station independently, the stations must be set up with numbered inputs and outputs (I/O).

In this section you will find the following:

 A description of generic and numbered I/O
 How to use Auto Select and Manual Select inputs to activate either Program or Manual
modes of operation
 How to assign the lifter and plasma power supply (or other cutting supply such as marker),
and enable the cut charts for each station on the Station Configuration screen

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Generic and numbered I/O

The inputs and outputs for stations, available in > > >

, can be used to control any of the cutting technologies supported by the CNC. The
CNC supports 2 types of I/O for controlling the cutting stations:
 Generic I/O – used for any cutting process and to control a single cutting station
 Numbered I/O – used for multiple cutting stations or with an operator console

Generic I/O
A standard group of inputs and outputs are used to control each cutting process. These I/O are
called generic because all cutting sequences use them. Examples of generic I/O include Cut
Control, Cut/Mark Sense, Torch Up, and Torch Down. Many generic I/O functions that affect
stations have an equivalent numbered I/O.

Numbered I/O
You must use numbered I/O to identify stations when the cutting system has more than 1 station or
uses an operator console (with either a single torch or multiple torches). Numbered I/O allow the
operation of individual cutting stations through the CNC instead of through a programmable logic
control (PLC) or relay logic interface. Each of the functions of generic inputs and outputs that affect
stations are also available as numbered I/O.

We recommend that you match the I/O number to the station number. For example, in a 2-torch
plasma cutting system, you would assign numbered I/O for each station as follows.

Torch 1 (Station 1) Torch 2 (Station 2)

Auto Select 1 input Auto Select 2 input

Manual Select 1 input Manual Select 2 input

Station Enable LED 1 output Station Enable LED 2 output

Cut Control 1 output Cut Control 2 output

Cut Sense 1 input Cut Sense 2 input

 If you have an HPRXD plasma power supply, the fixed function I/O
HPR Cut Control and HPR Cut Sense are automatically assigned. For
more information see Fixed function I/O (virtual) on page 119.

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Enable station I/O

Each station must be enabled before you can start operation. In some cutting systems, you enable a
station with a switch on a hardware operator console that activates an input (the Manual Select
input, for example). In other cases, the station is enabled with the M37 code in the part program.
(For more information about codes and part programs, see EDGE® Connect Programmer
Reference (809550).)

On the CNC’s standard Software Operator Console (Soft Op Con) you can choose one of
3 modes:
Disable Manual Program (Automatic)
Station Mode Mode

 The color of the mode you select changes from gray to green when you
select it.

 For more information about Soft Op Con, see Operate the standard
Hypertherm Soft Op Con on page 65.

Auto Select and Manual Select inputs and Station Enable LED output
When creating an operator console that allows the cutting stations to operate in either Manual
mode or Automatic mode (also called program mode), you must use the following inputs and
outputs (as either generic or numbered I/O).

 Once these I/O are assigned, the cutting stations show in the
Soft Op Con.

 Manual Select input: When the Manual Select input is on, the station is in Manual mode.
Manual mode allows operations such as jogging, Go to Home, and rip cutting. Manual mode
can also function as a program override for station selection. (The override function is
described in more detail in Use Manual mode as an override on page 159.)
 Auto Select input: When the Auto Select input is on, the station is in Automatic, or
program, mode. For Automatic mode to control the station, the part program must run the
M37 Tvalue code. The M37 code enables the station I/O. For more information on program
codes see the EDGE® Connect Programmer Reference (809550).

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9 Station Setup

 Station Enable LED output: When the Station Enable LED output is ON, the station is
enabled and the Cut Control output can be activated. This output can be turned ON in
2 different ways:
 The Manual Select input turns on the Station Enable LED output.
 The CNC reads the Auto Select input and the M37 Tvalue in the part program. Both of
these conditions must occur to turn on the Station Enable LED output.
The Station Enable LED output then activates the Cut Control output. Figure 29 shows the
logic of the inputs and outputs that implement both manual and program mode in the
operator console. The Soft Op Con also uses this logic for Station 1 and 2.

Figure 29

Station Enable LED

Manual Select input output
Auto Select input
M37 Tvalue
Select station code
where value = 1 – 20

Cut Control
output
Station Enable LED
output

Basic operating sequence:

1. Load a part program.

2. Choose a mode on the Soft Op Con.

 Automatic mode for a part program with automatic station selection and activation.
 Manual mode for a part program without automatic station selection, or when you want to
override the automatic station selection (see Use Manual mode as an override on
page 159).
 Disable mode for a station that will not be used in the part program.

3. Align the part to the workpiece. Use the jog arrows on the Soft Op Con or a joystick if available

to position the torch for cutting. To access the jog arrows choose on the Soft Op Con.

 A Ready to Move? message displays when you use the jog keys in the
Soft Op Con, unless the message is disabled in Special Setups.

4. Choose Start to start cutting the part.

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 Station Setup 9

Use Manual mode as an override

Another use of Manual mode is to override the station selection in a part program. For example, the
part program contains the M37 T1 code to select Station 1 for cutting the part. However, you want
the program to use Station 2. On the Soft Op Con, choose Station Disable for Station 1 and
choose Manual mode for Station 2. Load the part and choose Start. When you choose Manual
mode, it overrides the station selection in the part program. In this example, choosing Manual mode
would cause the part to be cut with Station 2 instead of Station 1.

Summary
The Auto Select and Manual Select inputs and the Station Enable LED output do the following.
 Give the operator manual control over the stations, but also allow part programs that use the
M37 code to select a station (program mode).
 Are used for the station modes on the Soft Op Con.
 Once assigned, make the cutting stations show in the Soft Op Con.
 Are an optimal method for controlling the stations when you have different tools on the same
table (for example, plasma and oxyfuel).

 Additional I/O may be necessary depending on the torch height controls

and other mechanisms that are part of your cutting system.

Figure 30 on page 160 shows an example of the Auto Select and Manual Select inputs, Station
Enable LED outputs, and additional I/O for a 2-torch operator console and control box.

 This is an example only and not intended as a recommendation for

system design.

 If you have an HPRXD plasma power supply, the fixed function I/O
HPR Cut Control and HPR Cut Sense are automatically assigned and
used instead of Cut Control 1 and 2 and Cut Sense 1 and 2. For more
information see Fixed function I/O (virtual) on page 119.

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9 Station Setup

Figure 30

Hardware operator console (OEM-supplied)

Manual Select 1 input Auto Select 2 input

Auto Select 1 input

Manual Select 2 input
Station Enable LED 2
output
VF
Station Enable LED 1
output

Station Enable LED 2 output

Station Enable LED 1 output

Auto Select 1 input

Manual Select 1 input

Auto Select 2 input

Manual Select 2 input

Control box (OEM-supplied)

Cut Control 1 output

Cut Control 2 output

Cut Sense 1 input

Plasma Start input (Torch 1)

Motion output (Torch 2)

Cut Sense 2 input

Motion output (Torch 1)

Plasma Start input (Torch 2)

Hypertherm CNC

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 Station Setup 9

THC and cut chart setup on the Station Configuration screen

The Station Configuration screen lets you define each station in the cutting system. In this screen,
you select the type of torch height control and the model of the tool (plasma or marker) for the
station. The selections you make in this screen do the following.
 Customize other screens in the CNC with features that are unique to the selected tool and
torch height control
 Enable the cut charts that are available for the selected tool

To open the Station Configuration screen, choose > > .

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9 Station Setup

Guidelines for using the Station Configuration screen

 Before you use the Station Configuration screen, make sure that you have made selections
for Tools Installed in the Special Setups screen (Setups > Password > Special Setups).
The Tools Installed selections define the processes used on the cutting system. For more
information on Plasma 1 and Plasma 2 processes, see Plasma Setup on page 169.
 When you use the Sensor THC for a lifter, make sure that you select the lifter in this screen.
Torch height control parameters specific to this lifter become available in the Process screen
so that you can optimize cutting performance.

 Before the Sensor THC is available in the Station Configuration screen,

you need to select it as the torch height control in the Machine Setups
screen (Setups > Password > Machine Setups). You also need to assign
the Sensor THC to an axis.

 Select the process used by the tool on the station. For example, for Plasma 1 you can select
HPR. This selection makes the cut charts available for the process.

 Oxyfuel systems DO NOT require a selection in the Station Configuration

screen. Oxyfuel cut charts become available after you select Oxyfuel as a
Tool Installed and enable Oxy Fuel Cut Charts in the Special Setups
screen (Setups > Password > Special Setups).

 Use the soft keys to open the Station Configuration screen for Stations 1 – 2, 3 – 4, 5 – 6,
and 7 – 8.
 Use the Reset All soft key to return all settings for all stations to None.

 See Plasma Setup on page 169 for more information on using the Station
Configuration screen for a cutting system with multiple stations.

Conflicting process

A conflicting process is an error condition that pauses a program or prevents a program from
loading. A conflicting process occurs when the cut mode does not match the process (or
processes) available for an active cutting station. The conflicting process feature in Phoenix
compares the selected cut mode to the processes assigned to each active station, and looks for a
match. This happens automatically after you choose Start on the controller. A station is active when
the Station Enable LED output associated with it is active.

For example, if the cut mode is Plasma 1, then all active cutting stations require a Plasma 1 process
or the program will pause with a conflicting process error message.

The conflicting process feature makes sure that different tools cannot operate if both of their
stations are accidentally left on by the operator. Conflicting process applies to all processes except
oxyfuel.

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Example of a conflicting process

How a tool is associated with a station

In this example you can tell Station 1 is active because the Station Enable LED 1 is illuminated.
When you choose Start, Phoenix compares the cut mode with the processes assigned to the active
station.

1. If the cut mode is Plasma 1, Phoenix checks for a valid Plasma 1 process on Station 1. HPR is a
valid process.

2. If the cut mode is Plasma 2, Phoenix checks for a valid Plasma 2 process on Station 1. There is
no plasma process selected (None) so you get a conflicting process error.

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A conflicting process example that prevents a program from loading

In this example, the CNC shows a message indicating that an M-code is invalid. It is a legitimate
M-code, but the Marker 1 process is not assigned to a station. For an M-code to be valid the
associated process must be assigned to a station.

The part program in this example contains an M36 T3 code (Marker 1 process select selection
code), but a Marker 1 process is not assigned to a cutting station. However, Marker 1 is assigned
as a tool. In order to make use of an M36 code within a program, the process being called must be
assigned to a station within the Station Configuration screen. This type of scenario applies to all
M36 process codes.
 M36 T1 (Plasma)
 M36 T2 (Plasma 2)
 M36 T3 (Marker 1)
 M36 T4 (Marker 2)

Adding a Marker 1 process to the Station Configuration screen resolves the issue.

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Troubleshooting a conflicting process error

The settings look correct on the screen below
1. Station 1 is the active station.

2. The cut mode is Plasma 1.

3. Plasma 1 is defined on Station 1 on the Station Configuration screen. See Figure 32 on

page 166.

Figure 31

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The cause of the error

Marker 1 is assigned to Station 2 in the Station Configuration screen and no station I/O is assigned
for Station 2, which makes Station 2 active in Phoenix.

Figure 32

Troubleshooting steps

1. Review the settings in the Station Configuration screen.

a. A station must have a process assigned that matches the cut mode.
b. The processes assigned to the station must be valid.
c. A physical tool with processes that match the station settings must be installed.

2. Review station I/O assignments.

a. Make sure that the station I/O is assigned correctly.
b. Each station should have the following I/O assigned: Auto Select # / Manual Select # /
Station Enable LED # (and same # for each station).
c. If one station has station I/O, all stations need station I/O.

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3. Review the following settings.
a. Make sure that the Tools Installed on the Special Setups screen are correct.
b. Make sure that all processes (for Tools Installed) are assigned on the Station Configuration
screen.
c. Make sure that station I/O is assigned correctly on the I/O screen.
d. Make sure that Station Select Override and Process Select Override are enabled on the
Cutting screen if you are using M36 Tvalue codes to select a process from the part
program.

4. Monitor the station I/O and processes (on a Watch Window).

a. Monitor the Station Enable LED outputs.
b. Monitor the Process Enable outputs.
c. Monitor Process Data for each available process (preferably in one Watch Window).

Remove a station from the Soft Op Con

Removing a station on the Station Configuration screen does not automatically remove the station
from the Soft Op Con. This is because the Auto Select and Manual Select inputs and the Station
Enable LED output are what make stations show in the Soft Op Con. To remove a station from the
Soft Op Con, you must also remove these I/O.

1. Choose > > > .

2. Set the I/O for the station that you want to remove to Spare.

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Overview

This section describes the tasks you need to perform to set up the Hypertherm CNC with a plasma
power supply. Because of the variation between cutting systems, Hypertherm CNCs provide built-in
flexibility for multiple methods of system setup, operation, and part programming. Since all cases
cannot be described here, this section makes the following assumptions.
 The cutting operations are being controlled by the CNC, not by a programmable logic
controller (PLC) or other external relay logic.
 The cutting system is equipped with a Sensor THC.

In this section you will find the following.

 An overview of the Plasma 1 and Plasma 2 processes and guidelines for setting up the
processes
 A detailed, step-by-step description of the plasma cut sequence
 Definitions of the inputs and outputs used for plasma cutting systems
 Plasma setup instructions for the CNC

Plasma part programs can use process selection variables to load the cut chart. The CutPro™
Wizard provides additional automation. For more information about plasma process selection
variables, see the EDGE® Connect Programmer Reference (809550).

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Plasma 1 and Plasma 2

Plasma 1 and Plasma 2 refer to two separate cutting processes. Marker 1 and Marker 2 likewise
refer to two separate marking processes.
 Select Plasma 1 and Plasma 2 as Tools Installed on the Special Setups screen to enable
the Plasma 1 and Plasma 2 Process screens.
 Assign the specific plasma power supply to Plasma 1 and Plasma 2 on the Station
Configuration screen to make the cut charts available along with other functionality specific
to the cutting systems. In the Station Configuration screen you match up the process
(Plasma 1 and Plasma 2) to the cutting station (Station 1, Station 2, and so on).

For more information on stations, see Station Setup on page 155.

In general, follow these guidelines for using Plasma 1 and 2 on the CNC.
 In a single-torch cutting system, you need only Plasma 1 for Station 1.
 In a multiple-torch cutting system where the torches cut parts using the same process and
cut chart, select only Plasma 1.
 In a multiple-torch system where the torches are from different plasma supplies, you need to
select Plasma 1 and Plasma 2 so that the CNC makes a second cut process and cut chart
available.
 Use both Plasma 1 and Plasma 2 when the part program calls for two different cutting
processes. For example, the part program cuts the detail portions of a part with a low
amperage consumable and then automatically switches to a higher amperage consumable
to cut the part contour. This type of part program would require two torches: One torch has
a low amperage consumable set while the second torch has a high amperage consumable
set. Therefore, use Plasma 1 for the low amperage cut chart and Plasma 2 for the high
amperage cut chart.

Sample settings for a single-torch cutting system

To set up a single-torch HPRXD system, follow these general steps on the CNC.

1. On the Setups > Password > Special Setups screen, select only Plasma 1 and Marker 1.

 THC selections must also be made on the Machine Setups screen before
selecting them on the Station Configuration screen. See Torch Height
Control (THC) on page 135.

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2. On the Setups > Password > Station Configuration screen, choose the torch height control
on Station 1 for the lifter.

3. Choose HPR for Plasma 1.

Sample settings for a multiple-torch cutting system

To set up a multiple-torch HPR Auto Gas system that uses one cutting process and one marking
process for all torches, follow these general steps on the CNC:

1. On the Setups > Password > Special Setups screen, select Plasma 1 and Marker 1.
Plasma 2 is a separate process and is not used in this example.

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2. On the Setups > Password > Station Configuration screen, choose HPR for Plasma 1 and
Marker 1 for Station 1 and Station 2.

3. On this screen you are assigning the cutting and marking processes that will be used for each
of the individual cutting stations.
If all torches are always going to cut and mark with the same consumable sets, then the
assignment is Plasma 1 and Marker 1 for all cutting tools.

Station 1 and Station 2

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4. Choose to advance to the screen for Stations 3 and 4, and repeat the assignment
of the HPR to Plasma 1 and Marker 1 for these stations.

Station 3 and Station 4

Sample settings for a two-torch cutting system

This example uses an HPR130XD Auto Gas plasma power supply on one station and an
HPR400XD Auto Gas plasma power supply on the other station. To set up a two-torch cutting
system where two different processes are being used, follow these general steps on the CNC.

1. On the Setups > Password > Special Setups screen, select Plasma 1 and Marker 1 and
Plasma 2 and Marker 2.

2. On the Setups > Password > Station Configuration screen, select HPR in both Plasma 1
and Plasma 2. Both are being used because the HPR130XD and HPR400XD plasma power
supplies use different cut processes and consumables. This is when the Plasma 2 selection is
required.

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Assigning the HPR400XD on Station 2 and Plasma 2 provides the ability to use two HPRXD
torches with different consumables for different cutting processes in the same part program.

Plasma 1 and
Plasma 2 are
required when the
cutting system
supports different
cutting processes in
the same part
program.

Plasma cut sequence

 Also see the THC sequence of operations timing diagram on page 151.

Hypertherm CNCs execute the plasma cut sequence in these basic steps.

1. The CNC sends the Cut Control output signal to the plasma power supply. Cut Control
connects to the Start input on the plasma power supply.

2. When the plasma power supply transfers an arc, it sends the Motion output signal to the CNC.
Motion is connected to the Cut Sense input on the CNC.

3. While waiting for the cut sense input to turn on, the CNC displays the message “Waiting for Arc
On.” When the Cut Sense input on the CNC turns on, the CNC initiates motion.

The Cut Control output and Cut Sense input are the minimum I/O signals needed in a plasma
cutting system. The CNC provides additional I/O for torch height controls (THCs), for multiple-torch
applications, and to enable features that reduce the cycle time between parts.

In most cutting systems, a THC manages the signals between the CNC and the plasma power
supply. When a signal is sent to the plasma power supply, it typically passes through a THC, but the
signal stays the same.

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The following plasma sequence assumes the use of the Sensor THC. When using a THC from
another manufacturer, the CNC provides a series of timers to control I/O to lower and raise the
torch. For more information on using the timers for a THC, see Torch Height Control (THC) on
page 135.

The CNC identifies each state of the cut sequence with a status message below the part preview
area of the Main screen.

The cut sequence begins when you press Cycle Start. At Cycle Start, the CNC begins reading and
executing the part program.

State and Status message: Lowering Torch

Initiated when: The CNC reads the M07 code in the part program.
 The THC performs its initial height sense (IHS).
 Torch Height Disable output turns on and remains on until the cutting system reaches
cutting speed.
 If Preflow During IHS is on in the Process screen (and you have an HPRXD plasma power
supply), then Cut Control and Hold Ignition turn on.

State and Status Message: Waiting for Arc On

Initiated when: IHS completes and the torch is at the Transfer Height.
 Cut Control output turns on. Cut Control activates the Plasma Start input to the plasma
power supply.
 Hold Ignition turns OFF.
 Cut Control remains on until the CNC reads the M08 code (Cut Off) in the part program.
 The Pierce Control output turns ON (if you have an HPRXD plasma power supply).

State and status message: Piercing

Initiated when: The plasma power supply ignites an arc.

 The plasma power supply turns ON the Motion output.
 The Cut Sense input at the CNC turns ON.
 The CNC delays motion until the Pierce Time set in the Process screen elapses.
 The Pierce Control output turns ON until the Pierce Time elapses.

State and status message: Creeping

Initiated when: Creep motion begins.

 Creep motion continues until the Creep Time elapses. If Creep Time is not set in the
Process screen, no creep motion will be used. Creep speed is a percentage of the Cut
Speed set on the Setups > Password > Machine Setups > Speeds screen.

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State and status message: Cutting

Initiated when: Cutting system accelerates to Cut Speed.

 Torch Height Disable turns OFF after the cutting system reaches cutting speed.
 Torch Height Disable toggles ON and OFF while cutting whenever the actual cut speed
drops to a percentage below the set cut speed (the Torch Height Disable Speed is set in
the Speeds screen).

State and status message: Raising Torch

Initiated when: The CNC reads the M08 code (Cut Off) in the part program.
 Cut Control turns OFF, which turns OFF the Start input at the plasma power supply.
 The Motion output at the plasma power supply turns OFF, which turns OFF the Cut Sense
input at the CNC.
 For an HPRXD plasma power supply: when the Cut/Mark Sense input at the CNC
turns OFF, it immediately retracts the torch because the HPRXD has already
extinguished the arc.
 For a non-HPRXD plasma power supply: when the Cut/Mark Sense input at the CNC
turns OFF, it starts a retract delay timer and waits before retracting the torch because
the arc may still be present.

State and status message: Stop Delay

Initiated when: A Stop Time has been entered in the Process screen.
 A stop delay prevents the gantry from moving to the next pierce point until the Stop Time
elapses. Setting a Stop Time makes sure the torch clears any tip-ups before moving to the
next pierce point.
 The THC raises the torch to the retract height.

State and status message: Traversing

Initiated when: The Stop Time elapses.

 The gantry moves to the next pierce point and the sequence repeats.

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Setting up inputs and outputs for plasma

Fixed function I/O for HPRXD

Phoenix assigns fixed function I/O automatically when HPR is selected on the Station Configuration
screen. Fixed function I/O for the HPRXD is not shown as assigned to any I/O points in the Inputs
and Outputs lists on the I/O screen and does not appear in the I/O Diagnostics screen.

The fixed function I/O for HPRXD plasma power supplies is shown below.

Digital inputs

HPR Cut Sense

HPR Not Ready For Start

HPR Nozzle Contact Sense

HPR Process Ready

Digital outputs

HPR Cut Control

HPR Hold Ignition

HPR Pierce Control

HPR Nozzle Contact Enable

HPR Remote On

Station I/O for the Soft Op Con

The I/O that makes a station show on the CNC’s standard Soft Op Con (Auto Select and Manual
Select inputs, and the Station Enable LED output) are automatically assigned by Phoenix when you
select HPR on the Station Configuration screen. See Station Setup on page 155.

Fixed function I/O descriptions

HPR Cut Sense / HPR Cut Sense 1 – 4 – These inputs notify the CNC that the torch has
transferred the arc to the workpiece. The input originates from the Motion output from the
plasma power supply or THC, and the CNC begins motion after this input activates and the
Pierce Time expires.
HPR Cut Sense 1 – 4 are the numbered versions of the HPR Cut Sense input. In a
multiple-torch cutting system, the HPR Cut Sense would be automatically assigned for each
station that you configure with an HPR in the Station Configuration screen.

HPR Not Ready for Start – When enabled, the torch will not fire.

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HPR Nozzle Contact Sense – Used during IHS to detect the surface of the workpiece. With
Sensor THC, this input is returned to the CNC through the external voltage divider card.

HPR Process Ready – This input turns on at the CNC when the HPR EtherCAT board has
finished handling the process update. This input does not mean that the HPR plasma power
supply has finished handling the process update or that the HPR is ready or waiting for a
plasma start signal.

HPR Cut Control 1 – 4 – These outputs activate the Start input of the plasma power supply. Cut
Control turns ON and remains ON until the M08 (Cut Off) command is executed in the part
program.

HPR Hold Ignition – Activates the IHS Sync input of the THC or the Hold input of a plasma power
supply. This output initiates Preflow During IHS and, if needed, a process change. This output
is also used in a multiple-torch cutting system to synchronize the ignition of all torches.

HPR Pierce Control – Activates during piercing and remains ON until the Pierce Time elapses (set
in the cut chart or Process screen). This output is used in some plasma power supplies to
keep the plasma power supply from switching out of shield preflow while piercing. Pierce
Control connects to the Pierce input at the plasma power supply.

HPR Nozzle Contact Enable – Active during Sensor THC IHS. This input is tied back to the CNC
through the external voltage divider card. This output can also be used to switch an external
drive system to low output mode (if equipped) during IHS for stall force workpiece sensing.

HPR Remote on 1 – 4 – Applies power to the plasma power supply from a remote location.

Summary: setting up the plasma routine

1. Select the Plasma 1 and Plasma 2 processes in the Special Setups screen.

2. Select a marking process if the plasma torch will be used as a marker.

3. Assign the inputs and outputs for the plasma power supply on the I/O setup screen. For more
information, see I/O – Inputs and Outputs on page 119.
a. The I/O assignments for the plasma power supply depend on the number of torches and
whether the CNC will be operating all the torches independently.
b. For the CNC to operate each torch independently, numbered outputs and Station Select
inputs must be assigned in the I/O setup screen. See Station Setup on page 155 for
numbered I/O and Station Select inputs.

4. Define timer settings and other cutting parameters in the Process screen.

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I/O, plasma power supply status, and diagnostics information

You can view status items for the plasma power supply, arc-on statistics, software revisions,
temperatures, gas types, gas pressures, remote tools, and I/O.

Choose > > .

Plasma power supply status

Choose to see status items for the plasma power supply on the HPR Information
screen.

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Remote tools (HPR diagnostics)

Test Preflow: Choose to test the preflow gases at the plasma power supply. This
feature is used to set the inlet gas pressures under normal flow conditions to the recommended
level.

Test Cutflow: Choose to test the cutflow gases at the plasma power supply. This
feature is used to set the inlet gas pressures under normal flow conditions to the recommended
level.

Test Gas Console: Choose to perform automated tests for the HPR Auto Gas
console. Contact an authorized service agent for use of these tests.

Coolant Override: Choose to override a coolant error and to test the coolant pump.
This is useful for bypassing the error and purging the coolant line of air bubbles when you turn ON
the plasma power supply.

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Plasma power supply and gas console I/O

Plasma power supply inputs

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Gas console inputs

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Plasma power supply outputs

 A password is required to see the outputs screens.

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Gas console outputs

 A password is required to see the outputs screens.

 The outputs screen shows the current status of the listed plasma power
supply outputs.

 Outputs for the plasma power supply cannot be activated through the
diagnostic screen.

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About setup files

Hypertherm CNCs save the values that you enter on each screen in a setup file named Phoenix.ini.

Setup files can be copied to other EDGE Connect/EDGE Connect TC CNCs. For example, after
configuring a CNC to run a particular cutting system, you can copy that setup file for the next
installation of an EDGE Connect/EDGE Connect TC CNC, table, and tool. When you load a setup
file into a CNC, that setup file that you load overwrites both the Phoenix.ini and Phoenix.bak.

CAUTION
Do not load a setup file from an EDGE Pro, MicroEDGE Pro or EDGE Pro Ti onto the
EDGE Connect/EDGE Connect TC. Doing so could cause the cutting machine to become
inoperable.

The CNC stores multiple copies of the Phoenix.ini setup file.

 Phoenix.ini is always the active setup file. Each time you make a change on a screen in
Phoenix, the changes are saved to Phoenix.ini. In the Special Setups screen you can save a
copy of Phoenix.ini with a different name for a backup or to use on another CNC. When you
load a setup file with another name, the contents of that file overwrite the contents of
Phoenix.ini and Phoenix.bak. Phoenix.ini is stored in the C:\Phoenix folder.
 Phoenix.bak is an identical copy of Phoenix.ini. The CNC saves Phoenix.bak each time it
saves Phoenix.ini. If Phoenix.ini becomes corrupted, the CNC loads the settings in
Phoenix.bak and creates a new Phoenix.ini. Phoenix.bak is stored in the C:\Phoenix folder.

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 Default.ini is an important backup of Phoenix.ini and is used to restore settings if both

Phoenix.ini and Phoenix.bak become corrupted. We recommend that you create the
Default.ini when you commission a cutting system. Default.ini is stored in the
C:\Phoenix\Setups folder.
 Factory settings represent the contents of the Phoenix.ini file as it was shipped from the
factory. Each CNC has factory settings that represent the available features and axes on
that CNC.
Factory settings are stored internally in Phoenix but are not stored in a specific file. Factory
settings can be very different from the settings on a CNC when it is commissioned in a
cutting system at a manufacturing site.

Setup files from previous versions of Phoenix

New versions of Phoenix contain new features with new factory settings that are saved to the
Phoenix.ini file. When you load a setup file from a previous version of Phoenix, a message shows you
the new factory settings that are not in your setup file. Phoenix then loads the new factory settings
for those new settings.

After you load a setup file from a previous version of Phoenix, make sure that you save a new version
of the setup file in the new version of Phoenix. By saving the Phoenix.ini in the new version, you
make sure that the setup file has settings for all new features in Phoenix.

CAUTION
Do not load a setup file from an EDGE Pro, MicroEDGE Pro or EDGE Pro Ti onto the
EDGE Connect/EDGE Connect TC. Doing so could cause the cutting machine to become
inoperable.

Save and load the setup file

We recommend that you save the setup file 3 times when first commissioning a cutting system:
 Save the setup file to a USB memory stick with the name EndUserDate.ini. We also
recommend that you save a copy to the hard drive on the CNC.
 Save the setup file using the Backup feature. See Back Up and Restore the System on
page 197.
 Save the setup file with the name Default.ini on the CNC’s hard drive in the
C:\Phoenix\Setups folder. This is the default location.

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Save a setup file with a different name

When you save a setup file with a different name, the CNC continues to use Phoenix.ini and does
not update your saved setup file. You would do this to save a particular configuration.

1. From the Main screen, choose > > .

2. Choose .

3. Choose Hard Drive, HD Backups, or Memory Stick for the location.

4. Enter a file name.

5. Choose OK.

The CNC saves the file in the selected location.

Load a setup file

The setup file that you load becomes the active setup file (Phoenix.ini).

1. From the Main screen, choose > > .

2. Choose .

3. Choose Hard Drive or Memory Stick for the location. The CNC lists the *.ini files that are in the
root folder of the hard drive or the USB memory stick.

4. Enter a setup file name.

5. Choose OK.

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Save system files for troubleshooting

The CNC can gather the Phoenix.ini, LastPart.txt, Phoenix.xml, Network.xml, SystemErrors.log, and
other files to a USB memory stick or to a .zip file on a USB memory stick. These files have important
information for troubleshooting the CNC. For more information, see Save system files for
troubleshooting on page 204.

Also see Back Up and Restore the System on page 197 for other options.

Save and load default settings

The CNC uses the Default.ini file to restore settings if both Phoenix.ini and Phoenix.bak become
corrupted.

CAUTION
Loading the default settings changes the setup on the CNC. The cutting system may no longer be
capable of motion and the I/O may not work. Only use this procedure if you do not have a
backup setup file.

Save Default.ini

1. From the Main screen, choose > > .

2. Choose .

3. Choose Hard Drive for the location.

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4. Enter Default for the file name.

5. Choose OK.

The CNC saves the Default.ini file in the C:\Phoenix\Setups folder.

Load Default.ini
Default.ini must exist in C:\Phoenix\Setups. If no Default.ini exists, the CNC provides an option to
reload factory settings instead.

1. Choose > > > .

2. Choose .

 If you haven’t saved a Default.ini file, then the soft key is labeled Reset
Setups instead and lets you reset the CNC to factory settings.

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Reload factory settings

If your system is experiencing motion or other problems for which you cannot find a solution,
reloading the factory settings gives you a known starting point for configuring the CNC to work with
your cutting system.

CAUTION
Reloading the factory settings changes the setup on the CNC. The cutting system may no longer
be capable of motion and the I/O may not work. Only use this procedure if you do not have a
backup setup file.

1. From the Main screen, choose > > > .

2. Choose .

 If the soft key is labeled Default Setups instead, then there is a Default.ini
file in C:\Phoenix\Setups. Reload the default settings instead of the
factory settings if possible.

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 Local Area Networking

Connect to a local area network with wireless or Ethernet

Use this procedure to connect to a local area network (LAN) with Ethernet or wireless for the first
time.

 Dynamic Host Configuration Protocol (DHCP) connections are expected

for the purpose of this document. With a DHCP connection, the
EDGE Connect/EDGE Connect TC automatically connects to the LAN
and automatically acquires the Internet Protocol (IP) address.

 Hypertherm cannot troubleshoot issues with password-protected network

domains. If you must connect the CNC to a password protected network
domain: 1.) It is your own responsibility to manage your network
credentials. 2.) Your IT department should automate the network login
process for the CNC operator. For best results, connect the EDGE
Connect/EDGE Connect TC to a trusted network workgroup that
does not require login credentials.

1. Connect a USB keyboard and USB mouse to the CNC to make LAN setup easier.

2. From the Main screen, choose Setups > Password.

3. Enter the Special Setups password.

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4. On the Special Setups screen, choose System > Network Tools to open the Network
Connections screen in Windows.

 The EDGE Connect does not use the Bluetooth connection.

 Do not change the Ethernet 2 (Intel) or Ethernet 3 (TenAsys) connections.

5. To connect to a LAN with Ethernet connect the Ethernet cable to the LAN connector on the
CNC. To connect to the LAN with wireless continue to step 6.

6. To connect to the LAN with wireless, in the Network

Connections screen, right-click the wireless connection,
and then choose Connect/Disconnect.

7. Choose the wireless

network that you want to
connect to.

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 Local Area Networking 12
8. If you want to connect automatically in the
future, select Connect automatically.

9. Choose Connect.

 You can also use the Windows 10

Network Connections Manager to
locate your router or wireless
network access point. Choose
Start Menu > Settings > Network
& Internet.

Notes
 The wireless network card in the EDGE Connect conforms to 802.11AC, 802.11N, and
802.11G standards and connects to any AC, N, or G wireless network. It provides at least
wireless G or better performance for part program downloads, Remote Help™, or other
network tasks. For best performance, use the fastest connection (802.11AC).
 The LAN must be set to broadcast its SSID for it to be visible as a connection. If you know
the SSID, Windows 10 can also connect to hidden wireless networks.
 If the network connection wizard does not list any internal wireless networks, use another
wireless device to make sure that the LAN is available and that the router or access point
connection is available.
 Wireless signal strength decreases with distance.
 A wireless connection does not require 100% signal strength (shown as 4 solid bars on the
screen) to operate correctly. If the Network Connections Manager shows 2 or 3 signal
strength bars, the network connection is satisfactory.
 If the wireless signal strength is below 2 bars, move the wireless router or access point
closer to the CNC, or add another access point closer to the CNC.
 For best wireless network performance, minimize the number of clients on the wireless
network.
 Avoid connecting slower wireless devices to the network (for example, 802.11B devices).
The performance of the entire network can decrease to that level. Contact your network
administrator for additional support.

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12 Local Area Networking

Map a drive

To access part programs from the LAN, you must map a network drive and folder in both
Windows 10 File Explorer and Phoenix.

 Part programs must be the only type of files in the mapped folder.

 You must map the root folder. Phoenix does not navigate subfolders.

 Make sure that the part program extension you are trying to access is in
the file extensions area of the Special Setups screen.

1. Map the drive in Windows 10:

a. Choose Start Menu > File Explorer.

b. Right-click This PC, and choose Map

Network Drive....

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 Local Area Networking 12
c. Choose a drive letter.
d. Choose the folder.

 Make note of the

folder path. When
you connect to the
folder in Phoenix,
you need to enter
the folder path
starting with the
drive letter.

e. Select Reconnect at
sign-in.
f. Choose Finish.

2. Map the drive in Phoenix:

 Before you begin, make sure that Mapping Drives and Adding Folders
are set to Allowed in the Special Setups screen. (Tip: To avoid
accidentally deleting files from your network, also set Deleting Folders to
Not Allowed.)

 ProNest CNC can use the mapped folders from Windows and Phoenix.

a. On the Main screen, choose Files.

b. Double-click or tap twice below the preview window where indicated to add the mapped
drive folder that you created in Windows.
c. Choose Mapped Drive.
d. Type a Drive Name.

 This is the name that

appears in the Load Files
list.

e. Type the absolute Drive Path

to the folder that has the files
using this format: [DriveLetter]:\[DirectoryName]\[FolderName] (Example:
Q:\MyDirectory\CustomerParts)

 Do NOT provide the UNC drive path (\\servername\foldername\).

f. Choose OK.

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12 Local Area Networking

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 Back Up and Restore the System

Introduction

It is very important to create a backup so you can restore the cutting system to a previous
operational state if files become corrupted or there is some other issue that requires you to restore
the cutting system.

A backup file is a snapshot of the software installed on your CNC. The backup file includes the
operating system software and the Phoenix software and configuration files.

What is backed up:

 Operating system software
 Licensing information
 Windows 10 operating system and configuration files
 INtime operating system and configuration files
 Hypertherm EtherCAT Studio
 The C:\Phoenix folder (Phoenix software and configuration files)
 Phoenix software
 Soft Op Con
 Phoenix configuration files
 Network configuration file
 Launcher

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13 Back Up and Restore the System

Backup

A new Backup and Restore utility has been created for the EDGE Connect/EDGE Connect TC
CNCs. The new process is very similar to the previous method.

1. Restart the CNC.

2. Windows allows you to choose an operating environment during startup. When the Choose an
Operating System screen shows, touch the screen anywhere.

 The Choose an Operating System screen shows for 5 to 15 seconds

before Phoenix starts. Touch the screen anywhere to stop the timer.

3. Choose the second option, Windows Preinstallation Environment, to show the Backup and
Restore screen.

4. Choose the Backup soft key to show the Backup and Restore screen.

Table_Setup_5_16_16_1:00PM
Backup created by the
end user
*
Backup created by the OEM
(Password protected)

Backup to an external device

Cancel

*unused is the description you see until a backup has

been created.

5. Choose the type of backup you want to create.

 An OEM backup requires the Special Setups password.
 Use the USB port to backup to an external device.

 To limit the amount of hard drive space that is used, only one OEM backup
and one User backup can be saved to the hard drive. This process will
overwrite a backup file if one was already on the hard drive.

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 Back Up and Restore the System 13

6. Type a description, and then choose the OK soft key .

Table_Setup_5_16_16_1:00PM

7. The CNC restarts when it completes the backup.

 If there is not enough space on the hard drive to create a backup, the
following message appears. You will have to delete files to make space on
the hard drive if you get this message.

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13 Back Up and Restore the System

Restore

The system can be restored from an end-user backup, OEM backup, factory default, or external
device.

To restore the system:

1. Restart the CNC.

2. Windows allows you to choose an operating environment during startup. When the Choose an
Operating System screen shows, touch the screen anywhere.

 The Choose an Operating System screen shows for 5 to 15 seconds

before Phoenix starts. Touch the screen anywhere to stop the timer.

3. Choose the second option, Windows Preinstallation Environment, to show the Backup and
Restore screen.

4. Choose the Restore soft key to show the Backup and Restore screen.

Table_Setup_5_16_16_1:00PM
Restore from an end user backup

*
Restore from an OEM backup
*

Restore to factory default

Restore from an external device

Cancel

*unused is the description you see until a backup has

been created.

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 Back Up and Restore the System 13
5. Choose the type of restore you want to do.
 The C:\Phoenix directory is overwritten if you choose to restore from an OEM backup. The
C:\Phoenix directory is restored to the state it was in when the backup was created.
 The C:\Phoenix directory is maintained if you choose to restore from an end user backup.
The current C:\Phoenix directory is maintained.
 The C:\Phoenix directory is overwritten if you choose to restore from an external device
through the USB port.

 To limit the amount of hard drive space that is used, only one OEM backup
and one end user backup can be saved to the hard drive. This process will
overwrite a backup file if one was already on the hard drive.

6. A message asks you to confirm that you want to restore. Choose the OK soft key to continue.

Table_Setup_5_16_16_1:00PM

Are you sure you want to continue?

7. The CNC restarts when it completes the restore process.

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13 Back Up and Restore the System

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 Troubleshooting and Diagnostics

Hypertherm assumes that the service personnel that do troubleshooting and diagnostics are
qualified technicians. Knowledge of final isolation troubleshooting techniques is also assumed.

In addition to being technically qualified, service personnel must do all tests with safety in mind.
Read the safety instructions in your product’s manual, the Safety and Compliance Manual
(80669C), the Waterjet Safety and Compliance Manual (80943C), and the Radio Frequency
Warning Manual (80945C).

CAUTION
Static electricity can damage circuit boards. Use precautions when handling printed
circuit boards.
Wear a grounded wrist strap when handling PC boards.

If you have questions or problems during servicing, call the Hypertherm Technical Service team
listed in the front of the manual.

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14 Troubleshooting and Diagnostics

Save system files for troubleshooting

The CNC can gather the Phoenix.ini, LastPart.txt, Phoenix.xml, Network.xml, SystemErrors.log, and
other files to a USB memory stick or to a .zip file. These files have important information for
troubleshooting the CNC. Use this procedure to save the CNC’s setup files or to gather files to
send to Hypertherm Technical Service.

Because this method does not require a password, it is a convenient procedure for an end user to
save the Phoenix.ini without being exposed to password-protected settings.

Also see Back Up and Restore the System on page 197 for other options.

1. Put a USB memory stick in a USB connector on the CNC.

2. From the Main screen, choose > > .

3. Select one or more files from the Select File to Save list.

4. Choose Save to Disk. Or, choose Save All to Zip File to save all of the files as Phoenix.zip on
the USB memory stick.

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 Troubleshooting and Diagnostics 14

Remote Help™ from a technician

Remote Help is an Internet-based diagnostic tool that uses screen-sharing to let a remote
technician and a CNC operator work together to troubleshoot issues.

For more information about Remote Help see the Remote Help™ for Hypertherm CNCs Application
Note (807560). Technical documentation is available at www.hypertherm.com/docs.

CNC troubleshooting

CNC messages
For help with CNC status messages, see Status messages on page 224.

For help with CNC pause, fault, and error messages, CNC pauses, faults, and errors on page 227.

CNC information screen

This Control Information screen displays the current software versions, the hardware configuration,
and the software modules installed on the CNC. You must provide this information if you contact
Hypertherm Technical Service for support.

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14 Troubleshooting and Diagnostics

From the Main screen, choose Setups > Diagnostics > Control Information.

Hardware Information: The Hardware Information section shows the current hardware
configuration which includes the processor type, processor speed, memory installed, hard drive
size, and hard drive free space.

Software Versions: The Software Versions section shows the current version of Windows®,
Phoenix, the real-time operating system, the field bus master, the real-time module, the PLC engine,
the system image, the Phoenix API Host, and the Phoenix API Client.

Control Information: The Control Information section shows the hardware key number, the CNC
serial number, and the CNC model number.

Software Modules: The Software Modules section shows the optional software that has been
installed, such as DXF-DWG Translator, McAfee® VirusScan® software, or NJWIN® font viewer. If a
number appears after the name of a software option, a timer is associated with this software and the
number shows you how many days or uses remain.

Limited Version: The Limited Version section shows only if the CNC is operating a trial version of
software. The trial version of software is available for 90 days. Contact your cutting system
manufacturer to have this timer reset if necessary.

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 Troubleshooting and Diagnostics 14
Control Days Left: The Control Days Left section only shows if a timer is set up on the Control
Information screen to limit the number of days that the Phoenix software is valid; for example, when
a limited version upgrade has been installed. Contact your cutting system manufacturer to have this
timer reset if necessary.

OEM Days Left: The OEM Days Left section only shows if your cutting system manufacturer set up
a timer to limit the number of days that the Phoenix software is valid.

 After the timer expires, a warning appears and you can no longer use the
Phoenix software. For more information, see The warning message Use of
this control has expired appears on page 259.

Touch Screen Calibration: Launches the touch screen calibration utility for tuning screen response.

General CNC troubleshooting

When you push the power button, the CNC does not power ON

Possible causes
 The external power supply or power cord are not connected to the CNC or power source.
 The external power supply is underrated.
 The external power supply connector is not compatible with the connector on the CNC.
 The terminal block is loose.
 The wall circuit breaker is not active.
 The power button and harness are defective.

Suggested actions
 Make sure that the external power supply and power cord are connected to the CNC and a
power source.
 Use the external power supply that comes with the CNC.
 Make sure that the terminal block is tightly in the connector on the embedded-CNC and the
wires are tight.
 Make sure that the wall circuit breaker is active.
 Remove all USB devices and USB cables inside and outside the CNC, such as:
 USB extension cables
 USB cable to the monitor
 USB hard drives
 USB memory sticks
 USB hubs
 Any other USB extension cables and devices
Then turn off the CNC, and turn it on again. Install one USB device and cable at a time until
you determine the cause of the problem.

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14 Troubleshooting and Diagnostics

 EDGE Connect TC only: Make sure that all of the power LEDs are ON on the PCB inside of
the CNC. See LEDs and test points for EDGE Connect TC on page 211.
 EDGE Connect TC only: Push the auxiliary power button on the PCB in the CNC. See
Figure 33 on page 212. If the CNC starts, replace the power button and harness.
 EDGE Connect TC only: The power distribution or operator console PCB in the CNC is
defective.

The power button is illuminated, but the touchscreen or monitor is black

Possible causes
 The DVI or HDMI cable is not connected to the embedded-CNC or touchscreen or monitor.
 Power is not connected to the touchscreen or monitor.
 The touchscreen or monitor is OFF.
 The touchscreen or monitor is in sleep mode.
 The power harness is defective. (EDGE Connect TC only)
 The power cord to your monitor is defective. (EDGE Connect only)
 The ambient temperature is out of the acceptable range.

Suggested actions
 Make sure that the DVI or HDMI cable is connected to the touchscreen or monitor and the
embedded-CNC.
 Make sure that power is connected to the touchscreen or monitor.
 Make sure that the touchscreen or monitor is ON.

 For EDGE Connect TC, use the OSD remote control to make sure that
the touchscreen is ON.

 Disconnect and reconnect power to the touchscreen or monitor to see if it comes out of
sleep mode.
 Replace the DVI or HDMI cable.
 Replace the power harness. (EDGE Connect TC only)
 Replace the power cord to your monitor. (EDGE Connect only)
 Make sure that the ambient temperature is within the acceptable range. See Environmental
requirements on page 30.

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 Troubleshooting and Diagnostics 14
The warning message The display settings for this system are not at the optimal values appears

Possible causes
 A screen resolution and aspect ratio that makes Phoenix and the Soft Op Con fully visible
on the screen is required. This warning message means that the monitor’s current display
settings do not meet this requirement.

Suggested actions
 See Table 1 on page 32 for a list of required display settings.
 To check the display settings that the monitor can support, see the instructions on
page 33.
 If the monitor can support the requirements, choose Yes. For more instructions, see
page 33.

 If you choose No, Phoenix keeps the current display settings and does not
show this warning message again.

 For more troubleshooting information for display issues, see page 34.

The monitor displays a burn-in, ghost, or dim outline of a previously displayed image

Possible cause

The CNC was turned ON when not in use. Monitors retain charge in their LCD crystals when power
has been ON for long periods of time.

Suggested action
 Turn OFF the CNC when not in use.

Previously mapped local network drives do not show when you try to load a part

Possible causes
 You don’t have a network connection. See Connect to a local area network with wireless or
Ethernet on page 191.
 The network drives are not mapped or are not a valid location. See Map a drive on
page 194.
 You restored from an image that did not have mapped network drives.

Suggested actions
 Connect to a local network in Windows. See Connect to a local area network with wireless
or Ethernet on page 191.
 Try to open the mapped network drive through the file explorer in Windows.
 Map the drives. See Map a drive on page 194.
 Contact your local network administrator.

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14 Troubleshooting and Diagnostics

You cannot download part programs over the local network (LAN or wireless)

Possible causes
 You don’t have a network connection.
 You do not have the correct file location address mapped.
 You are trying to load part programs that are not supported.
 You do not have the file extension in the Special Setups screen in Phoenix.
 Your mapped location includes sub folders, and the part program is not in the root folder.

Suggested actions
 Connect to a network in Windows.
 Contact your local network administrator.
 Make sure that the correct file location address is mapped.
 Make sure that the part programs you are trying to load are supported.
 Make sure that you include the correct file extensions in the Special Setups screen in
Phoenix. (Examples: CNC, DXF)
 Make sure that the mapped location for part programs is the root folder.

The CNC does not recognize a USB device

Possible causes
 The USB device is defective.
 The USB cable inside of the metal enclosure is disconnected from the embedded-CNC.
 The load from location is incorrect in Phoenix.
 Phoenix is slow to recognize the USB device.
 The USB connector on the CNC is defective.

Suggested actions
 Make sure that the USB device operates correctly in another computer.
 Make sure that the USB cable is connected to the embedded-CNC.
 Make sure that you select the correct load from location in Phoenix.
 Try the USB device in the embedded-CNC. See EDGE Connect connector locations on
page 41 for USB connector locations.
 If the device can be seen in Windows, make sure that you wait for Phoenix to load
completely before you plug in the USB device.
 Replace the defective USB connector or use a different USB device.

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 Troubleshooting and Diagnostics 14

Test the PC board and connectors

LEDs and test points for EDGE Connect TC

The following LEDs illuminate as soon as 12 VDC is applied to the CNC. It is not necessary to push
the power button.
 D1
 D2
 D3
 D6
 5V( 1 in Figure 33 on page 212)

The RUN LED stays OFF when you apply power to the CNC. When you push the power button on
the CNC, the RUN LED blinks for a few seconds, and then remains illuminated when the field-bus
has been established.

If none of the LEDs are on, make sure that the external power supply is working. Disconnect the
cable from the CNC and look for 12 VDC on the power supply connector.

Alternatively you can measure the voltages between the test points. See Table 3 on page 212.

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14 Troubleshooting and Diagnostics

Figure 33 – EDGE Connect TC PCB LEDs

5V
2

RUN
IN
OUT

EXT. 12V 12V 3.3V +5V

D1 D2 D3 D6

TP3 TP1 TP2 TP4TP5

POWER 12V OUT OP PANEL JOYSTICK SPEED POTS

ON/OFF

1 +5 VDC D6 +5 VDC
2 Run J1 Power
SW1 Auxiliary power button J2 12 VDC out (0.7 A maximum)
D1 External 12 VDC J6 Operator panel joystick
D2 12 VDC J5 Speed potentiometers
D3 3.3 VDC J3 On/off

Table 3 – Test points

Test points Voltage

TP1 (+) to TP4 (-) 12 VDC

TP5 (+) to TP4 (-) 5 VDC

TP2 (+) to TP4 (-) 3.3 VDC

TP3 (+) to TP4 (-) 12 VDC

J2-1 (+) to J2-2 (-) 12 VDC

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 Troubleshooting and Diagnostics 14
Test the USB, EtherCAT, and LAN connectors and hardware operator console

 Anything that is not connected will fail the test even if the connector on
the CNC is functional.

1. Install USB memory sticks in all open connectors.

 Disconnect all USB hubs. Install single USB memory sticks only.

2. Make sure that an EtherCAT slave or the EtherCAT test PCB is connected.

3. Make sure that the LAN cable is connected to a wireless network.

4. Make sure that the wireless LAN is connected.

5. Choose Setups > Passwords.

6. Enter the TESTHARDWARE password.

7. Follow the instructions on the screen.

 For the hardware operator console test, you have 10 seconds to respond
before the test times out.

Hardware operator console for EDGE Connect TC only

If any of the hardware operator console tests fail:

 Make sure that the I/O for the hardware operator console is set up correctly in Phoenix. See
I/O – Inputs and Outputs on page 119.
 Replace the component or wire harness that is defective. See Operator console parts on
page 335.

Log data with the oscilloscope

You can use the oscilloscope to log I/O, servo output voltage to the drive amplifiers, analog inputs,
and drive status while the CNC is operating. The grid represents the time rate in which the function
is recording data.

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14 Troubleshooting and Diagnostics

You can set up the oscilloscope to help you understand an issue with an input or output or to log a
function and then provide a visual representation of the log file.

To create an oscilloscope log:

1. Go to Setups > Diagnostics > Oscilloscope.

2. Double-click an item in the boxes on the left of the screen to add it to the oscilloscope grid. You
can add up to 8 items.

3. To remove an item from the grid, double-click it in the appropriate box.

4. In the Start list, select when you want the oscilloscope to begin recording.

5. In the Stop list, select when you want the oscilloscope to end recording.

6. In the Rate list, select the intervals at which the oscilloscope should record the data you
selected.

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 Troubleshooting and Diagnostics 14
Save an oscilloscope file

When you are finished with a test, you can save the log file so you can use it later.

If you have created a function that starts to record at the beginning of a part program and ends at
the last cut off, the file will be overwritten when the next part program is started. Be sure to save the
file before you execute the next nest.

To save the log file:

1. Choose the Save soft key.

2. Select the device where you want to save the file from the Save file to drop-down list.

3. Enter a name for the file in the File name field.

4. Choose OK.

Load an oscilloscope file

After you have saved an oscilloscope file, you can reload it and play it back on the CNC. This is the
only way you can view this type of file.

In addition, Hypertherm Technical Service can develop a customized log file for your operation, save
it, and email it to you. You can load this customized file onto your CNC, and execute the function.

To load an oscilloscope log file:

1. Choose Load on the oscilloscope screen.

2. Select a device from the Load file from list.

3. Enter the name of the file you want to load in the File name field.

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14 Troubleshooting and Diagnostics

4. Choose OK.

View an oscilloscope file

After you create and save a log file, you can replay it for diagnostics and troubleshooting.

To play an oscilloscope log file:

1. Load the file. See Load an oscilloscope file.

2. Use the soft keys at the bottom of the screen to control the file.
 Choose Play to start the file.
 Choose Stop to end the file.
 Choose Pause to stop the file temporarily.
 Choose Fast Forward to speed up the file.

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 Troubleshooting and Diagnostics 14

HPRXD plasma power supply troubleshooting

HPR error help

For help troubleshooting an HPR error message, see Tool dialog box messages on page 226.

HPR information screens

After communication has been established between the plasma power supply and the CNC, I/O
and remote diagnostics screens are accessible through the Diagnostics screen. You can view
status for the plasma power supply software revision, gas pressure, usage, I/O, and remote tools.
The screen below shows the information screens for an HPR system.

Test Preflow: Tests the preflow gases at the plasma power supply. This feature sets the inlet gas
pressures under normal flow conditions to the recommended level.

Test Cutflow: Tests the cutflow gases at the plasma power supply. This feature sets the inlet gas
pressures under normal flow conditions to the recommended level.

Test Gas Console: Performs automated tests for the AutoGas console. Contact an authorized
service agent for use of these tests.

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14 Troubleshooting and Diagnostics

Coolant Override: Overrides a coolant error and tests the coolant pump. This is useful for
bypassing the error and purging air bubbles from the coolant line when power is turned ON.

Inputs: Displays inputs to the plasma power supply or gas console.

Outputs: Displays the current status of the outputs from the plasma power supply or gas console,
but the outputs can’t be activated in this screen. The Machine Setups password is required to
access the Outputs screens.

Bypass an HPRXD on the EtherCAT network

When you turn ON the CNC, Phoenix opens and then starts the EtherCAT network. The EtherCAT
network becomes operational once network communications are established among all of the slave
devices defined in your network configuration. Your HPRXD plasma power supply is a slave device
on the network. If you turn OFF the HPRXD, network communications will fail and Phoenix will show
a field bus fault until you turn ON the HPRXD again.

 Restarting the CNC will generate an EtherCAT communications error on

the slave devices on the network. When the CNC starts again a
communication fault message will be displayed until the field bus is
manually started and can establish communication with the devices on
the network.

If you need to keep an HPRXD plasma power supply turned OFF temporarily (for example, for
maintenance), you can temporarily remove the HPRXD from the EtherCAT network configuration.
Removing an HPRXD from the network configuration, known as bypassing an HPRXD, lets you
continue to use the cutting system without field bus faults.

 To bypass an HPRXD, you use the inline EtherCAT cable connector

(208366) and bulkhead connector covers (108866) included in the
HPRXD interface EtherCAT adapter kits (428489 and 428447). For more
information, see the HPR130XD®, HPR260XD®, and HPR400XD®
EtherCAT® and VDC3 Board Installation Field Service Bulletin (809260).

 Only one HPRXD can be removed from the network at a time. If you need
to remove more than one HPRXD, contact your cutting system
manufacturer. Your network will need to be reconfigured without these
HPRXDs, and then reconfigured again when you are ready to put the
HPRXDs back on the network. For more information, see Configure the
EtherCAT Network on page 89.

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 Troubleshooting and Diagnostics 14
Bypass the HPRXD in a single-HPRXD cutting system

 These instructions are also applicable if you have multiple HPRXDs and
the HPRXD you want to bypass is the last HPRXD in physical order on
the network. See Figure 34. To the EtherCAT network, they are the same.

Figure 34

IN
OUT
Single-HPRXD
system

Last HPRXD in a
HPR1 HPR2 HPR3 multiple-HPRXD
system

IN IN IN
OUT OUT OUT

1. Turn OFF the CNC.

2. Turn OFF main power to the HPRXD.

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14 Troubleshooting and Diagnostics

3. Turn ON the CNC.

After Phoenix opens, it begins to start the EtherCAT network. Then the following message
appears.

 The message shows the HPRXD you are bypassing. In this example, it is
HPR1.

4. Choose Yes.
Phoenix removes the HPRXD from the network configuration and starts the EtherCAT network.

 If you restart the CNC while the HPRXD is bypassed, you will need to
respond to the Take HPR# Out for Service? message again. Choose
Yes.

Put the HPRXD back on the network in a single-HPRXD cutting system

 These instructions are also applicable if you have multiple HPRXDs and
the HPRXD you want to put back is the last HPRXD in physical order on
the network. See Figure 34 on page 219.

1. Turn OFF the CNC.

2. Turn ON main power to the bypassed HPRXD.

3. Turn ON the CNC.

Phoenix adds the HPRXD to the network configuration and starts the EtherCAT network.

Bypass an HPRXD in a multiple-HPRXD cutting system

 If the HPRXD you want to bypass is the last HPRXD in physical order on
the network (see Figure 34 on page 219), follow the instructions for a
single-HPRXD cutting system instead. For more information, see Bypass
the HPRXD in a single-HPRXD cutting system on page 219.

1. Turn OFF the CNC.

2. Turn OFF main power to the HPRXD you want to bypass.

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 Troubleshooting and Diagnostics 14
3. Make sure that the bulkhead EtherCAT cable connectors on the rear panel of the HPRXD you
want to bypass are clearly labeled. The top connector is IN and the bottom connector is OUT
(when installed as instructed). See Figure 35.

Figure 35

HPR1 HPR2 HPR3

IN 5 IN IN
OUT OUT OUT

6 8

4. Remove the inline EtherCAT cable connector (208366) from the rear panel of the HPRXD.

 Keep the two cable ties (343005).

5. Disconnect the IN EtherCAT cable from the HPRXD you want to bypass. See Figure 35.

6. Connect the IN EtherCAT cable to one end of the inline EtherCAT cable connector.

7. Disconnect the OUT EtherCAT cable from the HPRXD you want to bypass.

8. Connect the OUT EtherCAT cable to the other end of the inline EtherCAT cable connector.

9. Put a bulkhead connector cover (108866) on each of the bulkhead EtherCAT cable connectors
to keep metal dust and other material out of the connectors.

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10. Turn ON the CNC.

After Phoenix opens, it begins to start the EtherCAT network. Then the following message
appears.

 The message shows the HPRXD from which you disconnected the
EtherCAT cables. In this example, it is HPR2.

11. Choose Yes.

Phoenix removes the HPRXD from the network configuration and starts the EtherCAT network.

 If you restart the CNC while this HPRXD is bypassed, you will need to
respond to the Take HPR# Out for Service? message again.
Choose Yes.

Put an HPRXD back on the network in a multiple-HPRXD cutting system

 If the HPRXD you want to put back is the last HPRXD in physical order
on the network (see Figure 34 on page 219), follow the instructions for a
single-HPRXD cutting system instead. For more information, see Put the
HPRXD back on the network in a single-HPRXD cutting system on
page 220.

1. Turn OFF the CNC.

2. Remove the bulkhead connector covers from the bulkhead EtherCAT cable connectors on the
rear panel of the HPRXD.

 Keep them for future use.

3. Disconnect the IN EtherCAT cable from the inline EtherCAT cable connector. See Figure 36 on
page 223.

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 Troubleshooting and Diagnostics 14
Figure 36

HPR1 HPR2 HPR3

IN 4 IN IN
OUT OUT OUT
6

3 5

4. Connect the IN EtherCAT cable to the IN bulkhead EtherCAT cable connector on the rear panel
of the HPRXD.

5. Disconnect the OUT EtherCAT cable from the inline EtherCAT cable connector.

6. Connect the OUT EtherCAT cable to the OUT bulkhead EtherCAT cable connector on the rear
panel of the HPRXD.

 Attach the inline EtherCAT cable connector (208366) to the rear panel of
the plasma power supply again, using the two cable ties (343005) you
kept earlier.

7. Turn ON main power to the HPRXD.

8. Turn ON the CNC.

Phoenix adds the HPRXD to the network configuration and starts the EtherCAT network.

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14 Troubleshooting and Diagnostics

Status messages

Status messages appear in blue text within the status area below the part preview on the Main
screen. See Figure 37 on page 225. Status messages appear in order of priority to indicate the
current sequence of events on the cutting system.

Plasma cut sequence status messages

These messages appear after you start a part program, and tell you the current status of the cut
sequence. Many of the messages are informational, but some messages identify an error and
require you to take action.

Occurs during a part If the program

Status Message Description
program... pauses...

Traversing The torch is moving to the After Cycle Start and after Take no action.
next pierce point. each cut.

Lowering torch The torch is lowering at the At execution of Cut On • Press Stop, then Start.
pierce point and the Torch (M07). The status message • If the message persists,
Down output is activated. remains until the IHS is check for a fault input
complete. such as Torch Collision,
Fast Stop, Drive
Disable, or Remote
Pause. Set up I/O in
the Watch Window to
view these I/O while
the part program runs.

Waiting for Arc On The CNC is waiting for the After IHS is complete. • Add the Cut Sense
Cut Sense input. Cut input to a Watch
Sense is the Arc Transfer Window.
output from the plasma • Test the Cut Sense
power supply or the Motion input at the CNC to
output from the THC. make sure that it is
working.

Piercing The Pierce Control output During pierce. Take no action.

is active.

Creeping Creep Motion is occurring, After the Pierce timer Take no action.
after the pierce delay. expires, and indicates the
beginning of motion codes.

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Occurs during a part If the program

Status Message Description
program... pauses...

Cutting Torch is cutting and motion Execution of the motion. No action

is occurring.

Cut Sense Lost The arc was lost while The status message • The arc lost electrical
cutting. appears if a cut sense lost connection to the
occurs during program workpiece while
execution (after an M07) or cutting.
before executing the next • For suggested actions,
M08. see Cut Sense Lost on
page 232.

Raising Torch Torch has reached the end Occurs at the execution of No action
of the cut and starts Cut Off (M08).
retracting from the
workpiece.

Stop Delay Motion is delayed before The status message No action

the torch’s rapid traverse to appears after the torch has
the next pierce point. reached its retract position.

Tool status messages

Like the plasma cut sequence, a tool’s state can also appear in the status area. Since only one
status message can display at once, any errors that cause the tool to stop cutting have the
highest priority to appear in the status area. See Figure 37.

Figure 37 – Example of a tool error status message

Status message

To learn more about errors, see Dialog box messages: pauses, faults, and errors on page 226.

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14 Troubleshooting and Diagnostics

Dialog box messages: pauses, faults, and errors

A dialog box displays on the CNC screen when the cutting system is not operating correctly. Faults
and errors cause the arc to go out and cutting motion to pause. This prevents damage to the cutting
system, unsatisfactory cut quality, or a decline in productivity.

Dialog box messages look different depending on whether they are generated by the CNC or by an
external tool.

Tool dialog box messages

If the top left corner of the dialog box message on the CNC screen shows the name of an active
external tool (such as HPR, XPR, Powermax, etc.), then that tool is not operating correctly.

Indicates that the

message is from
a tool (HPR)

Tool error dialog box example

An example of a tool dialog box message is shown in Figure 38.

Figure 38 – Example of a tool error dialog box

Tool name and Tool and

error number station number Error summary

Closes the dialog box Shows the tool’s instruction

manual for troubleshooting
steps

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 Troubleshooting and Diagnostics 14
Troubleshooting tool errors

1. See the tool and error number in the top left corner of the tool error dialog box. See Figure 38
on page 226.

2. Choose the tool’s instruction manual button to view troubleshooting information. See Figure 38
on page 226.

 If the tool was not manufactured by Hypertherm, refer to the

troubleshooting guide provided by the tool’s manufacturer.

3. Follow the troubleshooting steps for the error number from step 1.

4. Close the instruction manual screen.

5. Choose OK to close the dialog box.

CNC pauses, faults, and errors

Dialog box messages for CNC pauses, faults, and errors have EDGE Connect or CNC in the top
left corner.
Indicates that the
message is from the
CNC

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14 Troubleshooting and Diagnostics

Troubleshooting CNC pauses, faults, and errors

CNC pauses, faults, and errors pause cutting motion for different reasons and have different effects.
For help troubleshooting CNC dialog box error messages, see Table 4 on page 228.

Table 4 – Differences between CNC pauses, faults, and errors

Pauses CNC faults CNC errors

Example See Figure 39 on page 229. See Figure 40 on page 229. See Figure 41 on page 230.

Cause • A problem occurred • A problem requires • A critical problem requires

during cutting or marking, resolution to prevent immediate resolution to
but no critical errors are damage to the cutting prevent damage to the
present. system, unsatisfactory cut cutting system,
• Cause is summarized on quality, or a decline in unsatisfactory cut quality,
the dialog box. productivity. or a decline in productivity.
• Cause is summarized on • Cause is summarized on
the dialog box. the dialog box.

Effects on • Motion decelerates to a • Motion decelerates to a • Motion decelerates to an

motion stop at a normal rate. stop at a fast or normal urgent stop prior to the
and part • The CNC maintains the rate. CNC disabling the drive.
programs current position and the • The CNC maintains the The part program is
part program pauses. current position. canceled.
• Motion and program • Motion and program • The CNC clears the
execution can continue execution cannot current position of all axes.
without action, but the continue until the fault is Homing may be required
fault could occur again if resolved. after clearing the error.
it is not fully resolved. • Motion and program
execution cannot
continue until the error is
resolved.

Resolution • Follow the instructions on • For troubleshooting steps, • For troubleshooting steps,
the Reason Paused dialog see CNC fault message see CNC error message
box. reference on page 231. reference on page 238.
• Choose OK to close the • Choose OK to close the • To clear the error with
dialog box message. dialog box message. manual motion, choose
Manual on the dialog box.
• To resolve a possible
setup issue, choose
Setups on the dialog box.

Next steps If the problem has been After the fault is cleared, Recover the part program by
resolved without canceling the choose Cycle Start again to choosing Resume Last Part
part program, choose Cycle resume cutting or marking. on the Main > Files screen.
Start again to resume cutting
or marking.

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CNC dialog box message examples

Figure 39 – Example of a pause dialog box

CNC name only Reason for the pause: “PS Link Failed” shows that Phoenix cannot communicate with
(no error number) the plasma power supply

Troubleshooting instructions Closes the dialog box

Figure 40 – Example of a fault dialog box

CNC name only (no error number)

CNC fault summary (varies)

Closes the dialog box

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14 Troubleshooting and Diagnostics

Figure 41 – Example of a CNC error dialog box

CNC error number CNC error summary

Opens the Setups screen to let you resolve Lets you do manual motion to clear Opens the Error Message section
a possible setups issue the fault in the online Help

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 Troubleshooting and Diagnostics 14

CNC fault message reference

 For all faults that result from input logic, refer to the Diagnostics Inputs
screen for the location of the input and to make sure that the input is
working correctly.

Fast Stop Active

This input is typically a Normally Closed input.

Possible causes
 An E-stop on the cutting table is depressed.
 The servo amplifiers are not turned ON.
 There is a faulty cable or electrical connection between the Fast Stop input to the drive or
I/O module and the device that activates the input.

Suggested actions
 Check the external device that turns on the Fast Stop input.
 Check the cables and wiring between the Fast Stop input and the drive or I/O module.
 If this is a new installation, check the logic of this input in the I/O setup screen. The logic
should match the logic of the device that activates the input (Normally Closed or Normally
Open).

HPR Fault

The HPRXD reports errors to the CNC by sending a message over the EtherCAT network. Then the
CNC prompts you with a dialog box message or a status message. These messages include an
HPR Manual soft key so you can open the Help screen and view the troubleshooting information in
the HPR instruction manual.

Possible cause
 The HPR has a fault and is reporting an error message to the CNC.

Suggested actions
 HPR errors are stored and displayed in the following areas of Phoenix:
 Within the HPR Watch Window or within the HPR Diagnostic screen, the parameter is
listed as Last Err (Last Error).
 In the System Errors Watch window.

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Cut Gas Lost

Possible causes
 The cut gas pressure dropped while cutting.
 There is a low pressure regulator setting.
 The cut gas source is low or empty.
 There is a gas leak or restriction in one of the gas lines.
 There is a faulty solenoid valve.

Suggested actions
 Check the pressure regulator setting while purging the cut gas.
 Check the volume in the cut gas supply.
 Check for loose or damaged gas lines.
 Make sure that the cut gas can flow through the torch when doing a test cut flow.

Cut Sense Lost

The arc lost electrical connection to the workpiece while cutting and before the execution of the
M08 (or the end of the lead-out).

Possible causes
 The CNC part program has an excessive lead-out length.
 One or more cut sense inputs turned off while cutting and the Arc Off time expired before a
cut sense input could turn on.

 For multiple torch applications, a Cut Sense Lost message only shows
when a single torch loses its arc if the Stop On Single Arc Lost setting is
enabled. If the Stop On Single Arc Lost is disabled, the program will
continue to cut without showing a Cut Sense Lost message until all
plasma torches lose their arcs while cutting.

Suggested actions
 Correct the conditions that caused the arc to lose electrical connection to the workpiece.
 Use the computer-aided manufacturing (CAM) software to decrease the lead-out length
and generate a new program.
 If these actions do not resolve the issue, consider increasing the Arc Off time in the Process
screen.

 Increasing Arc Off time can decrease consumable life. The maximum Arc
Off time is 2 seconds.

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Invalid Process Requested in Part Program

Possible causes
 The CNC part program has a cutting process (M36) or station code (M37) that Phoenix
does not recognize.
 The CNC part program is calling a process variable value in the cut chart that does not exist.
Examples include:
 Material Thickness
 Plasma/Shield Gases
 Process Current
 A programming code is disabled in the Cutting setup screen. Examples include:
 G59 Process codes
 M07 HS/M08 RT
 Process Select (M36)
 Station Select (M37)

Suggested actions
 Make sure that the station is in Program mode in the Soft Op Con.
 Make sure that the Station Configuration screen is correctly configured for your cutting
system.
 Update Phoenix and cut charts.
 If the CNC part program includes G59 V5xx Fvalue process override codes, make sure that
the parameters match the values in the cut chart.
 Material Thickness
 Torch Type
 Plasma/Shield Gas Type
 Cutting Current
 Make sure that these parameters exist in the Plasma/Marker Cut Charts. If one of these
values does not exist in the cut chart, create a custom cut chart to resolve the problem.
 Make sure that the correct parameters are enabled and/or disabled within the Program
Code section in the Cutting screen.
 Contact your table manufacturer if you are not sure which codes should be enabled or
disabled.

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14 Troubleshooting and Diagnostics

Remote Pause Active

Remote Pause is typically a Normally Closed input.

Possible causes
 The Remote Pause input has been activated by an external device.
 There is a faulty cable or electrical connection between the Remote Pause input and the
drive or I/O module.

Suggested actions
 Check the external device that turns on the Remote Pause input.
 Check cables and wiring between the Remote Pause input and the drive or I/O module.
 If this is a new installation, check the logic of this input in the I/O setup screen. The logic
should match the logic of the device that activates the input (Normally Closed or Normally
Open).

Safety Mat Active

This input is typically a Normally Closed input.

Possible causes
 The light curtain or safety mat or some other type of external device that activates when a
person is within a restricted area around the cutting table was activated.
 There is a faulty cable or electrical connection between the Safety Mat input and the drive or
I/O module.

Suggested actions
 Check the external device that turns on the Safety Mat input.
 Check the cables and wiring between the Safety Mat input and the drive or I/O module.
 If this is a new installation, check the logic of this input in the I/O setup screen. The logic
should match the logic of the device that activates the input (Normally Closed or Normally
Open).

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Software Limit Active

Possible cause
 Motion in either the Rail or Transverse (or both) axes has reached either the Maximum or
Minimum Travel Limit.

Suggested actions
 Motion is only allowed in the opposite direction of the limit that is active (Transverse or Rail).
 If both software limits are active concurrently, motion is allowed from the axis that reached
the limit last. For instance, motion results in both the Rail and Transverse software limits to
be active. If the Rail limit was reached after the Transverse limit, then motion will only occur
in the opposite direction of the Rail axis first.
 If problem persists, check the Minimum and Maximum Travel Limit settings in the Axis setup
screen.

Torch Collision

Active Torch Collision is typically a Normally Closed input.

Possible causes
 The torch collided with the plate and activated a momentary or sustained Torch Collision
input.
 There is a faulty cable or electrical connection between the Torch Collision input and the
drive or I/O module.

Suggested actions
 Raise the torch and reinstall the torch collision device used on the THC lifter.
 Check the torch collision device to make sure that the device is working correctly.
 If there is a magnetic breakaway, check the proximity switch to see if it switches on and off
when tripped manually.
 If there is a pneumatic breakaway, make sure that the switch is functioning correctly.
 Check the cables and wiring between the torch collision device and the drive or I/O module.
 If this is a new installation, check the logic of this input in the I/O setup screen. The logic
should match the logic of the device that activates the input (Normally Closed or Normally
Open).

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Field Bus Drives Not Ready

A field bus is sometimes referred to as a fieldbus or a network.

Possible cause
 The current drive status is not valid.

Suggested actions
 Look at the drive for any errors, then disable and re-enable the control in Phoenix to
reestablish communication.
 Remove power from all of the slaves on the network, then restore power to all of the slaves
and restart the network.

Take HPR# Out for Service?

Possible causes
 The EtherCAT cable to the HPRXD plasma power supply shown in the message is
disconnected or damaged.
 Main power to the HPRXD plasma power supply shown in the message is OFF.
 There is a problem with the EtherCAT plasma interface board inside the HPRXD.

Suggested actions

If you want to remove the HPRXD from the EtherCAT network, see Bypass an HPRXD on the
EtherCAT network on page 218.

If you do not want to remove the HPRXD from the EtherCAT network:
a. Choose No. Phoenix begins to start the EtherCAT network.
b. Choose Cancel to stop network start-up.
c. As necessary, reconnect or replace the EtherCAT cable. Or, turn ON main power to the
HPRXD.
d. On the Main screen in Phoenix, choose Manual. The following message appears.

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 Troubleshooting and Diagnostics 14
e. Choose Yes.
f. Phoenix starts the EtherCAT network.

 If the HPRXD error caused other errors, one or more error messages
appear before Phoenix finishes starting up the EtherCAT network. Click
Manual to close each message. Phoenix starts the EtherCAT network.

 If Phoenix continues to show the Take HPR# Out for Service? message,
the problem may be the EtherCAT plasma interface board. Contact your
cutting system manufacturer.

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14 Troubleshooting and Diagnostics

CNC error message reference

Error 1) Transverse position error

The position of the Transverse axis is behind the commanded position by more than the Servo Error
Tolerance value.

Possible causes
 The following error of the Transverse axis exceeded the Servo Error Tolerance value.
 There is a mechanical bind in the axis.
 The drive amplifier has produced a fault.
 If this is a new installation:
 The Servo Error Tolerance is set too low.
 The gains are set too low or too high in the drives.
 The Maximum Machine Speed is set too high.
 The Acceleration is set too high.
 There are other incorrect settings in the drive.

Suggested actions
 Correct the setting causing the error.
 Contact the drive manufacturer for further troubleshooting.

Error 2) Rail Position Error

The position of the Rail axis is behind the commanded position by more than the Servo Error
Tolerance value.

Possible cause
 Refer to the Transverse Position Error (Error 1) for information on possible causes.

Suggested action
 Refer to the Transverse Position Error (Error 1) for information on suggested actions.

Error 3) Dual Gantry Position Error

The position of the Dual Gantry axis is behind the commanded position by more than the Servo Error
Tolerance value.

Possible causes
 Refer to the Transverse Position Error (Error 1) for information on possible causes.

Suggested actions
 Refer to the Transverse Position Error (Error 1) for information on suggested actions.

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Error 4) Rotate Position Error

The position of the Rotate axis is behind the commanded position by more than the Servo Error
Tolerance value.

Possible cause
 Refer to the Transverse Position Error (Error 1) for information on possible causes.

Suggested action
 Refer to the Transverse Position Error (Error 1) for information on suggested actions.

Error 5) Tilt Position Error

The position of the Tilt axis is behind the commanded position by more than the Servo Error
Tolerance value.

Possible cause
 Refer to the Transverse Position Error (Error 1) for information on possible causes.

Suggested action
 Refer to the Transverse Position Error (Error 1) for information on suggested actions.

Error 6) CBH Position Error

The position of the CBH axis is behind the commanded position by more than the Servo Error
Tolerance value.

Possible cause
 Refer to the Transverse Position Error (Error 1) for information on possible causes.

Suggested action
 Refer to the Transverse Position Error (Error 1) for information on suggested actions.

Error 7) THC Position Error

The position of the THC axis is behind the commanded position by more than the Servo Error
Tolerance value.

Possible causes
 There is a mechanical bind in the lifter.
 The drive amplifier has produced a fault.
 In a Yaskawa drive, the Forward/Reverse External Torque Limit input is active all of the time.
 The Servo Error Tolerance, gain, or torque values are set too low.
 The Maximum Machine Speed, Acceleration, lifter speed, or stall force values are set too
high.

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14 Troubleshooting and Diagnostics

Suggested action
 Positive motion of the THC axis will lower the torch.

Error 8) Transverse Positive Hardware Overtravel

This input is typically a Normally Closed input. The Transverse Positive Hardware Overtravel switch
is named either +X Overtravel or +Y Overtravel. The switch is located on the far positive end of the
Transverse axis.

Possible causes
 The cutting station is engaging 1 of the 2 limit switches located along the Transverse axis.
 There is a faulty limit switch.
 There is a damaged cable or loose electrical connection between the limit switch and the
drive or I/O module.
 There is no DC voltage to the machine’s inputs.
 The drive or I/O module output is latched on.
 If this is a new installation, the logic of the overtravel inputs does not match the logic of the
actual limit switch (Normally Closed or Normally Open).

Suggested actions
 Jog the cutting station in the opposite direction to move off of the limit switch.
 Check the hardware limit switch on the gantry for damage and make sure that the switch is
functioning correctly.
 Test the limit switch inputs in the Diagnostics Inputs screen.
 Check the cables and wiring between the limit switch and the drive or I/O module.
 Make sure that the cutting table is turned ON.
 If this is a new installation:
 Check the logic of this input in the I/O setup screen. The logic should match the logic of
the device that activates the input (Normally Closed or Normally Open).
 Refer to the Diagnostics Inputs screen for the location of the Transverse Positive
Hardware Overtravel switch and to make sure that the input is working correctly.
 Make sure that Use Hardware Overtravels is set to Yes on the Transverse axis screen.

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Error 9) Rail Positive Hardware Overtravel

This input is typically a Normally Closed input. The Rail Positive Hardware Overtravel switch is
named either +X Overtravel or +Y Overtravel. The switch is located on the far positive end of the
Rail axis.

Possible causes
 The cutting station is engaging one of the two limit switches located along the Rail axis.
 There is a faulty limit switch.
 There is a damaged cable or loose electrical connection between the limit switch and the
drive or I/O module.
 There is no DC voltage to the machine’s inputs.
 There is a faulty input to the drive or I/O module.
 The drive or I/O module output is latched on.
 If this is a new installation, the logic of the overtravel inputs does not match the logic of the
actual limit switch (Normally Closed or Normally Open).

Suggested actions
 Jog the cutting station in the opposite direction to move off of the limit switch.
 Check the hardware limit switch on the gantry for damage and make sure that the switch is
functioning correctly. Test the limit switch inputs in the Diagnostics Inputs screen.
 Check the cables and wiring between the limit switch and the drive or I/O module.
 Make sure that the cutting table is turned ON.
 Make sure all cables are correctly installed at the drive or I/O module.
 If this is a new installation:
 Check the logic of this input in the I/O setup screen. The logic should match the logic of
the device that activates the input (Normally Closed or Normally Open).
 Refer to the Diagnostics Inputs screen for the location of the Rail Positive Hardware
Overtravel switch and to make sure that the input is working correctly.

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Error 13) Transverse Negative Hardware Overtravel

This input is typically a Normally Closed input.The Transverse Negative Hardware Overtravel switch
is named either -X Overtravel or -Y Overtravel. The switch is located on the far negative end of the
Transverse axis.

Possible causes
 The cutting station is engaging one of the two limit switches located along the Transverse
axis.
 There is a faulty limit switch.
 There is a damaged cable or loose electrical connection between the limit switch and the
drive or I/O module.
 There is no DC voltage to the machine’s inputs.
 There is a faulty input to the drive or I/O module.
 If this is a new installation, the logic of the overtravel inputs does not match the logic of the
actual limit switch (Normally Closed or Normally Open).

Suggested actions
 Jog the cutting station in the opposite direction to move off of the limit switch.
 Check the hardware limit switch on the gantry for damage and make sure that the switch is
functioning correctly. Test the limit switch inputs in the Diagnostics Inputs screen.
 Check the cables and wiring between the limit switch and the drive or I/O module.
 Make sure that the cutting table is turned ON.
 Make sure all cables are correctly installed at the drive or I/O module.
 If this is a new installation:
 Check the logic of this input in the I/O setup screen. The logic should match the logic of
the device that activates the input (Normally Closed or Normally Open).
 Refer to the Diagnostics Inputs screen for the location of the Transverse Negative
Hardware Overtravel switch and to make sure that the input is working correctly.

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Error 14) Rail Negative Hardware Overtravel

This input is typically a Normally Closed input. The Rail Negative Hardware Overtravel switch is
named either -X Overtravel or -Y Overtravel. The switch is located on the far negative end of the Rail
axis.

Possible causes
 The cutting station is engaging one of the two limit switches located along the Rail axis.
 There is a faulty limit switch.
 There is a damaged cable or loose electrical connection between the limit switch and the
drive or I/O module.
 There is no DC voltage to the machine’s inputs.
 There is a faulty input to the drive or I/O module.
 If this is a new installation, the logic of the overtravel inputs does not match the logic of the
actual limit switch (Normally Closed or Normally Open).

Suggested actions
 Jog the cutting station in the opposite direction to move off of the limit switch.
 Check the hardware limit switch on the gantry for damage and make sure that the switch is
functioning correctly.
 Test the limit switch inputs in the Diagnostics Inputs screen.
 Check the cables and wiring between the limit switch and the drive or I/O module.
 Make sure that the cutting table is turned ON.
 Make sure all cables are correctly installed at the drive or I/O module.
 If this is a new installation:
 Check the logic of this input in the I/O setup screen. The logic should match the logic of
the device that activates the input (Normally Closed or Normally Open).
 Refer to the Diagnostics Inputs screen for the location of the Rail Negative Hardware
Overtravel switch and to make sure that the input is working correctly.

Error 18) Transverse Positive Software Overtravel

Software overtravel minimum and maximum values are based on position from home and should
stop motion prior to engaging a hardware overtravel.

Possible causes
 Motion along the Transverse axis (positive direction) has reached the preset software limit.
 If this is a new installation, check the minimum, maximum, and fault settings in the Axis setup
screen.

Suggested action
 Jog the cutting station in the opposite direction to move off of the software limit.

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Error 19) Rail Positive Software Overtravel

Software overtravel minimum and maximum values are based on position from home and should
stop motion prior to engaging a hardware overtravel.

Possible causes
 Motion along the Rail axis (positive direction) has reached the preset software limit.
 If this is a new installation, check the minimum, maximum, and fault settings in the Axis setup
screen.

Suggested action
 Jog the cutting station in the opposite direction to move off of the software limit.

Error 23) Transverse Negative Software Overtravel

Software overtravel minimum and maximum values are based on position from home and should
stop motion prior to engaging a hardware overtravel.

Possible causes
 Motion along the Transverse axis (negative direction) has reached the preset software limit.
 If this is a new installation, check the minimum, maximum, and fault settings in the Axis setup
screen.

Suggested action
 Jog the cutting station in the opposite direction to move off of the software limit.

Error 24) Rail Negative Software Overtravel

Software overtravel minimum and maximum values are based on position from home and should
stop motion prior to engaging a hardware overtravel.

Possible causes
 Motion along the Rail axis (negative direction) has reached the preset software limit.
 If this is a new installation, check the minimum, maximum, and fault settings in the Axis setup
screen.

Suggested action
 Jog the cutting station in the opposite direction to move off of the software limit.

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Error 28) Tilt Positive Hardware Overtravel

This input is typically a Normally Closed input. The Tilt Positive Hardware Overtravel switch is named
Tilt + Overtravel. The switch is located on the far positive end of the Tilt axis.

Possible causes
 The cutting station is engaging one of the two limit switches located along the Tilt axis.
 There is a faulty limit switch.
 There is a damaged cable or loose electrical connection between the limit switch and the
drive or I/O module.
 There is no DC voltage to the machine’s inputs.
 There is a faulty input to the drive or I/O module.
 If this is a new installation, the logic of the overtravel inputs does not match the logic of the
actual limit switch (Normally Closed or Normally Open).

Suggested actions
 Jog the Tilt axis in the opposite direction to move off of the limit switch.
 Check the hardware limit switch on the bevel head for damage and make sure that the
switch is functioning correctly.
 Test the limit switch inputs in the Diagnostics Inputs screen.
 Check the cables and wiring between the limit switch and the drive or I/O module.
 Make sure that the cutting table is turned ON.
 Make sure all cables are correctly installed at the drive or I/O module.
 If this is a new installation:
 Check the logic of this input in the I/O setup screen. The logic should match the logic of
the device that activates the input (Normally Closed or Normally Open).
 Refer to the Diagnostics Inputs screen for the location of the Tilt Positive Hardware
Overtravel switch and to make sure that the input is working correctly.

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Error 29) Tilt Negative Hardware Overtravel

This input is typically a Normally Closed input. The Tilt Negative Hardware Overtravel switch is
named Tilt – Overtravel. The switch is located on the far negative end of the Tilt axis.

Possible causes
 The cutting station is engaging one of the two limit switches located along the Tilt axis.
 There is a faulty limit switch.
 There is a damaged cable or loose electrical connection between the limit switch and the
drive or I/O module.
 There is no DC voltage to the machine inputs.
 There is a faulty input to the drive or I/O module.
 If this is a new installation, the logic of the overtravel inputs does not match the logic of the
actual limit switch (Normally Closed or Normally Open).

Suggested actions
 Jog the Tilt axis in the opposite direction to move off of the limit switch.
 Check the hardware limit switch on the bevel head for damage and make sure that the
switch is functioning correctly.
 Test the limit switch inputs in the Diagnostics Inputs screen.
 Check the cables and wiring between the limit switch and the drive or I/O module.
 Make sure that the cutting table is turned ON.
 Make sure all cables are correctly installed at the drive or I/O module.
 If this is a new installation:
 Check the logic of this input in the I/O setup screen. The logic should match the logic of
the device that activates the input (Normally Closed or Normally Open).
 Refer to the Diagnostics Inputs screen for the location of the Tilt Positive Hardware
Overtravel switch and to make sure that the input is working correctly.

Error 30) Tilt Positive Software Overtravel

Software overtravel minimum and maximum values are based on position from home and should
stop motion prior to engaging a hardware overtravel.

Possible cause
 Motion along the Tilt axis (positive direction) has reached the preset software limit.

Suggested actions
 Jog the cutting station in the opposite direction to move off of the software limit.
 If this is a new installation, check the minimum, maximum, and fault settings in the Axis setup
screen.

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Error 31) Tilt Negative Software Overtravel

Software overtravel minimum and maximum values are based on position from home and should
stop motion prior to engaging a hardware overtravel.

Possible cause
 Motion along the Tilt axis (negative direction) has reached the preset software limit.

Suggested actions
 Jog the cutting station in the opposite direction to move off of the software limit.
 If this is a new installation, check the minimum, maximum, and fault settings in the Axis setup
screen.

Error 34) Rotate Positive Software Overtravel

Software overtravel minimum and maximum values are based on position from home and should
stop motion prior to engaging a hardware overtravel.

Possible cause
 Motion along the Rotate axis (positive direction) has reached the preset software limit.

Suggested actions
 Jog the cutting station in the opposite direction to move off of the software limit.
 If this is a new installation, check the minimum, maximum, and fault settings in the Axis setup
screen.

Error 35) Rotate Negative Software Overtravel

Software overtravel minimum and maximum values are based on position from home and should
stop motion prior to engaging a hardware overtravel.

Possible cause
 Motion along the Rotate axis (negative direction) has reached the preset software limit.

Suggested actions
 Jog the cutting station in the opposite direction to move off of the software limit.
 If this is a new installation, check the minimum, maximum, and fault settings in the Axis setup
screen.

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Error 36) Dual Gantry Skew Error

A Dual Gantry Skew can occur after homing the Rail/Dual Gantry.

Possible causes
 The Dual Gantry skew has exceeded the Dual Gantry Skew Limit.
 There is a mechanical bind in the axis.
 The Dual Gantry switch offset has changed or was set incorrectly.
 If this is a new installation:
 The skew limit is set too low.
 Check the switch offset.

Suggested actions
 Make sure that the gantry is square and that there are no mechanical binds on the Rail and
Dual Gantry axes.
 Check the Dual Gantry and Rail home switches for damage or a loose engagement block.
 Make sure that the switch offset setting is correct.
 Check the skew limit setting.
 The skew limit should be some value higher than the following error while homing and not
high enough to cause mechanical damage.

Error 37) Collision Fault

The Collision input is typically Normally Closed.

Possible causes
 The Collision Fault input is activated.
 The Collision Fault device is damaged.
 There is a faulty cable or electrical connection between the Collision input to the drive or I/O
module and the device that activates the input.

Suggested actions
 Clear the error and resume cutting.
 Check the collision fault device to make sure that the device is working correctly.
 Check the cables and wiring between the collision fault device and the drive or I/O module.
 If this is a new installation, check the logic of this input in the I/O setup screen. The logic
should match the logic of the device that activates the input (Normally Closed or Normally
Open).
 Refer to the Diagnostics Inputs screen for the location of the Torch Collision input and to
make sure that the input is working correctly.

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Error 38) Excessive Mechanical Skew

The difference in position between the Rail and the Dual Gantry was greater than 2 inches when the
CNC was turned ON.

Possible causes
 The position of the Dual Gantry axis changed prior to starting the CNC.
 There is a mechanical bind in the axis.
 The Dual Gantry or the Rail pinion gears were removed from the rack and then rotated prior
to engaging the pinion gear back into the rack.

Suggested actions
 Make sure that the gantry is square.
 Check the gantry for mechanical binds.
 If the pinion gears were disengaged from the drive rack when the CNC was turned OFF:
 Start the CNC with the pinion gears still disengaged. If there is excessive difference in
position, the Rail will rotate to equalize position.
 Turn OFF the cutting machine and then re-engage the pinion gears. This will prevent this
fault from occurring.
 If the Dual Gantry position changed, turn OFF the cutting machine, disengage the pinion
gear, and rotate the pinion until the Dual Gantry position matches the Rail position.

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Error 41) Dual Head Collision Fault

Torch Collision is typically a Normally Closed input.

Possible causes
 The two cutting stations were jogged too close to each other and this activated the Dual
Head Collision Fault switch.
 There is a faulty switch.
 There is a faulty cable or electrical connection between the Dual Head Collision Fault input
to the drive or I/O module and the device that activates the input.
 There is a faulty input on the drive or I/O module.

Suggested actions
 Park one of the stations and jog the other station to clear the fault.
 Check the Dual Head Collision Fault device to make sure that the device is working
correctly.
 Check the cables and wiring between the Dual Head Collision Fault device and the drive or
I/O module.
 If this is a new installation, check the logic of this input in the I/O setup screen. The logic
should match the logic of the device that activates the input (Normally Closed or Normally
Open).
 Refer to the Diagnostics Inputs screen for the location of the Torch Collision input and to
make sure that the input is working correctly.

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Error 42) Torch Collision

Torch Collision is typically a Normally Closed input.

Possible causes
 The torch collided with the plate and caused the Torch Collision input to activate, either
momentarily or sustained.
 There is a faulty cable or electrical connection between the Torch Collision input to the drive
or I/O module and the device that activates the input.
 If this is a new installation:
 Check the Torch Collision fault setting in the I/O setup screen.
 Fast Decel will result in a Fault.
 Fault Ramp will result in an Error.

Suggested actions
 Raise the torch and reseat the torch collision device used on the THC lifter.
 Check the torch collision device to make sure that the device is working correctly.
 If it is a magnetic breakaway, check the proximity switch to see if it activates on and off
when tripped manually.
 If it is a pneumatic breakaway, make sure that the switch is functioning correctly.
 Check the cables and wiring between the torch collision device and the drive or I/O module.
 If this is a new installation, check the logic of this input in the I/O setup screen. The logic
should match the logic of the device that activates the input (Normally Closed or Normally
Open).
 Refer to the Diagnostics Inputs screen for the location of the Torch Collision input and to
make sure that the input is working correctly.

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Error 44) Hardware Fault or Failure

This fault occurs when two or more opposing inputs are activated at the same time, for example,
Raise Torch 1, Lower Torch 1, Raise Torch 2, and Lower Torch 2 are all turned on at the same time,
or two opposing Joystick inputs are turned on at the same time (Left and Right or Up and Down).

Possible causes
 High-frequency noise is causing multiple jog inputs to suddenly turn on.
 A setup file is loaded that has inverted input logic for either the Raise/Lower Torch inputs or
the Joystick inputs.
 There is a faulty joystick.
 There is a faulty Raise or Lower Torch input.
 If this is a new installation:
 Check the logic of all jog inputs.
 Check the wiring of all jog inputs.

Suggested actions
 Restart the CNC to clear the fault. If the inputs were activated in error, the problem should
not re-occur.
 If the problem continues:
 Test the joystick hardware.
 If the joystick has a sticking or damaged switch, the hardware test will fail.
 To test the inputs, create a Watch Window, and assign the Op Con inputs for the
joystick (left and right, up and down) and the Op Con (raise and lower tool).
 Replace the joystick.

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Error 45) Dual Transverse Positive Hardware Overtravel

Possible cause
 In a Dual Transverse system, the second cutting station has engaged the hardware
overtravel switch on the gantry.

Suggested actions
 Jog the cutting station in the opposite direction to move off of the limit switch.
 Check the hardware limit switch on the gantry for damage and make sure that the switch is
functioning correctly.
 Test the limit switch inputs in the Diagnostics Inputs screen.
 Check the cables and wiring between the limit switch and the drive or I/O module.
 Make sure that the cutting table is turned ON.
 Make sure all cables are correctly installed at the drive or I/O module.
 If this is a new installation, check the logic of this input in the I/O setup screen. The logic
should match the logic of the device that activates the input (Normally Closed or Normally
Open).
 Refer to Diagnostics Inputs screen for the location of the Transverse Positive Hardware
Overtravel switch and to make sure that the input is working correctly.

Error 46) Dual Transverse Negative Software Overtravel

Possible cause
 In a Dual Transverse system, the second cutting station has reached the position of the
Minimum or Maximum Travel Limit set in the Transverse 2 axis screen.

Suggested action
 Jog the cutting station in the opposite direction to move off of the software limit.

Error 47) Dual Transverse Positive Software Overtravel

Possible cause
 In a Dual Transverse system, the second cutting station has reached the position of the
Minimum or Maximum Travel Limit set in the Transverse 2 axis screen.

Suggested action
 Jog the cutting station in the opposite direction to move off of the software limit.

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Error 48) Dual Transverse Negative Software Overtravel

Possible cause
 In a Dual Transverse system, the second cutting station has reached the position of the
Minimum Travel Limit set in the Transverse 2 axis screen.

Suggested action
 Jog the cutting station in the opposite direction to move off of the software limit.

Error 60) Field Bus Configuration Fault

This fault occurs when there is a problem with the EtherCAT network configuration (Phoenix.xml) file.
A field bus is sometimes referred to as a fieldbus or a network.

Possible causes
 There are incorrect or missing settings in a non-Hypertherm slave device's EtherCAT slave
information (ESI) file.
 There is an unsupported slave device on the EtherCAT network.
 Distributed clocks is set up incorrectly.

Suggested actions
 Create a new XML file. See Configure the EtherCAT Network on page 89.
 Contact the manufacturer of the non-Hypertherm slave device for a corrected ESI file.
 Replace the unsupported slave device with a supported slave device.
 Set up distributed clocks correctly. See Configure the EtherCAT Network on page 89.
 Create a new XML file. See Configure the EtherCAT Network on page 89.

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Error 61) Field Bus Device Fault

This fault occurs when there is an operational problem with a slave device that is active on the
EtherCAT network. The fault message shows the device with the problem. A field bus is sometimes
referred to as a fieldbus or a network.

 Phoenix can only report a Field Bus Device Fault if the device
communicates the error to Phoenix. Some devices may not be able to
communicate errors to Phoenix, or may be able to communicate some but
not all errors. If this is the case, you will need to check the drive itself.

 This fault is different from a Field Bus Slave Fault (error 64), which
indicates a network communications error rather than an operational error.

Possible cause
 These errors are device- and manufacturer-specific. See the documentation supplied by the
drive manufacturer for more information.

Suggested action
 Check the status of the drive. Then see the documentation supplied by the drive
manufacturer for more information.

Network diagnostic screen

The Network Diagnostic screen provides information about the CNC and devices on the EtherCAT
network. This information is read only and can be used for troubleshooting errors on the network or
communication problems with one of the devices.

To get to the Network Diagnostic screen from the Main screen select the following soft keys: Setups
> Diagnostics > Network Diagnostics. The Network Diagnostic screen is displayed in the upper
right corner of the screen.

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Error 62) Field Bus Network Fault

 Error 62 is broken down into 13 sub-categories (62-1 through 62-13)

This fault occurs when the EtherCAT network master (the CNC) has a non-recoverable EtherCAT
network fault that stops network communications. A field bus is sometimes referred to as a fieldbus
or a network.

Error code Fault Description Possible causes Solutions

62 - 1 Unrecognized Fault An unhandled EtherCAT • Noise on the • Make sure the
field bus fault occurred. network drive firmware is
62 - 2 Missed Update Data arrived too early or too • Cables that do not up to update.
late on one or more follow the Beckhoff • Remove power
connected devices. EtherCAT from all the
The master did not receive specifications. devices on the
the data from the • Other errors network,
connected devices in the specific to the including the
time allowed. EtherCAT network CNC. Turning
protocol. OFF the power
62 - 3 Network Down The network physical link is is not sufficient
disconnected. • One or more
to clear an error.
devices on the
The state of the EtherCAT Physically
network is in an
field bus does not match disconnect the
error state and
what Phoenix expected. power from the
must have the
For example, Phoenix is devices to clear
power removed to
trying to initiate a move to an error. Then
clear the error.
one of the drives and the restore power
• Loose, to all those
device is not operational.
disconnected, or devices to
damaged cable restart the
(Pulling a cable cutting system
with too much and Phoenix.
force damages the
• Replace the
shielding inside).
cables. See
EtherCAT cable
on page 34.
• Clear the error
and restart the
EtherCAT
network.
62 - 4 Configuration The Phoenix.xml • EtherCAT field bus • Recreate the
configuration file does not devices have Phoenix.xml file
match the discovered changed or the using
devices on the EtherCAT wrong Phoenix.xml Hypertherm
field bus. was installed. Studio.
• The Phoenix.xml file • Clear the error
may be corrupted. and restart the
EtherCAT
network.

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Error code Fault Description Possible causes Solutions

62 - 5 Watchdog Timeout EtherCAT real-time process Windows or INtime • Make sure the
timing constraints were not configuration issue drive firmware is
satisfied. up to update.
62 - 6 Parse There was a problem • Noise on the • Remove power
parsing data from the network from all the
network. • Cables that do not devices on the
follow the Beckhoff network,
62 - 7 Send Receive There was a problem
EtherCAT including the
sending or receiving data
specifications. CNC. Turning
on the network.
OFF the power
62 - 8 Slave to Slave Timeout A timeout occurred during • Other errors
is not sufficient
Slave to Slave specific to the
to clear an error.
communications. EtherCAT network
Physically
protocol.
62 - 9 Unknown Field Bus An unhandled EtherCAT disconnect the
Network Fault field bus fault occurred. • One or more power from the
devices on the devices to clear
62 - 10 Default Input Data An error on the EtherCAT network is in an an error. Then
field bus caused default error state. restore power
data to be used.
• Loose, to all those
62 - 11 Outputs Not Delivered EtherCAT field bus data disconnected, or devices to
was not delivered to one or damaged cable restart the
more devices. (Pulling a cable cutting system
62 - 12 Internal Sync Lost EtherCAT field bus internal with too much and Phoenix.
synchronization was not force damages the • Replace the
successful. shielding inside). cables. See
62 - 13 Propagation Delay Lost EtherCAT field bus EtherCAT cable
propagation delay was not on page 34.
successful. • Clear the error
62 - 15 Fieldbus: Timing Alert Communication errors and restart the
between the CNC and EtherCAT
connected devices. network.

Error 64) Field Bus Slave Fault

This fault occurs when a slave device that is active on the EtherCAT network has an EtherCAT
network protocol error and cannot communicate with the EtherCAT network. The fault message
shows the slave device with the problem. A field bus is sometimes referred to as a fieldbus or a
network.

 This fault is different from a Field Bus Device Fault (error 61), which
indicates an operational error rather than a network communications error.

Possible causes
 These faults are caused by errors specific to the EtherCAT network protocol.
 The physical location of one or more slave devices does not match the location described in
the EtherCAT network configuration (Phoenix.xml) file.

Suggested actions
 See the documentation supplied by the drive manufacturer for more information.

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 Clear the error and restart the EtherCAT network.

 Turn OFF the slave device, and then turn ON the slave device to restart it. Then restart the
EtherCAT network.

Error 66) RTOS Watchdog Fault

Possible cause
 These faults are caused when Windows does not respond to the real-time operating system
(RTOS).

Suggested action
 Clear the error and restart the CNC.

Error 67) PLC application

Possible cause
 The cutting system manufacturer has introduced a fault in the CNC using the PLC’s Create
Fault function block. The fault shows an error number that is specific to the cutting system
manufacturer’s application that is running in the PLC.

Suggested actions
 Restart the CNC.
 See the documentation supplied by the cutting system manufacturer.

Error 68) PLC

Possible cause
 The PLC has encountered an operational error and stopped running the PLC program.

Suggested action
 Restart the CNC to restart the PLC.

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HASP warning and error message reference

The warning message Use of this control has expired appears

Figure 42

Possible causes
 Your cutting system manufacturer (OEM) set up a timer to limit the number of days that the
Phoenix software is valid, and the timer has expired. You can no longer use the Phoenix
software.

Suggested actions
 Contact your OEM to have the timer extended or removed. The OEM will email you a *.V2C
file to use to update the HASP in the EDGE Connect.
Then do the following.
 Save the *.V2C file to the root directory of a USB memory stick.
 Put the USB memory stick in a USB connector on the CNC.
 On the warning dialog box shown in Figure 42, choose Update HASP.
 In Load HASP update from, choose Memory Stick.
 Choose the *.V2C file, and then choose OK. The HASP is updated.
 If you get an error, then there is a problem with the *.V2C file. Do the following.
 Make sure that the USB memory stick is still in a USB connector on the CNC.
 Choose HASP Information on the warning dialog box shown in Figure 42.
 In Save HASP information to, choose Memory Stick.
 Keep the default name for the *.C2V file, and then choose OK.
 Contact your OEM, and email the *.C2V file to them.

 See also Error 54) HASP Update Too Old on page 260 and Error 55)
HASP Update Too New on page 261.

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 *.V2C files must be installed in the order in which they were generated for
your CNC, and all **.V2C files that have been generated must be applied.
(You cannot skip **.V2C files.) The *.C2V file that you email to your OEM
shows the current **.V2C file, so that they can troubleshoot the problem
with Hypertherm Technical Service.

Error 18) HASP key ID not found

Possible cause
 The HASP is not physically connected to the CNC.
 The HASP is not detected by Windows.

Suggested action
 Install the HASP if it is not connected.
 Disconnect and reconnect the HASP if it is connected.

Error 19) HASP invalid update data

Possible cause
 Using the UPDATEFEATURES password with a corrupted V2C file.

Suggested action
 Make sure you have selected the correct *.V2C file
 Contact your OEM and email them the *.V2C file so that they can troubleshoot the problem
with Hypertherm Technical Service.

Error 54) HASP Update Too Old

Possible cause
 You tried to update the HASP on the EDGE Connect CNC, but the selected *.V2C file is
invalid. The reason is that *.V2C files must be installed in the order in which they were
generated for your CNC, and all *.V2C files that have been generated must be applied. This
error means that one or more later *.V2C files have not yet been installed.

Suggested action
 Contact your OEM and email them a *.C2V file containing your information so that they can
troubleshoot the problem with Hypertherm Technical Service. To get the *.C2V file, do the
following.
 Make sure that the USB memory stick is still in a USB connector on the CNC.
 Choose Setups > Password > HASPINFORMATION.
 In Save HASP information to, choose Memory Stick.
 Keep the default name for the *.C2V file, and then choose OK.

 See also The warning message Use of this control has expired appears
on page 259.

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Error 55) HASP Update Too New

Possible cause
 You tried to update the HASP on the EDGE Connect CNC, but the selected *.V2C file is
invalid. The reason is that *.V2C files must be installed in the order in which they were
generated for your CNC, and all *.V2C files that have been generated must be applied. This
error means that one or more earlier *.V2C files have not yet been installed.

Suggested action
 Contact your OEM and email them a *.C2V file containing your HASP information so that
they can troubleshoot the problem with Hypertherm Technical Service. To get the *.C2V file,
do the following.
 Make sure that the USB memory stick is still in a USB connector on the CNC.
 Choose Setups > Password > HASPINFORMATION.
 In Save HASP information to, choose Memory Stick.
 Keep the default name for the *.C2V file, and then choose OK.

 See also The warning message Use of this control has expired appears
on page 259.

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14 Troubleshooting and Diagnostics

Plasma cutting tips

The following reference guide offers several solutions to help improve cut quality.

Consider the following factors when evaluating plasma cut quality.

 Type of machine (example: XY table, punch press)
 Plasma cutting system (example: plasma power supply, torch, consumables)
 Motion control device (example: CNC, torch height control)
 Process variables (example: cutting speed, gas pressures, flow rates)
 External variables (example: material variability, gas purity, operator experience)

All of these factors can affect the appearance of a cut.

Cut quality problems

Angularity

Positive cut angle: More material is

removed from the top of the cut surface
than from the bottom.

Negative cut angle: More material is

removed from the bottom of the cut surface
than from the top.

Top edge rounding: There is a slight

rounding along the top edge of the cut
surface.

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Dross

High-speed dross: A small, linear bead of molten

material attaches and hardens along the bottom edge
of the cut. In addition, S-shaped lag lines are present;
dross is difficult to remove and requires grinding.

Low-speed dross: A bubbly or globular accumulation

of molten material attaches and hardens along the
bottom edge of the cut. In addition, vertical lag lines
may be present; dross is easy to remove and flakes off
in large chunks.

Top spatter: A light spatter of molten material collects

on the top edges of the cut. Usually, this spatter is
inconsequential and is most common with air plasma.

Surface finish

Roughness: Depending on the type of metal being cut, some roughness can be expected;
“roughness” describes the texture of the cut face (the cut is not smooth).

Aluminum

Top: Air/Air
 Best for thin material under 3 mm (1/8 inch)

Bottom: H35/N2
 Excellent edge quality
 Weldable edge

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Mild steel

Top: Air/Air
 Clean cut
 Nitrided edge
 Increased surface hardness

Bottom: O2
 Exceptional edge quality
 Weldable edge

Color

Color results from a chemical reaction between a

metal and the plasma gas that is used to cut it. Color
changes are expected and vary most dramatically with
stainless steel.

Top: N2/N2

Middle: H35/N2

Bottom: Air/Air

Basic steps to improve cut quality

Step 1: Is the plasma arc cutting in the appropriate direction?

 The squarest cut angles are always on the right side in relation to the forward motion of the
torch.
 Make sure that the direction of the cut is correct.
 Adjust the cutting direction, if necessary. The plasma arc typically spins clockwise with
standard consumables.

Contour
 The torch travels clockwise.
 The good side of the cut is to the right side of the
torch, as it travels forward.

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Internal feature (hole) End point
 Torch travels
counterclockwise. Start point
 Good side of the cut is to
the right side of the torch as
it travels forward.

Step 2: Was the correct process selected for the material and thickness?

Refer to the cut charts. On the CNC, choose the Cut Chart soft key on the Main screen to view the
cut chart for the selected torch type, material, and thickness.

Follow the specifications in the cut charts.

 Select the appropriate process for:
 Material type
 Material thickness
 Desired cut quality
 Productivity goals
 Select the correct plasma and shield gas.
 Select correct parameters for:
 Gas pressures (or flow rates)
 Cut height and arc voltage
 Cutting speed
 Make sure that the correct consumables are being used, and make sure that the part
numbers are correct.

 Generally, lower amperage processes offer better angularity and surface

finish. However, cutting speeds are slower and dross levels are higher.

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Step 3: Are the consumables worn?

 Inspect consumables for wear.

 Replace worn consumables.
 Always replace the nozzle and electrode at the same time.
 Avoid over-lubricating O-rings.

 Use genuine Hypertherm consumables to maximize cutting performance.

Step 4: Is the torch square to the workpiece?

 Level the workpiece.

 Square the torch to the workpiece, both from the front and side of
the torch.

 Examine the material to see if it is bent or warped. In extreme

cases this limitation cannot be corrected.

Step 5: Is the cut height set at the proper height?

 Adjust the cut height to the correct setting.

 If you are using arc voltage control, adjust the voltage.

 As consumable parts wear, arc voltage settings need continual

adjustment to maintain cut height.

 Cut height can impact angularity.

 Negative cut angle: torch too low;
increase cut height.
 Positive cut angle: torch too high;
decrease cut height.
Negative cut angle

 A slight variation in cut angles can be

normal if the variation is within
Square cut

tolerance. Positive cut angle

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Step 6: Is the cutting speed set too fast or too slow?

 Adjust the cutting speed as needed.

 Cutting speed can also impact your dross levels.

 High-speed dross: The cutting speed is too fast and the arc lags behind. Reduce the cutting
speed.
 Low-speed dross: The cutting speed is too slow and the arc shoots ahead. Increase the
cutting speed.
 Top spatter: The cutting speed is too fast. Reduce the cutting speed.

 In addition to speed, both material chemistry and surface finish can impact
dross levels. When the workpiece heats up, more dross can form on
subsequent cuts.

Step 7: Are there problems with the gas delivery system?

 Identify and repair any leaks or restrictions.

 Use correctly sized regulators and gas lines.
 Use pure, high-quality gas.
 If a manual purge is required, confirm that the purging cycle was completed.
 Consult the gas distributor.

Step 8: Is there torch vibration?

 Make sure that the torch is tightly attached to the table gantry.
 Consult the cutting system manufacturer. Your table may require maintenance.

Step 9: Does the table need to be tuned?

 Make sure that the table is cutting at the specified speed.

 Consult the cutting system manufacturer. The table speed may need tuning.

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Bevel cutting tips

Cutting bevel angles with plasma requires specialized computer-aided manufacturing (CAM)
software, process parameters, and a post-processor for the Hypertherm CNC. In some cases,
cutting parts to specification can take several iterations. Use the following information to identify and
solve cut-quality issues when cutting bevel angles.

Types of bevel cuts

Plasma bevel cutting has six distinct cuts. Each cut is shown below from a side view and with
another bevel-cut part. Straight, vertical cuts are referred to as I cuts. Refer to your CAM software
for information on programming these cuts.

I cut

V cut

A cut

Y Top cut

Y Bottom cut

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X cut

K cut

Bevel cutting tips

When troubleshooting a bevel-cut part, perform the following actions in order.

1. Measure and correct for bevel angle.

2. Measure and correct for land dimension if cutting Y Top cut parts.

3. Measure and correct for part dimension.

Quality bevel-cut parts result from a strong partnership between the part programmer and machine
operator. The part programmer can take advantage of bevel parameters available in the CAM
software used to produce the part program, and the operator can perform adjustments available on
the CNC. Correcting a cut quality issue often requires that the part programmer make changes in
the CAM software and generate a new part program.

Following are several common cut quality issues that can occur when bevel cutting, and
suggestions for both the part programmer and machine operator to follow to eliminate the issues.

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Clipped corner

In bevel cutting, a corner loop is used by the CAM software to reposition the bevel head when the
cutting angle changes between two cuts. A clipped corner on a part could result when the corner
loop is not large enough. To correct corner loop size, refer to the CAM software, then generate a
new part program. Two types of corner loops are shown below.

Linear corner loop Arc corner loop

Inconsistent cut quality on a single part surface

The graphic below shows two cut quality issues: a transition in cut quality from the part corner into
the part profile, and a divot in the cut.

Transition between corner

and part profile

Divot

Increase the length of the lead-in segment. A longer lead-in allows the torch to lock on to the
correct combination of arc voltage and cut height. To correct lead-in length, refer to the CAM
software, then generate a new program.

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Rounded edges on Y Top cuts

For Y Top cuts, a rounded edge can sometimes result if the land is cut before the bevel angle is cut.
The examples below show the side view of the Y Top cut bevel part.
Scrap material

2 1

Bevel angle

Bevel part Scrap material

Land

Scrap material

To change the order in which the passes (also called profiles) are cut, refer to your CAM software,
then generate a new part program.
Scrap material

1 2
Bevel angle

Bevel part Scrap material

Land

Scrap material

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Part dimensions change within a nest

A change in part dimensions when cutting a nest of parts can result from incorrect torch height due
to an incorrect arc voltage setting, or worn consumables.
 Arc voltage is set in the cut chart but can be overridden on a job-by-job basis by adjusting
the setting on the Process screen. To change the arc voltage setting, choose Setups >
Process, and enter the new value for Set Arc Voltage. If you are using the torch height
control in Manual mode, enter a new cut height in the Process screen.
 If your torch height control supports arc voltage sampling, make sure to turn it on in the
Process screen (Setups > Process). Arc voltage sampling adjusts the arc voltage
automatically as consumables wear.

 Check the torch consumables and replace them if they are worn.

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Jagged cut

A jagged cut can result from the torch repeatedly touching the workpiece.

Jagged cut along the top

surface of the part

 Arc voltage can be set for the thickness of the material and not for the effective thickness of
the material when cutting on an angle. To increase arc voltage on the CNC, choose Setups
> Process, and adjust the arc voltage.

 Turn on arc voltage sampling (Setups > Process). If arc voltage sampling is on, check the
consumables and replace them if they are worn.
 Check and possibly increase the cut height in the part program. Since cut height affects the
part dimension, you may also need to adjust additional process parameters that work with
the cut height and affect part dimension. Changing these parameters requires you to
generate a new part program.

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Incorrect dimension for the land on a Y Top cut

Land is reduced in size

 Increase the Set Arc Voltage parameter in the Setups > Process screen to account for the
change in material thickness because you are cutting at an angle.
 Turn on Sample Arc Voltage, also in the Setups > Process screen.
 Check and possibly increase the cut height in the Process screen (Setups > Process).

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Change consumables

This screen tracks consumable life data for statistical analysis. In addition, this feature can prompt
the operator that a consumable has reached its expected life by using an output from the CNC to
activate an indicator such as a light or alarm. This feature allows the operator to change the
consumable and avoid a consumable failure that can affect cut quality or damage the torch.

 This Change Consumable feature can only track consumable life data and
offer features related to that data. The CNC cannot detect consumable
condition or failures.

If New Torch Tip, New Nozzle, or New Electrode is chosen every time a torch tip or electrode is
changed, the last information for the corresponding consumable will be added to a database. This
database shows the date a consumable was changed and how long it lasted in minutes, pierces,
and millimeters or inches.

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To reset the current consumable value:

 Choose the corresponding soft key.
 The CNC resets the tracking information to zero and starts counting down from the
user-defined set point as you cut in the selected mode. The installation date for the selected
consumable is updated and the current values for the selected consumable are recorded,
with the date, in a database. This can be saved to a USB memory stick.

 You can set up a Watch Window to view this data during cutting. See Set
up a Watch Window on page 153.

 The consumable information that is updated (Oxyfuel torch 1–12 / Plasma

torch 1–8) is determined by the Station Select 1–20 inputs. For example,
the Plasma Torch 1 torch tip has a limit of 5,000 minutes of operation.
After 5,000 minutes, the Change Consumable output becomes active and
is indicated with a lamp or audible alarm. The intent is to set the limits at
an expected life value of the consumable so that the operator is reminded
to change the consumable when it has reached its expected life.

 If Auto update max consumable life is enabled on the Special Setups

screen, consumable life is tracked beyond the user-defined set point and
then assigned that value as the new set point. If this feature is disabled the
user-defined set point remains the same until the user changes it
manually.

Minutes: The estimated life in time that the torch tip, nozzle, or electrode lasts. This value increases
to the maximum life achieved or a maximum value can be entered.

Pierces: The estimated life in pierces that the torch tip, nozzle, or electrode lasts. This value
increases to the maximum life achieved or a maximum value can be entered.

Inches or Millimeters: The estimated life in distance that the torch tip, nozzle, or electrode lasts.
This value increases to the maximum life achieved or a maximum value can be entered.

Minutes per Pierce: Piercing causes additional wear on the consumables. This parameter allows
you to enter a value which is added to the overall minutes value for each pierce, providing a more
accurate representation of overall consumable wear.

Arc Errors: Arc errors can be tracked using the Arc Error Counter input to the CNC from the
plasma power supply. The plasma power supply indicates an arc error when the plasma arc does
not achieve a long-life ramp down.

Volts per Minute: The Volts per Minute parameter changes the THC Voltage Offset based on the
number of minutes that have elapsed while cutting in Plasma 1 or Plasma 2 cut mode. By adding a
small fraction of a volt per minute of cutting to the THC voltage offset, the CNC compensates for
consumable wear. Volts per Minute applies only to Station 1 or Station 2.

The Volts per Minute will continue to increase the THC voltage offset until you reset the Volts per
Minute to 0 and the THC voltage offset to 0.

This parameter is available for use only with the Sensor THC while cutting in Set Arc Voltage mode.
If cutting in Sample Arc Voltage mode, set the Volts per minute to 0.

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Last Torch Tip Installed: The date and time when the selected tip was installed.

Last Electrode Installed: The date and time when the selected electrode was installed.

SilverPlus® Electrode: Choose Yes if you are using the SilverPlus electrode in the torch. The
screen updates with the correct part number for the SilverPlus electrode.

New Torch Tip soft key: Choose the New Torch Tip soft key to select which Torch Tip has been
replaced and to update the database.

New Electrode soft key: Choose the New Electrode soft key to select which electrode has been
replaced and to update the database.

New Nozzle soft key: Choose the New Nozzle soft key to select which nozzle has been replaced
and to update the database.

Manual Options soft key: Opens the Manual Options screen so that you can reposition the torch
to change the consumables.

Reset Database soft key: Resets the values in the database on the CNC and clears the torch tip,
nozzle, or electrode information after uploading or saving the database.

Upload Database soft key: Uploads the current database to a host computer.

Save Database soft key: Saves the current database to the USB memory stick.

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 Part Replacement

 For a list of replacement parts, see Parts on page 333.

CAUTION
Static electricity can damage circuit boards. Use precautions when handling printed circuit
boards.
Wear a grounded wrist strap when handling PC boards.

Required tools

These tools are used in most of the procedures in this section.

 T20 driver
 T15 driver
 Adjustable wrench

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Remove the rear enclosure

1. Turn OFF the CNC.

2. Disconnect the power cord from the CNC.

3. Disconnect the remaining cables from the front and rear of the CNC.

4. Remove the wireless antennas and any extension cables.

5. Put the CNC on a clean, flat surface with the front panel assembly face up.

6. Remove the screws from the front panel assembly.

 After you remove the screws from the front panel assembly, the front panel
assembly will be loose but still connected by the screws in the rear I/O
panel.

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7. Pick up the CNC and turn it over, with the front panel assembly face down on the clean, flat
surface. Leave the joystick hanging off the side of the surface.

CAUTION
Any debris under the CNC could cause damage to the touchscreen.

 Do not push down on the part of the CNC that is off the surface.

8. Remove the screws from the rear I/O panel.

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9. Lift the rear enclosure away from the front panel assembly.

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Install the rear enclosure

1. Put the CNC on a clean, flat surface with the front panel assembly face down. Leave the joystick
hanging off the side of the surface.

CAUTION
Any debris under the CNC could cause damage to the touchscreen.

 Do not push down on the part of the CNC that is off the surface.

2. Put the rear enclosure on the front panel assembly.

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3. Install the screws on the rear I/O panel.

4. Pick up the CNC and turn it over, with the front panel assembly face up.

 The front panel assembly will be loose but connected to the rear
enclosure by the screws in the rear I/O panel.

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5. Install the screws on the front panel assembly. Tighten the screws to 1.1 N∙m (10 in∙lb).

6. Connect all of the cables to the front and rear of the CNC.

7. If necessary, install the wireless antennas.

Replace the touchscreen

1. Make sure that you have the correct touchscreen kit for your CNC model (see Table 5). You can
find the CNC model (part) number on the data plate on the rear of the CNC. See Data plate on
page 28 for more information about the data plate.

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Table 5 – Touchscreen kits

Model number Kit number Kit contents

090198 428765 • 495.3 mm (19.5 inch) touchscreen

• HDMI cable
• USB cable
• 9 screws

090185 428632 • 469.9 mm (18.5 inch) touchscreen

• DVI cable
• USB cable
• 9 screws

The touchscreens also come with an on-screen-display (OSD) remote control. You do not
need the OSD remote control to install the touchscreen. You may want to use the OSD
remote control to adjust the screen brightness or turn on the touchscreen during
troubleshooting if it does not turn on automatically.

2. Remove the rear enclosure. See Remove the rear enclosure on page 280.

3. Cut the cable tie on the yellow/black power connector wires.

4. Disconnect the power connector from the touchscreen. (Leave the other end of the power
connector connected to the printed circuit board.)

5. (Model number 090198 only) Cut the cable tie on the USB cable.

6. Remove the USB cable and video cable from between the touchscreen and the
embedded-CNC.

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Figure 43 – Remove cables from model number 090198 (495.3 mm/19.5 in. touchscreen)

HDMI cable
USB cable

Power connector

Cable tie

Cable tie

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Figure 44 – Remove cables from model number 090185 (469.9 mm/18.5 inch touchscreen)

DVI cable
USB cable

Cable tie

Power connector

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7. Remove the screws from the rear of the front panel assembly.

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8. Hold down the touchscreen while you lift the front panel up. Do not let the touchscreen fall.

9. Put the new touchscreen on the clean, flat surface.

10. Lower the front panel over the new touchscreen.

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11. Firmly push down on the edges of the front panel until it is flush with the surface.

12. Start all of the screws. Do not tighten them into the touchscreen.

 If necessary, push down on the edge of the front panel near the screw
hole to put the screw into the opening.

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13. Lift the bottom edge of the CNC until the CNC is on its top edge. See Figure 45.

14. Push the edges of the touchscreen into the front panel until the touchscreen has a recess of
approximately 1 mm (0.04 inch).

Figure 45

15. Keep the recess at approximately 1 mm (0.04 inch) while you tighten all of the screws to
1.1 N∙m (10 in∙lb). Turn the CNC onto its other edges to get access to the other screw holes.

16. Install the USB cable and video cable between the touchscreen and the embedded-CNC, and
connect the power connector to the touchscreen.

17. Install a cable tie on the yellow/black power connector wires.

18. (Model number 090198 only) Install a cable tie on the USB cable.

19. Put the cables through the cable clips.

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Figure 46 – Install the cables on model number 090198 (495.3 mm/19.5 in. touchscreen)

HDMI cable
USB cable

Power connector

Cable tie

Cable tie

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Figure 47 – Install the cables on model number 090185 (469.9 mm/18.5 inch touchscreen)

DVI cable
USB cable

Cable tie

Power connector

20. Install the rear enclosure on the front panel. See Install the rear enclosure on page 283.

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Replace the embedded-CNC

1. Remove the rear enclosure. See Remove the rear enclosure on page 280.

2. Disconnect all of the cables and the HASP software key from the embedded-CNC.

 Keep the HASP software key to use in the replacement

embedded-CNC.

1 2 3

4 4
5
6
8 9 10
7

1 Power terminal and wiring harness 5 HDMI cable to touchscreen – model number
090198 (495.3 mm/19.5 in. touchscreen)
2 EtherCAT cable to PCB or EtherCAT
only
connector
6 HASP software key (top connector)
3 DVI cable to touchscreen – model number
090185 (469.9 mm/18.5 inch touchscreen) 7 USB to rear USB connector (bottom
only connector)
4 Wireless antenna cables to rear I/O panel 8 Ethernet cable to rear I/O panel
9 USB cable to front USB connector
10 USB cable to touchscreen

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3. Remove the screws from the mounting plate.

4. Remove the mounting plate from the 3 pins.

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5. Use a #2 Phillips® screwdriver to
remove the screws from the sides of
the mounting plate.

6. Remove the embedded-CNC from the

mounting plate.

7. Use the screws to install the new

embedded-CNC onto the mounting
plate with the wireless connectors
toward the rear I/O panel.

8. Install the mounting plate onto the front

panel assembly.

 Make sure to engage all 3 pins.

9. Install the screws on the mounting plate.

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10. Connect all of the cables and the HASP to the embedded-CNC.

 You must use the same HASP software key that you disconnected in
step 2 on page 295.

1 2 3

4 4
5
6
8 9 10
7

1 Power terminal and wiring harness 5 HDMI cable to touchscreen – model number
090198 (495.3 mm/19.5 in. touchscreen)
2 EtherCAT cable to PCB or EtherCAT
only
connector
6 HASP software key (top connector)
3 DVI cable to touchscreen – model number
090185 (469.9 mm/18.5 inch touchscreen) 7 USB to rear USB connector (bottom
only connector)
4 Wireless antenna cables to rear I/O panel 8 Ethernet cable to rear I/O panel
9 USB cable to front USB connector
10 USB cable to touchscreen

11. Install the rear enclosure on the front panel assembly. See Install the rear enclosure on
page 283.

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Replace the power distribution or hardware operator console PCB

1. Turn OFF the CNC.

2. Disconnect the power cord from the CNC.

3. Remove the screws from the right rear access panel.

4. Remove the right rear access panel.

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5. Disconnect all of the cables from the PCB.

6. Remove the screw from the PCB.

7. Remove the PCB from the pins.

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8. Install the new PCB onto the front panel assembly.

 Make sure to engage all 3 pins.

9. Install the screw.

10. Connect the blue EtherCAT cable (from the

rear I/O panel) to the OUT connector on the
PCB.

11. Connect the yellow EtherCAT cable (from the

embedded-CNC) to the IN connector on the
PCB.

12. Connect all of the other cables to the PCB.

13. Install the right rear access panel.

14. Connect the power cord to the CNC.

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Replace the power button

1. Remove the rear enclosure. See Remove the rear enclosure on page 280.

2. Disconnect the power button connector from the

PCB.

3. Remove the nut from the power button.

4. Pull the power button and wires through the hole.

5. Install the new power button in the hole.

6. Put the nut over the wires, and tighten it onto the
power button to 1.4 N∙m (12 in∙lb).

7. Connect the power button connector to the PCB.

8. Put the wires through the cable clip.

9. Install the rear enclosure on the front panel

assembly. See Install the rear enclosure on
page 283.

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Replace the front USB connector

1. Remove the rear enclosure. See Remove the rear enclosure on page 280.

2. Disconnect the front USB connector cable from the embedded-CNC.

3. Remove the nut and washer from the front of the USB connector.

4. Install the new USB connector in the hole.

5. Install the washer and nut on the front of the USB connector, and tighten the nut to 3.4 N∙m
(30 in∙lb).

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6. Connect the USB cable to the embedded-CNC.

7. Put the cable through the cable clips.

Figure 48 – Model number 090198 (495.3 mm/19.5 in. touchscreen)

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 Part Replacement 15
Figure 49 – Model number 090185 (469.9 mm/18.5 inch touchscreen)

8. Install the rear enclosure on the front panel assembly. See Install the rear enclosure on
page 283.

EDGE Connect Installation and Setup Manual 809340 305

15 Part Replacement

Replace the start or stop switch assembly

This procedure shows only the start button. You can follow the same procedure to replace the stop
button. Do one button at a time so that you do not interchange the wires. These buttons do not
come with a wiring harness.

1. Remove the rear enclosure. See Remove the rear enclosure on page 280.

2. Loosen the screws that hold the wire pins in place on the switch block.

3. Remove the wires from the switch block.

Figure 50 – Wires on model number 090198 (495.3 mm/19.5 in. touchscreen)

STOP

START

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 Part Replacement 15
Figure 51 – Wires on model number 090185 (469.9 mm/18.5 inch touchscreen)

STO
P

STA
RT

4. Push the latch on the switch block to the left.

5. Remove the switch block.

6. Remove the plastic nut.

7. Remove the button.

8. Install the new button.

 Make sure that the TOP

marking on the button is
toward the touchscreen.

 Make sure that the button

locks in position.

9. Install the plastic nut, and tighten to

0.7 N∙m (6 in∙lb).

10. Install the switch block.

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15 Part Replacement

11. Push the latch on the switch block to the right.

12. Install the wire pins into the switch block, and tighten the screws.

STOP START

GRY GRN

BLK BLK

Label Wire color Signal J6 pin number

Black (BLK) Start sw com 1A

START
Green (GRN) Start sw 1B

Black (BLK) Stop sw com 2A

STOP
Gray (GRY) Stop sw 2B

13. Install the rear enclosure on the front panel assembly. See Install the rear enclosure on
page 283.

Replace the potentiometers and harness

The potentiometers come attached to the wiring harness.

1. Remove the rear enclosure. See Remove the rear enclosure on page 280.

2. Disconnect the connector from J5 on the PCB.

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 Part Replacement 15
Figure 52 – Model number 090198 (495.3 mm/19.5 in. touchscreen)

Figure 53 – Model number 090185 (469.9 mm/18.5 inch touchscreen)

3. Use a 5/64-inch Allen® wrench to loosen the set screws one full turn.

4. Remove the knobs.

5. Use a 1/2-inch wrench to remove the nut and lock washer from each potentiometer.

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15 Part Replacement

6. Remove the harness and potentiometers.

7. Install the new potentiometers.

 Make sure that the tab on the potentiometer goes into the hole in the front
panel.

8. Install the lock washer and nut on each potentiometer, and tighten the nut to 1.4 N∙m (12 in∙lb).

9. Put the wires in the cable clips.

10. Connect J5.

11. Turn each potentiometer shaft clockwise (when viewed from the back of the CNC) until it stops.

12. Install the rear enclosure on the front panel assembly. See Install the rear enclosure on
page 283.

13. Put the knobs onto the potentiometer shafts as shown.

14. Lift the knobs away from the front panel about 1 mm (0.04 inch), and install the set screws.

 This prevents the knobs from scratching the paint.

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 Part Replacement 15

Replace the toggle switch

The toggle switch does not come with a wiring harness.

1. Discard the hardware that comes with the switch.

2. Remove the rear enclosure. See Remove the rear enclosure on page 280.

3. Disconnect the 3 wires from the rear of the toggle switch.

4. Remove the nut from the front of the toggle switch.

5. Remove the toggle switch from the hole.

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15 Part Replacement

6. Install the new toggle switch.

 Make sure that the notch on the toggle switch aligns with the mark in the
hole.

7. Install the nut on the front of the toggle switch, and tighten to 1.4 N∙m (12 in∙lb).

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 Part Replacement 15
8. Connect the 3 wires to the toggle switch.

ORG BLK WHT

BOT CEN TOP

Label Wire color Signal J6 pin number

BOT (bottom terminal) Orange (ORG) Lift switch up 7B

CEN (center terminal) Black (BLK) Lift switch com 7A

TOP (top terminal) White (WHT) Lift switch down 8B

9. Install the rear enclosure on the front panel assembly. See Install the rear enclosure on
page 283.

EDGE Connect Installation and Setup Manual 809340 313

15 Part Replacement

Replace the joystick

The joystick does not come with a wiring harness.

1. Remove the rear enclosure. See Remove the rear enclosure on page 280.

2. Pull up and then out to remove the rear I/O panel. Tilt it toward the touchscreen. Be careful not
to damage any connectors or cables.

Figure 54 – Model number 090198 (495.3 mm/19.5 in. touchscreen)

314 809340 Installation and Setup Manual EDGE Connect

 Part Replacement 15
Figure 55 – Model number 090185 (469.9 mm/18.5 inch touchscreen)

3. Remove the joystick. See Figure 56 on page 316 or Figure 57 on page 317.

4. Disconnect the connectors from the switch block.

EDGE Connect Installation and Setup Manual 809340 315

15 Part Replacement

Figure 56 – Remove the joystick from model number 090198 (495.3 mm/19.5 in. touchscreen)

1 Remove the black plastic nut.

2 Remove the joystick and switch block assembly.
3 Disconnect the connectors.

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 Part Replacement 15
Figure 57 – Remove the joystick from model number 090185 (469.9 mm/18.5 inch touchscreen)

1 Push the latch on the switch block to the right,

and remove the switch block.
2 Remove the black plastic nut.
3 Remove the joystick.
4 Disconnect the connectors.

5. Connect the wires to the switch block on the new joystick. See Figure 58.

 The joystick does not come with a new wiring harness. Use the same
connectors that you disconnected in step 4 on page 315.

6. Install the new joystick and switch block in the front panel assembly.

7. Install the black plastic nut, and tighten it with your fingers. Do not tighten the nut too much.

EDGE Connect Installation and Setup Manual 809340 317

15 Part Replacement

Figure 58 – Install the new joystick

4 3

BLK BLU BLK BRN

1 2

BLK WHT BLK VIO

For each side, the black wire goes to

the pin on the right, and the colored
wire goes to the pin on the left.

Wire color Signal J6 pin number

Black (BLK) Joy up com 3A

White (WHT) Joy up 3B

Black (BLK) Joy left com 5A

Blue (BLU) Joy left 5B

Black (BLK) Joy down com 4A

Brown (BRN) Joy down 4B

Black (BLK) Joy right com 6A

Violet (VIO) Joy right 6B

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 Part Replacement 15
8. Install the rear I/O panel.

9. Install the rear enclosure on the front panel assembly. See Install the rear enclosure on
page 283.

EDGE Connect Installation and Setup Manual 809340 319

15 Part Replacement

Replace the hardware operator console wiring harness

1. Remove the rear enclosure. See Remove the rear enclosure on page 280.

2. Disconnect the connector from J6 on the PCB.

3. Disconnect the wires from the start and stop buttons.

4. Disconnect the wires from the toggle switch.

5. Disconnect the wires from the joystick switch block.

 You may need to remove the joystick from the front panel assembly to
access the joystick wires. See step 2 of Replace the joystick on
page 314.

Figure 59 – Model number 090198 (495.3 mm/19.5 in. touchscreen)

STOP
TOP

START
CEN
BOT

320 809340 Installation and Setup Manual EDGE Connect

 Part Replacement 15
Figure 60 – Model number 090185 (469.9 mm/18.5 inch touchscreen)

TOP
CEN
BOT

STO
P

STA
RT

EDGE Connect Installation and Setup Manual 809340 321

15 Part Replacement

6. Remove the wires from the cable clips.

7. Connect the new wires to the joystick switch block.

Figure 61 – Switch block for joystick with part number 005715

4 3

BLK BLU BLK BRN

1 2

BLK WHT BLK VIO

For each side, the black wire goes to

the pin on the right, and the colored
wire goes to the pin on the left.

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 Part Replacement 15
Figure 62 – Switch block for joystick with part number 005644

1 BLK BLU
BLK BRN 2

BLK WHT
BLK VIO

For each side, the black wire goes

to pin 4, and the colored wire goes
to pin 3.

Figure 63 – Pinouts for 005715 and 005644

Label (005644 only) Wire color Signal J6 pin number

1 Black (BLK) Joy up com 3A

White (WHT) Joy up 3B

4 Black (BLK) Joy left com 5A

Blue (BLU) Joy left 5B

3 Black (BLK) Joy down com 4A

Brown (BRN) Joy down 4B

2 Black (BLK) Joy right com 6A

Violet (VIO) Joy right 6B

EDGE Connect Installation and Setup Manual 809340 323

15 Part Replacement

8. Connect the wires to the toggle switch.

ORG BLK WHT

BOT CEN TOP

Label Wire color Signal J6 pin number

BOT Orange (ORG) Lift switch up bottom 7B

CEN Black (BLK) Lift switch com center 7A

TOP White (WHT) Lift switch down top 8B

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 Part Replacement 15
9. Connect the wires to the start and stop buttons and tighten the screws.

STOP START

GRY GRN

BLK BLK

Label Wire color Signal J6 pin number

Black (BLK) Start sw com 1A

START
Green (GRN) Start sw 1B

Black (BLK) Stop sw com 2A

STOP
Gray (GRY) Stop sw 2B

10. Put the wires through the cable clips.

11. Connect the connector to J6 on the PCB.

12. Install the rear enclosure on the front panel assembly. See Install the rear enclosure on
page 283.

EDGE Connect Installation and Setup Manual 809340 325

15 Part Replacement

Replace the rear I/O panel

1. Remove the rear enclosure. See Remove the rear enclosure on page 280.

2. Remove the USB cover assembly.

3. Remove the nut and washer from the

front of the USB connector.

4. Remove the USB connector from

the rear I/O panel.

5. Remove the nut and lock

washer from the front of both
of the wireless connectors. Wireless connectors
12 VDC connector
6. Remove the wireless
connectors from the rear I/O
panel.

7. Remove the nut and washer

from the front of the 12 VDC
connector.

8. Remove the 12 VDC

connector from the rear I/O
panel.

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 Part Replacement 15
9. Pull up and then out to remove the rear I/O panel. Point it toward the touchscreen. Be careful
not to damage any connectors.

10. Remove the 4 nuts from the

Ethernet and EtherCAT
connectors.

11. Remove the Ethernet and

EtherCAT connectors from the
rear I/O panel.

12. In the new rear I/O panel, install

the Ethernet and EtherCAT
connectors.

13. Install the 4 nuts on the

connectors. Tighten them to
0.7 N∙m (6 in∙lb).

14. Install the new rear I/O panel on

the front panel assembly.

15. Install the 12 VDC connector in the rear I/O panel.

16. Install the washer and nut on the front of the 12 VDC connector, and tighten the nut to 1.4 N∙m
(12 in∙lb).

17. Install the wireless connectors in the rear I/O panel.

18. Install the lock washer and nut on the front of both of the wireless connectors, and tighten the
nut to 1.1 N∙m (10 in∙lb).

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15 Part Replacement

19. Install the USB connector in the rear I/O panel.

20. Install the washer and nut on the front of the USB connector, and tighten the nuts to 3.4 N∙m
(30 in∙lb).

21. Install the USB cover assembly.

22. Install the rear enclosure on the front panel assembly. See Install the rear enclosure on
page 283.

Replace the rear USB connector

1. Remove the rear enclosure. See

Remove the rear enclosure on
page 280.

2. Disconnect the USB cable that goes

to the rear USB connector from the
embedded-CNC.

3. Remove the nut and washer from the

front of the USB connector.

4. Remove the USB connector from

the rear I/O panel.

5. Install the new USB connector in the

rear I/O panel.

6. Install the washer and nut on the

front of the USB connector, and
tighten the nut to 3.4 N∙m (30 in∙lb).

7. Connect the USB cable to the embedded-CNC.

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 Part Replacement 15
Figure 64 – Model number 090198 (495.3 mm/19.5 in. touchscreen)

Figure 65 – Model number 090185 (469.9 mm/18.5 inch touchscreen)

8. Put the cable through the cable clips.

9. Install the rear enclosure on the front panel assembly. See Install the rear enclosure on
page 283.

EDGE Connect Installation and Setup Manual 809340 329

15 Part Replacement

Replace the Ethernet or EtherCAT connector

This procedure shows both connectors.

1. Remove the rear enclosure. See Remove the rear enclosure on page 280.

2. Pull up and then out to remove the rear I/O panel. Point it toward the touchscreen. Be careful
not to damage any connectors.

3. Disconnect the cable from the rear of the connector that you are replacing.

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 Part Replacement 15
4. Remove the 2 nuts from the
rear of the connector.

5. Install the new connector.

6. Install the 2 nuts. Tighten

them to 0.7 N∙m (6 in∙lb).

7. Connect the blue cable to the

EtherCAT connector from
PCB. Connect the red cable
to the Ethernet LAN
connector from the
embedded-CNC.

8. Install the rear I/O panel.

9. Install the rear enclosure on

the front panel assembly. See
Install the rear enclosure on
page 283.

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15 Part Replacement

332 809340 Installation and Setup Manual EDGE Connect

 Parts

 For instructions on part replacement, see Part Replacement on page 279.

Internal EtherCAT cables

Part number For model Color Length Quantity

223503 EDGE Connect TC Blue 0.53 m (21 in.) 1

223504 EDGE Connect TC Yellow 0.36 m (14 in.) 1

223505 EDGE Connect TC Red 0.23 m (9 in.) 1

Touchscreen cables

Part number For model Cable type Length Quantity

223474 EDGE Connect TC USB 0.30 m (12 in.) 1

223475 EDGE Connect TC – model number Video DVI-D 0.61 m (24 in.) 1
090185 (18.5 inch touchscreen) only

223740 EDGE Connect TC – model number Video HDMI 0.30 m (12 in.) 1
090198 (19.5 inch touchscreen) only

EDGE Connect Installation and Setup Manual 809340 333

16 Parts

Enclosure and hardware

Part number For model Description Quantity

101378 EDGE Connect TC – model number Rear enclosure 1

090185 (18.5 inch touchscreen) only

101467 EDGE Connect TC – model number Rear enclosure 1

090198 (19.5 inch touchscreen) only

428633 EDGE Connect TC Kit: Plastic cable clips (13)

428634 EDGE Connect TC Kit: Screws

Front panel and rear I/O panel parts

Part number For model Description Quantity

104827 EDGE Connect/EDGE Connect TC USB cover with chain assembly 1

223244 EDGE Connect/EDGE Connect TC USB panel mount connector bulkhead 1

with cable, 0.5 m (19.7 in.)

223501 EDGE Connect/EDGE Connect TC Wireless antenna extension cable, 1

0.18 m (7 in.)

228445 EDGE Connect/EDGE Connect TC Ethernet connector 1

229736 EDGE Connect/EDGE Connect TC Power button with wiring harness 1

229762 EDGE Connect/EDGE Connect TC Rear I/O panel with gasket (does not 1
include connectors)

428631 EDGE Connect/EDGE Connect TC Kit: 12 VDC power supply (1), AC

rewireable connector (1), AC cord (1),
and plug for 120 V (1)

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 Parts 16

Internal parts

Part number For model Description Quantity

229728 EDGE Connect/EDGE Connect TC 12 VDC power input with wiring 1

harness

229827 EDGE Connect TC Operator console PCB 1

229840 EDGE Connect/EDGE Connect TC Embedded-CNC 1

Note: Disconnect and keep the HASP
software key from the defective
embedded-CNC to use in the
replacement embedded-CNC.

428632 EDGE Connect/EDGE Connect TC Kit: 469.9 mm (18.5 inch) touchscreen

– model number 090185 (18.5 inch (1), DVI cable (1), USB cable (1),
touchscreen) only screws (9)

428652 EDGE Connect/EDGE Connect TC HASP software key 1

428765 EDGE Connect TC – model number Kit: 495.3 mm (19.5 inch) touchscreen
090198 (19.5 inch touchscreen) only (1), HDMI cable (1), USB cable (1),
screws (9), cable ties (2)

Operator console parts

Part number For model Description Quantity

005688 EDGE Connect TC Stop switch assembly (red) 1

005689 EDGE Connect TC Start switch assembly (green) 1

005715 EDGE Connect TC Joystick 1

104827 EDGE Connect/EDGE Connect TC USB cover with chain assembly 1

108861 EDGE Connect TC Potentiometer knob, 24.8 mm 1

(0.975 inch) diameter

223244 EDGE Connect TC USB panel mount connector bulkhead 1

with cable, 0.5 m (19.7 in.)

229727 EDGE Connect TC Wiring harness for toggle switch, start 1

and stop buttons, and joystick

229729 EDGE Connect TC Potentiometers with wiring harness 2

229736 EDGE Connect TC Power button with wiring harness 1

428635 EDGE Connect TC Kit: Toggle switch (1) and nut (1)

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16 Parts

Optional accessories

Wireless antenna extension cables

Part number For model Length Quantity

223250 EDGE Connect 0.30 m (12 in.) 1

223251 EDGE Connect 3.1 m (10 feet) 1

Ethernet and EtherCAT bulkhead connector

Part number For model Quantity

208367 EDGE Connect 1

Mounting options
Part number For model Description Quantity

104844 EDGE Connect Wall mount for EDGE Connect 1

104845 EDGE Connect DIN rail mount for EDGE Connect 1

428636 EDGE Connect TC Kit: Rear or flush mount bracket (1) with
screws (4) for EDGE Connect TC

USB with instruction manuals

Part number For model Quantity

428628 EDGE Connect/EDGE Connect TC 1

EtherCAT test PCB

Part number For model Quantity

428715 EDGE Connect TC 1

* If you want to connect a Powermax® or MAXPRO® to an EDGE Connect CNC, use a discrete connection
through the drive I/O or an I/O module on the network.

336 809340 Installation and Setup Manual EDGE Connect

 Parts 16

External EtherCAT cables

All EtherCAT cables used in the cutting system must follow the guidelines in EtherCAT cable on
page 36 (EDGE Connect) or EtherCAT cable on page 43(EDGE Connect TC).

All Hypertherm cables are manufactured to these guidelines and are listed here.

Part number Length Quantity

223506 0.3 m (1 feet) 1

223507 0.6 m (2 feet) 1

223508 1.5 m (4.9 feet) 1

223672 2.5 m (8.2 feet) 1

223509 3 m (9.8 feet) 1

223510 6 m (19.7 feet) 1

223511 7.5 m (24.6 feet) 1

223512 10 m (32.8 feet) 1

223513 15 m (49.2 feet) 1

223514 22.5 m (73.8 feet) 1

223515 30 m (98.4 feet) 1

223516 45 m (147.6 feet) 1

223517 60 m (196.9 feet) 1

223714 75 m (246.1 feet) 1

EDGE Connect Installation and Setup Manual 809340 337

16 Parts

EtherCAT drives and I/O modules

For a list of supported EtherCAT drives and I/O modules, see the EtherCAT Devices Supported by
EDGE Connect CNCs Application Note (809660). Technical documentation is available at
www.hypertherm.com/docs.

 If you want to connect a Powermax® or MAXPRO® to an

EDGE Connect CNC, use a discrete connection through the drive I/O or
an I/O module on the network.

338 809340 Installation and Setup Manual EDGE Connect

 Wiring Diagrams

The following diagrams are connection diagrams for the EDGE Connect and EDGE Connect TC.

EDGE Connect Installation and Setup Manual 809340 339

17 Wiring Diagrams

340 809340 Installation and Setup Manual EDGE Connect

EDGE Connect CNC connection diagram (Sheet 1 of 1)

Metal enclosure
428631
IEC C13 Power supply kit

Metal enclosure
108842
5.5 mm O.D. X 2.5 mm I.D. plug
Rewireable plug
AC to 12 VDC power supply (Switchcraft 760K)
1 m (3.3 ft)
2 m (6.5 ft)

NEMA 5-15-P plug IEC C13 100 – 240 VAC 1 diameter

Antenna

C14 receptacle

DVI-D to monitor
See note 3. Primary 12 VDC input
Coaxial extension cable with B A
See note 1 and 2.
RP-SMA type, bulkhead mount 428652 HASP USB
223250 0.3 m (1 ft)
127501 CPU
223251 3 m (10 ft) EDGE Connect CNC V-V+ PWR

See note 6. Top view DC 12V

DVI-D DC 12V

3.81 mm terminal block can take

EDGE Connect CNC
EMI chassis M6 stud with nut 1.31 mm2 – 0.08 mm2
Bottom view
Antenna

ANTENNA ANTENNA
(16 AWG – 28 AWG) wire.
CPU CNC on/off button

EtherCAT cable
HDMI to monitor
See note 3.

PWR
PWR
See note 5.

COMMON
+12V
Coaxial extension cable with Cat5e F/UTP
RP-SMA type, bulkhead mount
223250 0.3 m (1 ft)
223251 3 m (10 ft) Chassis Alternative 12 VDC input
See note 6 and 7. See note 1 and 2. Chassis

Notes: Bulkhead connector Bulkhead connector

208367 208367
1. Connect 12 VDC power-in to location A OR B, not both. See note 7.
Chassis
See note 7.
 A = 12 VDC input using locking barrel plug (Switchcraft 760K)
 B = Alternative method of 12 VDC input using screw terminal block.
To office LAN To 1st EtherCAT slave
2. Location A and B are for 12 VDC input. Do not use to output power to any Cat5e F/UTP EtherCAT cable
devices.
3. Connect either DVI-D or HDMI type monitor. 8. Shorter cable lengths are better to reduce signal attenuation. Test in place to
make sure that the cables are compatible and robust. Maximum lengths:
4. Monitor requirements: 1366 X 768 resolution, if touchscreen, at least 47 cm
(18.5 inch) diagonal. See Monitor on page 32.  USB cable: 5 m (16 ft)
 DVI-D cable: 5 m (16 ft)
5. On/off button and cable, OEM provided. Requirements:
 HDMI cable: 5 m (16 ft)
 SPST, momentary, gold plated contacts
 Antenna coaxial extension cables: 3 m (10 ft)
 Use a minimum 0.33 mm2 (22 AWG) shielded twisted pair cable. 5 m
(16 ft) maximum length.
 Terminate the cable shield to chassis at the switch end.
6. Mount the wireless antennas on the exterior of the overall metal enclosure.
7. Make sure that the bulkhead connectors electrically bond to the metal
enclosure. 013394 Revision A
341
EDGE Connect TC CNC connection diagram (Sheet 1 of 3)
Front Back

Touchscreen

Antennas

Joystick

USB
CNC on/off momentary EMI chassis M6 screw
Speed Jog speed
switch with blue LED Start

To machine frame
See Recommended grounding and
Up/down toggle shielding on page 55.
USB Stop

428631 To 1st EtherCAT slave

IEC C13 Power supply kit EtherCAT cable
108842
Rewireable plug
AC to 12 VDC power supply
1 m (3.3 ft)
2 m (6.5 ft)

NEMA 5-15-P plug 100 – 240 VAC 1 diameter 5.5 mm O.D. X 2.5 mm I.D. plug To office LAN
IEC C13
C14 receptacle (Switchcraft 760K) Cat5e F/UTP (Optional, OEM-provided cable)

013395 Revision C
342
EDGE Connect TC CNC connection diagram (Sheet 2 of 3)

223475 DVI-D 0.6 m (24 in.)

223504 Cat5e 0.35 m (14 in.) yellow EtherCAT
428632 Model number 090185
47 cm (18.5 in.) touchscreen for (18.5 in. touchscreen)
Analog VGA model number 090185 ONLY DVI-D ONLY
(Not used) Includes 0.3 m (12 in.) USB cable
Includes 0.6 m (24 in.) DVI-D cable

Display OSD 428765 229827

remote port 49.5 cm (19.5 in.) touchscreen for 223474 USB A-B PCB assembly:
(Not used) model number 090198 ONLY USB 0.3 m (12 in.) Operator console
Includes 0.3 m (12 in.) USB cable
Includes 0.3 m (12 in.) HDMI cable
To touchscreen

Display OSD
pendant port
12 VDC HDMI

428652 HASP
To front panel
223244 USB A-A M-F
0.5 m (1.3 ft)
104827 Dust cover with
chain
5.5 mm O.D. X 2.1 mm I.D. plug
223740 HDMI 0.3 m (12 in.)

Model number 090198 (19.5 in. touchscreen) ONLY

Auxiliary 12 V power out 0.7 A

maximum at 50 C° (122 F°)
Use 1.31 mm2 – 0.08 mm2
(16 AWG – 28 AWG) wire (spring
223501 Coaxial extension M-F 0.17 m (7 in.) terminals)

229728 12 V harness
223505 Cat5e UTP, 0.22 m (9 in.) red LAN
RJ45-RJ45
bulkhead connector 223501 Coaxial extension M-F 0.17 m (7 in.)

223503 Cat5e 0.53 m (21 in.) blue EtherCAT 229728 12 V harness pinout
Antenna
J1pin Wire color Signal Label
Antenna
1A Black DC-in common

RJ45-RJ45 bulkhead 1B Yellow DC-in +12 V DC-IN

connector 2A Black Display DC common
5.5 mm O.D. X 2.5 mm I.D. jack 2B Yellow Display +12 V Display
3A Black CPU-1 common
3B Yellow CPU-2 +12 V
4A White CPU-3 power switch
4B Blue CPU-4 power switch CPU

To rear I/O panel

12 VDC input 229736
223244 USB A-A M-F 0.5 m (1.3 ft)
See sheet 1, Power CNC on/off momentary switch
104827 Dust cover with chain
supply kit with blue LED
013395 Revision C CNC rear I/O panel

343
EDGE Connect TC CNC connection diagram (Sheet 3 of 3)
229727 I/O harness pinout

J6 pin Wire color Signal Label 229827

PCB assembly:
1A Black (BLK) Start sw com Operator console
START
1B Green (GRN) Start sw (EtherCAT slave
attached)
2A Black (BLK) Stop sw com
STOP
2B Gray (GRY) Stop sw
3A Black (BLK) Joy up com
1
3B White (WHT) Joy up
4A Black (BLK) Joy down com
3
4B Brown (BRN) Joy down
5A Black (BLK) Joy left com
4
5B Blue (BLU) Joy left
6A Black (BLK) Joy right com
2
6B Violet (VIO) Joy right
005644 Joystick 7A Black (BLK) Lift switch com CEN
Original equipment in model number
090185 (18.5 in. touchscreen) ONLY
7B Orange (ORG) Lift switch up BOT
Replaced with joystick 005715 8B White (WHT) Lift switch down TOP

229727 Switch I/O harness

229729 Potentiometer harness pinout

J5 pin Wire color Signal Destination

Jog speed Cut speed
potentiometer potentiometer 1A Orange (ORG) +3.3 V POT1-3
2A White (WHT) Wiper POT1-2
3A Black (BLK) Common POT1-1
1B Orange (ORG) +3.3 V POT2-3
2B White (WHT) Wiper POT2-2
428635 Toggle switch kit 3B Black (BLK) Common POT2-1
005688 Red push- 005689 Green push-
Raise/lower button switch button switch
Stop Start

229729 Harness (includes speed potentiometers)

005715 Joystick

013395 Revision C
344