Hypertherm Command THC Instruction Manual

X-y table torch height control system

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Command

THC

X-Y Table

Torch Height Control

(THC) System

Instruction Manual

802780 – Revision 11

EN50199

EN60974-1

Table of Contents

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Summary of Contents for Hypertherm Command THC

Page 1 Command ® X-Y Table Torch Height Control (THC) System Instruction Manual 802780 – Revision 11 EN50199 EN60974-1...
Page 2 Register your new Hypertherm system Register your product on-line at www.hypertherm.com/registration for easier technical and warranty support. You can also receive updates on new Hypertherm products and a free gift as a token of our appreciation. For your records Serial number:...
Page 3 Revision 11 – February 2009 Hypertherm, Inc. Hanover, NH USA www.hypertherm.com © Copyright 2009 Hypertherm, Inc. All Rights Reserved Hypertherm, HyPerformance, HPR, HSD and CommandTHC are trademarks of Hypertherm, Inc., and may be registered in the United States and/or other countries...
Page 4 Hypertherm, Inc. Hypertherm (Shanghai) Trading Co., Ltd. Etna Road, P.O. Box 5010 Unit A, 5th Floor, Careri Building Hanover, NH 03755 USA 432 West Huai Hai Road 603-643-3441 Tel (Main Office) Shanghai, 200052 603-643-5352 Fax (All Departments) PR China info@hypertherm.com (Main Office Email)
Page 5: Electromagnetic Compatibility (Emc
Immunity of other equipment in the en viron ment. User shall ensure that other equip ment being used in the Hypertherm’s CE-marked equipment is built in compliance environment is com pat i ble. This may require ad di tion al with standard EN60974-10.
Page 6 Screening and shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of in ter fer ence. Screening of the entire plasma cutting installation may be con sid ered for special applications. Hypertherm 4-08...
Page 7: Warranty
Hypertherm repair facility, all costs, insurance and freight needed to comply with the European EMC Directive are pre paid. Hypertherm shall not be liable for any repairs, incorporated within versions of the power supply with a replacement, or adjustments of Products covered by this CE Marking.
Page 8 A higher-level system with hazardous moving parts may constitute industrial machinery or robotic In no event shall Hypertherm be liable to any person equipment, in which case the OEM or end-use customer or entity for any incidental, consequential, indirect,...
Page 9 National and Local codes governing plumbing and electrical installation shall take precedent over any instructions contained in this manual. In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices.
Page 10: Table Of Contents
TABLE OF CONTENTS ELECTROMAGNETIC COMPATIBILITY (EMC) ........................i WARRANTY....................................ii Section 1 SAFETY ................................1-1 Recognize safety information...................................1-2 Follow safety instructions ..................................1-2 Cutting can cause fire or explosion................................1-2 Electric shock can kill ....................................1-3 Static electricity can damage circuit boards............................1-3 Toxic fumes can cause injury or death..............................1-4 A plasma arc can cause injury and burns .............................1-5 Arc rays can burn eyes and skin ................................1-5 Grounding safety......................................1-6...
Page 11 TABLE OF CONTENTS Electricidad estática puede dañar tablillas de circuito........................1b-3 Humos tóxicos pueden causar lesiones o muerte ...........................1b-4 El arco de plasma puede causar lesiones y quemaduras ......................1b-5 Los rayos del arco pueden producir quemaduras en los ojos y en la piel .................1b-5 Seguridad de toma a tierra ..................................1b-6 Seguridad de los equipos de gas comprimido ..........................1b-6 Los cilindros de gas pueden explotar si están dañados.........................1b-6...
Page 12 TABLE OF CONTENTS Plasma interface cable....................................3-22 CNC interface cable ....................................3-23 Pendant extension cable ..................................3-25 Motor drive cable .....................................3-26 HD3070 system interconnections ...............................3a-1 HT2000 system interconnections................................3b-1 HT2000LHF system interconnections..............................3c-1 HT4001 system interconnections................................3d-1 MAX100 System interconnections ..............................3e-1 MAX200 System interconnections ...............................3f-1 POWERMAX system interconnections..............................3g-1 HT4400 system interconnections................................3h-1 HPR system interconnections................................3i-1 HSD system interconnections................................3j-1...
Page 13 TABLE OF CONTENTS Section 6 PARTS LIST THC control module ....................................6-2 Plasma interface assembly ..................................6-4 2 Rail X-Y lifter assembly ..................................6-5 X-Y lifter torch mounting block kits ................................6-6 X-Y lifter torch breakaway kit – optional ..............................6-7 Operator pendant ......................................6-8 Power cords ........................................6-8 Ohmic contact wire....................................6-9 Recommended spare parts ..................................6-10 Interface cables..............................See Section 3a through 3j...
Page 14: Safety
Gas cylinders can explode if damaged ..............................1-6 Noise can damage hearing..................................1-7 Pacemaker and hearing aid operation ..............................1-7 A plasma arc can damage frozen pipes ..............................1-7 Additional safety information..................................1-8 Symbols and markings ....................................1-8 Warning labels ......................................1-9 Dry dust collection information ................................1-11 Hypertherm 11/08...
Page 15: Recognize Safety Information
WARNING CAUTION The symbols shown in this section are used to identify Hypertherm uses American National Standards Institute potential hazards. When you see a safety symbol in this guidelines for safety signal words and symbols. A signal manual or on your machine, understand the potential for...
Page 16: Electric Shock Can Kill
This switch allows grounding conductor first. the operator to turn off the power supply quickly in • Each Hypertherm plasma system is designed to be an emergency situation. used only with specific Hypertherm torches. Do not •...
Page 17: Toxic Fumes Can Cause Injury Or Death
The air quality level in any relevant workplace depends on site-specific variables such as: • Table design (wet, dry, underwater). • Material composition, surface finish, and composition of coatings. Hypertherm 11/08...
Page 18: A Plasma Arc Can Cause Injury And Burns
Less than 40 A 41 to 60 A 61 to 80 A 81 to 125 A 126 to 150 A 151 to 175 A 176 to 250 A 251 to 300 A 301 to 400 A 401 to 800 A Hypertherm 11/08...
Page 19: Grounding Safety
• Never allow electrical contact between the plasma arc and a cylinder. • Never expose cylinders to excessive heat, sparks, slag or open flame. • Never use a hammer, wrench or other tool to open a stuck cylinder valve. Hypertherm 11/08...
Page 20: Noise Can Damage Hearing
• Do not wrap or drape the torch lead or work cable around your body. Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch. • Keep as far away from the power supply as possible. Hypertherm 11/08...
Page 21: Additional Safety Information
SYMBOLS AND MARKS Your Hypertherm product may have one or more of the following markings on or near the data plate. Due to differences and conflicts in national regulations, not all marks are applied to every version of a product.
Page 22: Warning Label
7. Do not remove, destroy, or cover this label. 7. Ne pas enlever, détruire ni couvrir cette étiquette. Replace if it is missing, damaged, or worn (PN 110584 Rev C). La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C). Hypertherm 11/08...
Page 23 6. Become trained. Only qualified personnel should operate this equipment. Use torches specified in the manual. Keep non-qualified personnel and children away. Do not remove, destroy, or cover this label. Replace if it is missing, damaged, or worn. 1-10 Hypertherm 11/08...
Page 24: Dry Dust Collection Information
Note 2 – Users of Hypertherm manuals should consult and comply with all applicable federal, state, and local laws and regulations. Hypertherm does not, by the publication of any Hypertherm manual, intend to urge action that is not in compliance with all applicable regulations and standards, and this manual may never be construed as doing so.
Page 25: Section 1A
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .................1a-6 Le bruit peut provoquer des problèmes auditifs ..........................1a-7 Pacemakers et prothèses auditives ..............................1a-7 Un arc plasma peut endommager les tuyaux gelés..........................1a-7 Symboles et marquage ...................................1a-8 Étiquettes de sécurité .....................................1a-9 Information sur le dépoussiérage...............................1a-11 Hypertherm 1a-1 11/08...
Page 26: Dentifier Les Consignes De Sécurité
IDENTIFIER LES CONSIGNES DANGER AVERTISSEMENT ATTENTION DE SÉCURITÉ Hypertherm adopte les lignes directrices de l’American Les symboles indiqués dans cette section sont utilisés pour National Standards Institute relativement aux termes, aux identifier les risques éventuels. Si vous trouvez un symbole de symboles et à...
Page 27: Les Chocs Électriques Peuvent Être Fatals
Prévention des chocs électriques de courant. Tous les systèmes plasma Hypertherm utilisent des hautes • Ne jamais contourner ou court-circuiter les verrouillages tensions pour le coupage (souvent de 200 à 400 V).
Page 28: Les Vapeurs Toxiques Peuvent Provoquer Des Blessures Ou La Mort
Le niveau de qualité de l’air dans tout lieu de travail dépend du site afin d’assurer une qualité de l’air sûre. des variables propres au site comme : • Type de table (humide, sèche, sous l’eau). • Composition du matériau, fini de la surface et composition des revêtements. 1a-4 Hypertherm 11/08...
Page 29: L'arc Plasma Peut Provoquer Des Blessures Ou Des Brûlures
Moins de 40 A 41 à 60 A 61 à 80 A 81 à 125 A 126 à 150 A 151 à 175 A 176 à 250 A 251 à 300 A 301 à 400 A 401 à 800 A Hypertherm 1a-5 11/08...
Page 30: Mise À La Masse Et À La Terre
• Ne jamais exposer des bouteilles à une chaleur excessive, aux étincelles, aux scories ou aux flammes nues. • Ne jamais utiliser des marteaux, des clés ou d’autres outils pour débloquer le robinet des bouteilles. 1a-6 Hypertherm 11/08...
Page 31: Le Bruit Peut Provoquer Des Problèmes Auditifs
• Ne pas s’enrouler le faisceau de la torche ou le câble de retour autour du corps. Les tuyaux gelés peuvent être endommagés ou éclater si l'on essaie de les dégeler avec une torche plasma. • Se tenir le plus loin possible de la source de courant. Hypertherm 1a-7 11/08...
Page 32: Symboles Et Marquage
La marque CE signifie la déclaration de conformité du fabricant aux directives et normes européennes applicables. Seules les versions des produits Hypertherm portant la marque CE placée sur la plaque signalétique ou à proximité ont été mises à l’essai de conformité à la directive européenne sur la basse tension et la compatibilité électromagnétique européenne (CEM).
Page 33: Étiquettes De Sécurité
7. Do not remove, destroy, or cover this label. 7. Ne pas enlever, détruire ni couvrir cette étiquette. Replace if it is missing, damaged, or worn (PN 110584 Rev C). La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C). Hypertherm 1a-9 11/08...
Page 34: Étiquettes De Sécurité
Le personnel non qualifié et les enfants doivent se tenir à l’écart. Ne pas enlever, détruire ni couvrir cette étiquette. La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C). 1a-10 Hypertherm 11/08...
Page 35: Information Sur Le Dépoussiérage
à tous les systèmes de dépoussiérage. Note 2 – Les utilisateurs des manuels d’Hypertherm doivent consulter tous les règlements et lois fédéraux et locaux applicables et s’y conformer. Hypertherm n’a pas l’intention, en publiant un manuel d’Hypertherm, de demander des mesures qui ne sont pas conformes aux règlements et normes applicables et ce manuel ne peut jamais être interprété...
Page 36: Seguridad
Los cilindros de gas pueden explotar si están dañados.........................1b-6 El ruido puede deteriorar la audición..............................1b-7 Operación de marcapasos y de audífonos ............................1b-7 Un arco plasma puede dañar tubos congelados..........................1b-7 Símbolos y marcas ....................................1b-8 Etiquetas de advertencia..................................1b-9 Información sobre la colección de polvo seco ..........................1b-11 Hypertherm 1b-1 11/08...
Page 37: Reconocimiento De Información De Seguridad
RECONOCIMIENTO DE PELIGRO ADVERTENCIA PRECAUCIÓN INFORMACIÓN DE SEGURIDAD Hypertherm usa las directivas del Instituto Americano de Los símbolos que se muestran en esta sección se utilizan para Normas Nacionales (American National Standards Institute) identificar los posibles peligros. Cuando vea un símbolo de para las palabras y símbolos que señalan seguridad.
Page 38: El Choque Eléctrico Puede Provocar La Muerte
Prevención ante el electrochoque Deje la pieza en su lugar o sobre la mesa de trabajo con Todos los sistemas por plasma de Hypertherm usan alto el cable de trabajo conectado en todo momento. voltaje en el proceso de corte (son comunes los voltajes CD •...
Page 39: Humos Tóxicos Pueden Causar Lesiones O Muerte
• Diseño de mesa (mojada, seca, bajo agua). • La composición del material, el acabado de la superficie, y la composición de los recubrimientos. • Volumen que se quita del material. 1b-4 Hypertherm 11/08...
Page 40: El Arco De Plasma Puede Causar Lesiones Y Quemaduras
Menos de 40 A 41 a 60 A 61 a 80 A 81 a 125 A 126 a 150 A 151 a 175 A 176 a 250 A 251 a 300 A 301 a 400 A 401 a 800 A Hypertherm 1b-5 11/08...
Page 41: Seguridad De Toma A Tierra
• No exponga nunca los cilindros a calor excesivo, chispas, escorias o llamas. • No emplee nunca martillos, llaves u otro tipo de herramientas para abrir de golpe la válvula del cilindro. 1b-6 Hypertherm 11/08...
Page 42: El Ruido Puede Deteriorar La Audición
Se puede hacer daño a los tubos congelados, o se los puede • Manténgase tan lejos de la fuente de energía como reventar, si uno trata de descongelarlos con una antorcha por sea posible. plasma. Hypertherm 1b-7 11/08...
Page 43: Símbolos Y Marcas
SÍMBOLOS Y MARCAS Su producto de Hypertherm puede tener una o más de las marcas que siguen en, o cerca de la placa de datos. Debido a diferencias y conflictos en reglamentos nacionales, no todas las marcas se aplican a toda versión del producto.
Page 44: Etiquetas De Advertencia
7. Do not remove, destroy, or cover this label. 7. Ne pas enlever, détruire ni couvrir cette étiquette. Replace if it is missing, damaged, or worn (PN 110584 Rev C). La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C). Hypertherm 1b-9 11/08...
Page 45 Proteja su cuerpo completamente. Antes de trabajar en la máquina o de proceder a cortar, capacítese y lea las instrucciones completamente. No retire las etiquetas de advertencia ni las cubra con pintura. 1b-10 Hypertherm 11/08...
Page 46: Información Sobre La Colección De Polvo Seco
Kst, índice de deflagración” y otros términos. Nota 1 – La interpretación de Hypertherm de estos nuevos requisitos es que, a no ser que se haya completado una evaluación específica del sitio para determinar que todo polvo generado no es combustible, la edición del 2007 de la NFPA 68 requiere el uso de respiraderos de explosión diseñados para el peor caso del valor Kst (vea anexo F) que...
Page 47 Section 2 SPECIFICATIONS In this section: General .........................................2-3 Specifications......................................2-4 THC control module..................................2-4 Plasma interface assembly ................................2-5 X-Y lifter assembly....................................2-6 Operator pendant.....................................2-7 X-Y lifter breakaway option ................................2-8 CommandTHC for X-Y Table Instruction Manual...
Page 48 SPECIFICATIONS X-Y lifter assembly Plasma control module interface assembly Operator pendant Figure 2-1 X-Y CommandTHC system interfaced with plasma cutting system and CNC CommandTHC for X-Y Table Instruction Manual...
Page 49: General
SPECIFICATIONS General Hypertherm’s X-Y CommandTHC is a torch height control/initial height sensing (THC/IHS) system designed for plasma cutting applications on a X-Y cutting table (Figure 2-1). The system uses the plasma arc voltage to control the physical stand-off (distance) between the torch and workpiece during plasma arc cutting. IHS is accomplished by ohmic contact sensing or by a limited force stall detection method.
Page 50: Specifications
SPECIFICATIONS Specifications THC control module Electrical Input power (automatic selecting dual range) ..115 VAC or 230 VAC, 1 phase, 50/60 Hz Parallel digital I/O............+ 12 VDC Serial digital I/O (RS-422) ..........+ 5 VDC (operator pendant), CNC 14" (355 mm) 24 lb (11 kg) 5.6"...
Page 51: Plasma Interface Assembly
SPECIFICATIONS Plasma interface assembly Electrical Input power ..............+ 24 VDC Parallel digital I/O............+ 12 VDC Serial digital I/O (RS-422)..........+ 5 VDC Voltage divider function ..........41 :1 Arc voltage (isolated) HT4400 and HPR installation Note: Instructions to install the plasma interface PCB into the HT4400 power supply are included in section 3h.
Page 52: X-Y Lifter Assembly
SPECIFICATIONS X-Y lifter assembly Electrical Motor ..................+ 2.48 VDC, 2 phase (3.3 amp per phase) Limit switches..............+ 24 VDC Lifter control function Motor ................Stepper Motor drive................Stepper, chopped constant current Lifter feedback ..............Encoder Lifter limit switches............Home switch and lower limit switch Maximum Z axis speed ..........200 inches (508 cm) per minute Maximum Z axis stroke ..........8- inches (203 mm) Torch mounting dimensions...
Page 53: Operator Pendant
SPECIFICATIONS Operator pendant Electrical Input power ..............+ 12 VDC Serial digital I/O (RS-422) ..........+ 5 VDC 4.1" (104 mm) 1.1" (28 mm) 7 oz (0.2 kg) 8.25" (210 mm) (7.6 m) Figure 2-5 Operator pendant CommandTHC for X-Y Table Instruction Manual...
Page 54: X-Y Lifter Breakaway Option
SPECIFICATIONS X-Y lifter breakaway option Electrical Pressure switch ..............CNC emergency stop circuit voltage Breakaway control function Shop air pressure............100 psi (6.9 bar) maximum Size Breakaway width ............3.8 inches (97 mm) Breakaway height (thickness)........2.25 inches (57 mm) Air filter/regulator height ..........7.06 inches (179 mm) Air filter/regulator width ..........1.56 inches (40 mm) Air filter/regulator depth (from gauge to back) ..3.125 inches (79 mm) Weight...
Page 55: Setup
Section 3 SETUP In this section: Upon receipt........................................3-2 Standard components ..................................3-2 Optional components ..................................3-2 Claims ...........................................3-2 Power requirements....................................3-2 System unit mounting....................................3-3 THC control module..................................3-3 Plasma interface assembly ................................3-4 X-Y lifter assembly....................................3-5 Torch mounting block kit.................................3-6 Torch breakaway kit (optional) ..............................3-8 Install the torch (without torch breakaway option).........................3-10 Install the torch (with torch breakaway option) ........................3-11 System interconnections..................................3-12...
Page 56: Upon Receipt
Claims for damage during shipment — If your unit was damaged during shipment, you must file a claim with the carrier. Hypertherm will furnish you with a copy of the bill of lading upon request. If you need additional assistance, call Customer Service listed in the front of this manual, or your authorized Hypertherm distributor.
Page 57: System Unit Mounting
SETUP System unit mounting Before interconnecting the THC system, mount the units as required, using customer-supplied hardware. Do not allow the units to lie unsecured on top of cabinets or on the floor. Refer to Section 2, Specifications, for unit dimensions. THC control module •...
Page 58: Plasma Interface Assembly
SETUP Plasma interface assembly HT4400 and HPR installation Note: Instructions to install the plasma interface PCB into the HT4400 power supply are included in section 3h. Instructions to install the plasma interface PCB into the HPR power supply are included in section The plasma interface enclosure is not used for the HT4400.
Page 59: X-Y Lifter Assembly
SETUP X-Y lifter assembly • Mount the X-Y lifter assembly on the cutting table. See Figure 3-3. 1/4" (6 mm) 22.4" (570 mm) 3.5" (89 mm) 1.26" (32 mm) 3.5" 1.42" 2.12" (89 mm) (36 mm) (54 mm) 1.75" 1/4-20 (44.5 mm) 3.5"...
Page 60: Torch Mounting Block Kit
SETUP Torch mounting block kit • Mount the torch mounting block kit to the X-Y lifter assembly. See Figure 3-4. Refer to Section 6, Parts List for a complete list of available kits and kit parts breakdowns. Spacer Hex screws (4) Hex screws (2) Block Figure 3-4...
Page 61 SETUP Blank CommandTHC for X-Y Table Instruction Manual...
Page 62: Torch Breakaway Kit (Optional)
SETUP Torch breakaway kit (optional) Install the torch breakaway kit as follows. Refer to Figure 3-5. 1. Mount the fiberglass bracket to the X-Y lifter using the 4 hex screws. 2. Mount the breakaway to fiberglass bracket using the 6 screws. 3.
Page 63 SETUP Fiberglass bracket Spacer and 4 hex screws not Tube connector used if breakaway is installed. 6 screws Collar Hex screws (4) Collar Breakaway Block X-Y Lifter Hex screws (2) Pin 4 Pin 1 Pin 3 Wire to emergency stop circuit Tubing 1-5/16 inch...
Page 64: Install The Torch (Without Torch Breakaway Option)
SETUP Install the torch (without torch breakaway option) Mount the torch to the lifter with the mounting block and 2 screws. See Figure 3-6. Install the shield to the mounting block with 4 screws. Figure 3-6 Torch installed without torch breakaway option 3-10 CommandTHC for X-Y Table Instruction Manual...
Page 65: Install The Torch (With Torch Breakaway Option)
SETUP Install the torch (with torch breakaway option) Install the shield to the mounting block with 4 screws. See Figure 3-7. Mount the torch to the lifter with the mounting block and 2 screws. Figure 3-7 Torch installed with torch breakaway option CommandTHC for X-Y Table Instruction Manual 3-11...
Page 66: System Interconnections
SETUP System interconnections Cable part numbers and signal lists are provided in figures 3-14 through 3-18. THC system cables Caution: Do not run the pendant cable in parallel and near to the torch lead. There is a possibility that electrical noise will cause erratic operation of the operator pendant or damage it.
Page 67 SETUP X-Y Lifter Assembly IHS ohmic contact wire Lifter I/O interface cable Motor drive cable THC Control Module Plasma Interface Assembly Plasma interface cable Electrode and work leads HT4400: See NOTE on page 3-12 Power Supply Power supply Machine interface interface cable cable Optional Operator Pendant:...
Page 68: Machine Interface Cable
SETUP Machine interface cable 1. Cable-installed signal – See Figure 3-9. The machine interface cable provides a signal to verify that the cable is installed properly. Continuity must be provided through pins 3 and 22 so that the signal is not interrupted. Install a jumper wire in the CNC to provide continuity between pins 3 and 22 when the machine interface cable is installed to the CNC receptacle.
Page 69 SETUP 3. Install the machine interface cable as shown in Figure 3-11. Machine interface cable Control Module Not used THC.87 Figure 3-11 Machine interface cable 4. If installation requires removal of a cable connector, all wires must be properly terminated, including shield, or system problems may occur.
Page 70: Thc Selectable Responses
In other countries, follow appropriate local or national safety procedures. Remove the THC control module cover to access the DIP switch on the motor drive board. DIP switch Note: The DIP switch positions are set to ON (default settings) at Hypertherm. 3-16 CommandTHC for X-Y Table Instruction Manual...
Page 71: Dip Switch Positions
SETUP DIP switch positions Fast/Slow response • ON slows response speed of lifter by approximately one half in both up and down directions. • OFF enables "normal" or fast response. Conventional/HyDefinition resolution • ON enables the THC to respond to larger voltage error changes. •...
Page 72: Commandthc Serial Protocol
SETUP CommandTHC serial protocol Commands can be sent over a serial link to control the function of the torch height control. The interface is 4 wire RS422 on the MACHINE INTERFACE CABLE (pins (1) RX–, (20) RX+, (2) TX–, (21) TX+). The serial frame runs at: Old protocol (041507 control PCB) –...
Page 73 SETUP Application notes: 1. To do manual movements Jog up, down and Step up, down the THC must be in manual mode (Automatic Voltage Control = 0). 2. When the THC receives a Jog up or down command, it will move the torch up/down for 50 milliseconds. If a new command is not received after this time the motion will stop.
Page 74: Grounding Requirements
SETUP Grounding requirements To ensure personal safety and proper operation, and to reduce electromagnetic interference (EMI), the THC system must be properly grounded. Power cord grounding The THC control module must be properly grounded through the power cord according to national or local electrical codes.
Page 75: Lifter I/O Cable
SETUP Lifter I/O cable To THC To lifter control assembly THC.84 module Part number Length Part number Length 123209 5 ft./1.5 m 123215 40 ft./12.2 m 123210 10 ft./3 m 123216 45 ft./13.7 m 123211 15 ft./4.6 m 123023 50 ft./15.2 m 123212 20 ft./6.1 m 123217...
Page 76: Plasma Interface Cable
SETUP Plasma interface cable To interface To THC assembly control THC.84 module Part number Length Part number Length 123209 5 ft./1.5 m 123215 40 ft./12.2 m 123210 10 ft./3 m 123216 45 ft./13.7 m 123211 15 ft./4.6 m 123023 50 ft./15.2 m 123212 20 ft./6.1 m 123217...
Page 77: Cnc Interface Cable
SETUP CNC interface cable To THC To CNC control module THC.84 Part number Length Part number Length 123209 5 ft./1.5 m 123215 40 ft./12.2 m 123210 10 ft./3 m 123216 45 ft./13.7 m 123211 15 ft./4.6 m 123023 50 ft./15.2 m 123212 20 ft./6.1 m 123217...
Page 78 SETUP Notes to Figure 3-16 THC output Note 1. All THC outputs are optically coupled transistors with maximum ratings of 24 VDC and 10 mA. Output – 24 VDC maximum 10 mA maximum THC input Note 2. All THC inputs are optically isolated 12 VDC signals. Signals are made active by sinking 3 mA per input.
Page 79: Pendant Extension Cable
SETUP Pendant extension cable To THC To operator control pendant module THC.83 Part number Length 123018 25 ft./7.6 m 123019 50 ft./15.2 m number Color Signal name Function Signal name number 1 Input Black RX– RS-422 serial inverting receiver. TX– 1 Output Green RS-422 serial non-inverting receiver.
Page 80: Motor Drive Cable
SETUP Motor drive cable To THC To THC lifter control motor module THC.83 Part number Length Part number Length 123197 5 ft./1.5 m 123203 40 ft./12.2 m 123198 10 ft./3 m 123204 45 ft./13.7 m 123199 15 ft./4.6 m 123021 50 ft./15.2 m 123200 20 ft./6.1 m...
Page 81: Hd3070 System Interconnections
HD3070 SETUP Section 3a HD3070 SYSTEM INTERCONNECTIONS CommandTHC for X-Y Table Instruction Manual 3a-1...
Page 82 HD3070 SETUP Electrode and work lead arc voltage wires DANGER ELECTRIC SHOCK CAN KILL Turn off all electrical power before removing the power supply cover. Press the power supply OFF (0) pushbutton switch and set the line disconnect switch to OFF. In the U.S., use a “lock-out and tag-out”...
Page 83 HD3070 SETUP Plasma interface assembly THC.80 1XPCB1 PC board Figure 3a-1 HD3070 electrode and work lead arc voltage wires connection CommandTHC for X-Y Table Instruction Manual 3a-3...
Page 84 HD3070 SETUP Power supply interface cable The HD3070 power supply is equipped with a potentiometer for adjusting the pierce delay time. Disable the pierce delay potentiometer in the power supply per Section 3 of the HD3070 instruction manual. See Figure 3a-2. Connect the interface cable plug to the 1X1 receptacle on the back of the power supply.
Page 85 HD3070 SETUP Plasma interface assembly Power supply Plasma Interface assembly Green wire Black wire Orange wire Black wire Black wire White wire Black wire Red wire Black wire Yellow wire Figure 3a-2 HD3070 Power supply interface cable connections CommandTHC for X-Y Table Instruction Manual 3a-5...
Page 86 HD3070 SETUP Part number Description Length 123270 HD3070 Power Supply Interface Cable 6 ft./1.8 m Power Plasma Supply Interface Signal Name Color End (1X1) Function Hold I/O – Black J4-6 (Optional) Hold Ignition (I/O) signal used for preflow Hold I/O + Connected J4-5 during IHS.
Page 87 HD3070 SETUP Ohmic contact wire Install the ohmic contact wire through the strain relief of the plasma interface assembly. Install appropriate size fork terminal on the wire end and attach the wire to the J5-5 terminal labeled SHIELD. Install the other end of the ohmic contact wire to the IHS tab on the torch retaining cap.
Page 88: Ht2000 System Interconnections
HT2000 SETUP Section 3b HT2000 SYSTEM INTERCONNECTIONS CommandTHC for X-Y Table Instruction Manual 3b-1...
Page 89 HT2000 SETUP Electrode and work lead arc voltage wires DANGER ELECTRIC SHOCK CAN KILL Turn off all electrical power before removing the power supply cover. Press the power supply OFF (0) pushbutton switch and set the line disconnect switch to OFF. In the U.S., use a “lock-out and tag-out”...
Page 90 HT2000 SETUP Plasma interface assembly THC.75 Input/Output panel Figure 3b-1 HT2000 electrode and work Lead arc voltage wires connection CommandTHC for X-Y Table Instruction Manual 3b-3...
Page 91 HT2000 SETUP Power supply interface cable See Figure 3b-2. Connect the interface cable plug to the 1X6 receptacle on the back of the power supply. Connect the other plug of the interface cable to the CNC. Install the 3 pairs of wires of the interface cable to the plasma interface assembly as shown in Figure 3b-2.
Page 92 HT2000 SETUP Plasma interface assembly Power supply Plasma interface assembly Pilot Arc- Pilot Arc+ Transfer IN- Red wire Black wire Transfer IN+ Pierce Complete+ Pierce Complete- Hold Ignition- Black wire Hold Ignition+ White wire Plasma Start Black wire Plasma Start Blue wire 24V - 24V +...
Page 93 HT2000 SETUP Part number Description Length 123329 HT2000 Power Supply Interface Cable 6 ft./1.8 m Power Plasma Supply Interface Signal Name Color End (1X6) Function Hold – Black J4-6 (Optional) Hold Ignition (I/O) signal used for preflow during Hold + White Connected J4-5...
Page 94 HT2000 SETUP Ohmic contact wire Install the ohmic contact wire through the strain relief of the plasma interface assembly. See Figure 3b-4. Install appropriate size fork terminal on the wire end and attach the wire to the J5-5 terminal labeled SHIELD. Install the other end of the ohmic contact wire to the IHS tab on the torch retaining cap.
Page 95: Ht2000Lhf System Interconnections
HT2000LHF SETUP Section 3c HT2000LHF SYSTEM INTERCONNECTIONS CommandTHC for X-Y Table Instruction Manual 3c-1...
Page 96 HT2000LHF SETUP Electrode and work lead arc voltage wires DANGER ELECTRIC SHOCK CAN KILL Turn off all electrical power before removing the power supply cover. Press the power supply OFF (0) pushbutton switch and set the line disconnect switch to OFF. In the U.S., use a “lock-out and tag-out”...
Page 97 HT2000LHF SETUP Plasma interface assembly THC.75 Input/Output panel Figure 3c-1 HT2000LHF electrode and work lead arc voltage wires connection CommandTHC for X-Y Table Instruction Manual 3c-3...
Page 98 HT2000LHF SETUP Power supply interface cable See Figure 3c-2. Connect the interface cable plug to the 1X6 receptacle on the back of the power supply. Connect the other plug of the interface cable to the CNC. Install the 3 pairs of wires of the interface cable to the plasma interface assembly as shown in Figure 3c-2.
Page 99 HT2000LHF SETUP Plasma interface assembly Power supply Plasma interface assembly Pilot Arc- Pilot Arc+ Transfer IN- Red wire Black wire Transfer IN+ Pierce Complete+ Pierce Complete- Hold Ignition- Black wire Hold Ignition+ White wire Plasma Start Black wire Plasma Start Blue wire 24V - 24V +...
Page 100 HT2000LHF SETUP Part number Description Length 123329 HT2000LHF Power Supply Interface Cable 6 ft./1.8 m Power Plasma Supply Interface Signal Name Color End (1X6) Function Hold – Black J4-6 (Optional) Hold Ignition (I/O) signal used for preflow Hold + White Connected J4-5 during IHS.
Page 101 HT2000LHF SETUP Ohmic contact wire Install the ohmic contact wire through the strain relief of the plasma interface assembly. See Figure 3c-4. Install appropriate size fork terminal on the wire end and attach the wire to the J5-5 terminal labeled SHIELD. Install the other end of the ohmic contact wire to the IHS tab on the torch retaining cap.
Page 102: Ht4001 System Interconnections
HT4001 SETUP Section 3d HT4001 SYSTEM INTERCONNECTIONS CommandTHC for X-Y Table Instruction Manual 3d-1...
Page 103 HT4001 SETUP Electrode and work lead arc voltage wires DANGER ELECTRIC SHOCK CAN KILL Turn off all electrical power before removing the power supply cover. Press the power supply OFF (0) pushbutton switch and set the line disconnect switch to OFF. In the U.S., use a “lock-out and tag-out”...
Page 104 HT4001 SETUP Plasma interface assembly THC.74 Figure 3d-1 HT4001 electrode and work lead arc voltage wires connection CommandTHC for X-Y Table Instruction Manual 3d-3...
Page 105 HT4001 SETUP Power supply interface cable See Figure 3d-2. Connect the interface cable plug to the 1X6 receptacle on the back of the power supply. Connect the other plug of the interface cable to the CNC. Install the 3 pairs of wires of the interface cable to the plasma interface assembly as shown in Figure 3d-2.
Page 106 HT4001 SETUP Plasma interface assembly Power supply Plasma interface assembly Pilot Arc- Pilot Arc+ Transfer IN- Red wire Black wire Transfer IN+ Pierce Complete+ Pierce Complete- Hold Ignition- Black wire Hold Ignition+ White wire Plasma Start Black wire Plasma Start Blue wire 24V - 24V +...
Page 107 HT4001 SETUP Part number Description Length 123330 HT4001 Power Supply Interface Cable 6 ft./1.8 m Power Plasma Supply Interface Signal Name Color End (1X6) Function Hold – Black J4-6 (Optional) Hold Ignition (I/O) signal used for preflow Hold + White Connected J4-5 during IHS.
Page 108: Max100 System Interconnections
MAX100 SETUP Section 3e MAX100 SYSTEM INTERCONNECTIONS CommandTHC for X-Y Table Instruction Manual 3e-1...
Page 109 MAX100 SETUP Electrode and work lead arc voltage wires DANGER ELECTRIC SHOCK CAN KILL Turn off all electrical power before removing the power supply cover. Press the power supply OFF (0) pushbutton switch and set the line disconnect switch to OFF. In the U.S., use a “lock-out and tag-out”...
Page 110 MAX100 SETUP Plasma interface assembly THC.73 1XPCB1 PC board Figure 3e-1 MAX100 electrode and work lead arc voltage wires connection CommandTHC for X-Y Table Instruction Manual 3e-3...
Page 111 MAX100 SETUP Power supply interface cable See Figure 3e-2. 1. Remove access covers from the power supply, as required. 2. Locate TB1 inside the power supply. 3. Install the interface cable: Fabricate sensing wires as follows: • Use 18AWG (≈0.9 mm ), double pair, shielded wire, rated for 600V or greater.
Page 112 MAX100 SETUP Plasma interface assembly THC.77 Pilot Arc- Pilot Arc+ Transfer IN- Transfer IN+ Plasma Start Plasma Start 24V - 24V + Figure 3e-2 MAX100 power supply interface cable connections CommandTHC for X-Y Table Instruction Manual 3e-5...
Page 113: Max200 System Interconnections
MAX200 SETUP Section 3f MAX200 SYSTEM INTERCONNECTIONS CommandTHC for X-Y Table Instruction Manual 3f-1...
Page 114 MAX200 SETUP Electrode and work lead arc voltage wires DANGER ELECTRIC SHOCK CAN KILL Turn off all electrical power before removing the power supply cover. Press the power supply OFF (0) pushbutton switch and set the line disconnect switch to OFF. In the U.S., use a “lock-out and tag-out”...
Page 115 MAX200 SETUP Plasma interface assembly THC.75 Input/Output panel Figure 3f-1 MAX200 electrode and work lead arc voltage wire connections CommandTHC for X-Y Table Instruction Manual 3f-3...
Page 116 MAX200 SETUP Power supply interface cable See Figure 3f-2. Connect the interface cable plug to the receptacle on the back of the power supply. Install the 3 pairs of wires of the interface cable to the plasma interface assembly as shown in Figure 3f-2 See Figure 3f-3 for the interface cable part numbers and signal list.
Page 117 MAX200 SETUP Plasma interface assembly Power supply Pilot Arc- Pilot Arc+ Transfer IN- Red wire Transfer IN+ Black wire THC.78 Pierce Complete- Pierce Complete+ Hold Ignition- Black wire Hold Ignition+ White wire Plasma Start Plasma Start Black wire 24V - Green wire 24V + Figure 3f-2...
Page 118 MAX200 SETUP Part number Description Length 123358 MAX200 Power Supply Interface Cable 6 ft./1.8 m Power Plasma Supply Interface Signal Name Color End (1X6) Function Hold I/O – Black J4-6 (Optional) Hold Ignition (I/O) signal used for preflow Hold I/O + White J4-5 during IHS.
Page 119 MAX200 SETUP Ohmic contact wire Install the ohmic contact wire through the strain relief of the plasma interface assembly. See Figure 3f-4. Install appropriate size fork terminal on the wire end and attach the wire to the J5-5 terminal labeled SHIELD. Install the other end of the ohmic contact wire to the IHS tab on the torch retaining cap.
Page 120: Powermax System Interconnections
POWERMAX SETUP Section 3g POWERMAX SYSTEM INTERCONNECTIONS Verify power supply machine interface (Powermax800, Powermax900 and Powermax 1100) Look at the back of the power supply and verify that it is equipped with the machine interface option. Machine Interface Panel Power supply machine interface kits If your power supply is not equipped with the machine interface option, install one of the following kits: Power Supply Voltage...
Page 121 POWERMAX SETUP Electrode and work lead arc voltage wires DANGER ELECTRIC SHOCK CAN KILL Turn off all electrical power before removing the power supply cover. Press the power supply OFF (0) pushbutton switch and set the line disconnect switch to OFF. In the U.S., use a “lock-out and tag-out”...
Page 122 POWERMAX SETUP Plasma interface assembly VOLTAGE THC.72 Machine interface board Figure 3g-1 Powermax800, Powermax900 and Powermax 1100 electrode and work lead arc voltage wire connections CommandTHC for X-Y Table Instruction Manual 3g-3...
Page 123 POWERMAX SETUP Plasma interface assembly THC.72G3 Machine interface board Figure 3g-2 Powermax1000, Powermax1250 and Powermax 1650 electrode and work lead arc voltage wire connections 3g-4 CommandTHC for X-Y Table Instruction Manual...
Page 124 POWERMAX SETUP Power supply interface cable See Figure 3g-3. Connect the interface cable to the receptacle on the back of the power supply. Install the 2 pairs of wires of the interface cable to the plasma interface assembly as shown in Figure 3g-3.
Page 125 POWERMAX SETUP Plasma interface assembly Power supply Pilot Arc- Pilot Arc+ Transfer IN- Red wire Transfer IN+ Black wire THC.78 Pierce Complete- Pierce Complete+ Hold Ignition- Hold Ignition+ Plasma Start Green wire Plasma Start Black wire 24V - 24V + Figure 3g-3 Powermax power supply interface cable connections 3g-6...
Page 126: Ht4400 System Interconnections
HT4400 SETUP Section 3h HT4400 SYSTEM INTERCONNECTIONS CommandTHC for X-Y Table Instruction Manual 3h-1...
Page 127 HT4400 SETUP Plasma interface PC board preparation See Figure 3h-1. Remove and discard the access cover from the plasma interface assembly. Remove and discard the 2 connectors from the plasma interface PC board. Remove the plasma interface PC board from the interface enclosure. Save the PC board, the 4 standoffs and the 4 mounting screws.
Page 128 HT4400 SETUP THC.102 Figure 3h-1 Plasma interface PC board preparation CommandTHC for X-Y Table Instruction Manual 3h-3...
Page 129 HT4400 SETUP Install the plasma interface PC board into the HT4400 power supply DANGER ELECTRIC SHOCK CAN KILL Turn off all electrical power before removing the power supply cover. Press the power supply OFF (0) pushbutton switch and set the line disconnect switch to OFF. In the U.S., use a “lock-out and tag-out”...
Page 130 HT4400 SETUP mid plane mid plane THC.104 Figure 3h-2 Install the plasma interface PC board CommandTHC for X-Y Table Instruction Manual 3h-5...
Page 131 HT4400 SETUP Plasma interface PC board connection See Figure 3h-3. Install the 37-pin connector to the plasma interface PC board. Install the J2 and J3 connectors to the plasma interface PC board. NOTE: Wire No. 42 and 45 are secured to the 37-pin connector cable inside the power supply. Remove the wires and install as follows.
Page 132 HT4400 SETUP mid plane mid plane THC.105 Figure 3h-3 Plasma interface PC board connection CommandTHC for X-Y Table Instruction Manual 3h-7...
Page 133 HT4400 SETUP Ohmic contact wire See Figure 3h-4. Install the ohmic contact wire through the strain relief of the power supply. Install appropriate size fork terminal on the wire end and attach the wire to the J5-5 terminal labeled SHIELD of the plasma interface PC board. Install the other end of the ohmic contact wire to the IHS tab on the torch retaining cap.
Page 134 HT4400 SETUP Ohmic contact wire THC.106 Torch retaining cap with IHS tab P/N 120907 Figure 3h-4 HT4400 ohmic contact wire connection CommandTHC for X-Y Table Instruction Manual 3h-9...
Page 135: Hpr System Interconnections
HPR SETUP Section 3i HPR SYSTEM INTERCONNECTIONS CommandTHC for X-Y Table Instruction Manual 3i-1...
Page 136 HPR SETUP HPR130 and HPR260 power supplies DANGER ELECTRIC SHOCK CAN KILL Turn off all electrical power before removing the power supply cover. Press the power supply OFF (0) pushbutton switch and set the line disconnect switch to OFF. In the U.S., use a “lock-out and tag-out”...
Page 137 HPR SETUP Figure 3i-2 Install the plasma interface PC board Male Female Figure 3i-3 Plasma interface and control PC board connections inside the power supply CommandTHC for X-Y Table Instruction Manual 3i-3...
Page 138 HPR SETUP Connect the plasma interface assembly to the THC control module Install the plasma interface cable (see page 3-22 for part numbers) from the plasma interface PCB in the power supply to the THC control module. Install the machine interface cable (see page 3-23 for part numbers) from the THC control module to the CNC. Plasma Interface PCB (inside the power supply) THC Control...
Page 139 HPR SETUP Plasma interface and I/O board connections See Figures 3i-4, .3i-5, 3i-6, and 3i-7 Cut the cable tie on the wires bundled below the plasma interface board (numbered 25 and 26). Attach wire number 25 to stud marked WORK, and wire number 26 to stud marked ELECTRODE. Cut the cable tie on the wires bundled near the I/O board (numbered 25 and 26).
Page 140 HPR SETUP Figure 3i-6 I/O wire location Figure 3i-7 I/O board connections 3i-6 CommandTHC for X-Y Table Instruction Manual...
Page 141 HPR SETUP Ohmic contact wire See Figure 3i-8. Install the ohmic contact wire through the strain relief of the power supply. Install appropriate size fork terminal on the wire end and attach the wire to the terminal labeled SHIELD on the plasma interface PC board. Install the other end of the ohmic contact wire to the IHS tab on the torch retaining cap.
Page 142 HPR SETUP HPR400XD power supply Install the plasma interface PC board See Figures 3i-9 and 3i-10 Remove left and right side panels from the power supply (not shown). Install the plasma interface PC board (229145) on the 4 standoffs in the power supply. Install the machine interface cable (123760) from the control board to the plasma interface board.
Page 143 HPR SETUP Male Female Figure 3i-10 Plasma interface and control PC board connections CommandTHC for X-Y Table Instruction Manual 3i-9...
Page 144 HPR SETUP Connect the plasma interface assembly to the THC control module Install the plasma interface cable (see page 3-22 for part numbers) from the plasma interface PCB in the power supply to the THC control module. Install the machine interface cable (see page 3-23 for part numbers) from the THC control module to the CNC. Plasma Interface PCB (inside the power supply) THC Control...
Page 145 HPR SETUP Plasma interface and I/O board connections See Figures 3i-4, .3i-5, 3i-6, and 3i-7 Cut the cable tie on the wires bundled below the I/O board (numbered 25 and 26). Make the connections to the plasma interface board using the wire ends with fork terminals. Attach wire number 25 to the terminal marked WORK and wire number 26 to the terminal marked ELECTRODE.
Page 146 HPR SETUP Figure 3i-12 Plasma interface PC board connection Figure 3i-13 I/O board connections 3i-12 CommandTHC for X-Y Table Instruction Manual...
Page 147 HPR SETUP Ohmic contact wire See Figure 3i-8. Route the ohmic contact wire through the braided cover and torch sleeve and attach the connector to the torch. See figures below. Insert the wire through the rear of the power supply, install the appropriate size fork terminal on the wire end, and attach the wire to the terminal labeled SHIELD on the plasma interface PC board.
Page 148 HPR SETUP Figure 3i-14 Ohmic contact wire connection 3i-14 CommandTHC for X-Y Table Instruction Manual...
Page 149: Hsd System Interconnections
HSD130 SETUP Section 3j HSD SYSTEM INTERCONNECTIONS CommandTHC for X-Y Table Instruction Manual 3j-1...
Page 150 HSD130 SETUP Remove the cover and the rear panel DANGER ELECTRIC SHOCK CAN KILL Turn off all electrical power before removing the power supply cover. Press the power supply OFF (0) pushbutton switch and set the line disconnect switch to OFF. In the U.S., use a “lock-out and tag-out”...
Page 151 HSD130 SETUP Remove the rear panel from the HSD power supply. Arc voltage wires Fabricate the wires as follows: • Use 18AWG (0.9 mm 2 ), single pair, unshielded wire, rated for 600V or greater. • Wire length: As required, from the power supply to the plasma interface assembly. •...
Page 152 HSD130 SETUP Install the arc voltage wires Make the connections to the HSD power supply as shown below. Put the wire ends through the strain relief, where shown, in the power supply. Install the appropriate size fork terminal on the end of the negative (–) wire, and attach the wire to the terminal strip, in the plasma interface assembly, labeled ELECTRODE.
Page 153 HSD130 SETUP Ohmic contact wire Install the ohmic contact wire through the strain relief of the plasma interface assembly. Install the appropriate size fork terminal on the wire end and attach the wire to the terminal labeled SHIELD on the plasma interface PC board. Install the other end of the ohmic contact wire to the IHS tab on the torch retaining cap.
Page 154 HSD130 SETUP Install the machine interface cable (see page 3-22 for part numbers) from the power supply to the plasma interface assembly. 3j-6 CommandTHC for X-Y Table Instruction Manual...
Page 155 HSD130 SETUP Connect the plasma interface assembly to the THC control module Install the plasma interface cable (see page 3-22 for part numbers) from the plasma interface assembly to the THC control module. Install the machine interface cable (see page 3-23 for part numbers) from the plasma interface assembly to the CNC.
Page 156: Operation
Section 4 OPERATION In this section: Operating controls .....................................4-2 THC control module..................................4-2 Operator pendant ....................................4-2 Pendant display screens ................................4-4 Pendant programmable fields ...............................4-6 Automatic operation screen ..............................4-6 Manual operation screen................................4-8 Setup screen A ...................................4-9 Determining pierce height factor................................4-11 Typical pierce height factor .................................4-11 Pierce height factor for thicker materials ..........................4-12 THC operating cycle time-lines ................................4-14 Automatic mode time-line ................................4-15...
Page 157: Operating Controls
OPERATION Operating controls THC control module Figure 4-1 Power switch Operator pendant The operator pendant consists of the LCD display, the keypad, and the connecting cable. See Figure 4-2 and the following table for pendant keypad use. = NOT USED Figure 4-2 Operator pendant key pad CommandTHC for X-Y Table Instruction Manual...
Page 158 OPERATION FUNCTION/USE Lifter moves to home position (full up), the brake locks to prevent the torch from diving, and system ignores the Cycle Start signal. Selects main operating screen for either automatic or manual control mode. Selects the height the torch retracts after completing a cut. FULL = full retract MID = programmable dimension Initiates IHS test;...
Page 159: Pendant Display Screens
OPERATION Pendant display screens Pendant display screens are shown in Figure 4-3. TO GET TO SCREEN THIS SCREEN FUNCTION Can view and adjust basic operating parameters. AUTOMATIC Press Can perform initial height sensing (IHS). OPERATION Automatic voltage control (AVC) is active. Torch height is automatically adjusted during a cut to maintain the displayed Set Arc Volts.
Page 160: Automatic Operation Screen
OPERATION Automatic Operation Screen Manual Operation Screen Setup Screen A Diagnostic Screen B Remote Mode Screen Maintenance Mode Screen Figure 4-3 Pendant display screens CommandTHC for X-Y Table Instruction Manual...
Page 161 OPERATION Pendant programmable fields The following fields can be changed to adjust system operating parameters. Automatic Operation Screen Set Arc Volts Sets the automatic voltage control (AVC) setpoint. Set Arc Volts can be changed any time (stationary or during a cut). When the AUTO mode is selected and after the Pierce Delay and Machine Accel Delay times have elapsed, the arc voltage is controlled by the THC (torch height).
Page 162 OPERATION Pierce Delay Sets Pierce Delay (motion dwell time). After receiving the “Transfer” signal from the plasma system, the THC will delay both the “Machine Motion” and the “Pierce Complete” signals during the pierce delay time. After the “Pierce Delay” time, the “Machine Motion”...
Page 163: Manual Operation Screen
OPERATION Manual Operation Screen Torch Position Torch height can be changed when the torch is stationary or during a cut. Small change: +/– 0.002 inch/0.05 mm Large change: starts/stops continuous motion Note: IHS and AVC are disabled when viewing the Manual Operation Screen. CommandTHC for X-Y Table Instruction Manual...
Page 164: Setup Screen A
OPERATION Setup Screen A Range 50%–300% 1 – 10 1 – 10 ON – OFF ON – OFF 0 – 9 sec ON – OFF 1 – 10 inch or mm 0 – 1 sec Pierce Height Factor A percent value used to calculate the pierce height. During a normal cut cycle, the torch will move down and sense the workpiece, then retract to the Pierce Height (Set Cut Height X Pierce Height Factor).
Page 165 Note that the gas preflow time is determined by the plasma system and will not be reduced by activating this parameter. This function occurs with no interaction with the CNC and is totally under THC control. Some Hypertherm power supplies may not include a “Hold Ignition” signal.
Page 166: Determining Pierce Height Factor
Set this delay as short as possible, so that the torch does not retract when the plasma arc is still active. Retract Delay should be used on Hypertherm LongLife plasma systems. Determining pierce height factor Typical pierce height factor See Figure 4-4 for sequence of events.
Page 167: Pierce Height Factor For Thicker Materials
OPERATION EVENT Pierce Height Plate Pierce Delay Machine Automatic Acceleration Voltage Cut Height Delay Control Plate Plate Figure 4-4 Typical pierce height factor – sequence of events Pierce height factor for thicker materials General: When cutting materials 3/4 inch (19 mm) or thicker, the torch may contact the molten metal accumulated on top of the plate during piercing.
Page 168 OPERATION Molten metal accumulated on top of plate during piercing. Figure 4-5 Arc piercing thicker materials EVENT Pierce Height Plate Pierce Delay Machine Automatic Acceleration Voltage Cut Height Delay Control Plate Plate Figure 4-6 Pierce height factor for thicker materials – sequence of events CommandTHC for X-Y Table Instruction Manual 4-13...
Page 169: Thc Operating Cycle Time-Lines
OPERATION THC Operating cycle time-lines The following pages describe the normal operating cycle time-lines for the THC in the automatic and manual modes. Table 4-1 lists the problems that can occur during a typical operating cycle in the automatic mode, as well as solutions that can be done by the operator.
Page 170: Automatic Mode Time-Line
OPERATION Automatic mode time-line Start CNC traverses to next piercing position. For multiple torch /THC installations only: CNC issues INS-SYNC-IN signal to each THC. This signal holds arc firing until all THCs are at IHS position. CNC issues a CYCLE-START-IN to THC. If Preflow During IHS is enabled, THC issues a PLASMA-START-OUT and a HOLD-IGNITION-OUT signal to plasma power supply.
Page 171: Problems And Solutions
OPERATION Table 4-1 THC operating cycle (automatic mode) process problems and solutions (Refer to operating cycle time-line on previous page) Problem Solution • Check power to THC. On THC control PCB, D41 – D44 should be illuminated. Check line input fuses in THC power module. •...
Page 172 OPERATION Problem Solution • Check that Pierce Height is not too high by checking Set Cut Height on Main Operating Screen and Pierce Height Factor on Setup Screen A. Torch arc fails to transfer to workpiece. • Check work lead connection. •...
Page 173: Manual Mode Time-Line
OPERATION Manual mode time-line Start 1. CNC traverses to next piercing position. 2. CNC issues a CYCLE-START-IN to THC. 3. THC issues a PLASMA-START-OUT to plasma power supply. 4. Preflow completes. 5. Torch fires and arc transfers to workpiece. 6. Plasma power supply issues TRANSFER-OUT signal to THC. Programmed pierce delay signal elapses.
Page 174: Maintenance
Section 5 MAINTENANCE In this section: Routine maintenance....................................5-2 X-Y lifter sealing band removal and replacement..........................5-2 Troubleshooting ......................................5-6 Diagnostic screen B..................................5-6 Error messages ....................................5-6 AC power distribution ..................................5-10 Motor drive board status lights during normal power-up.....................5-11 DC power distribution..................................5-12 Control board status lights during normal power-up......................5-14 Interface board status lights during normal power-up......................5-16 CommandTHC for X-Y Table Instruction Manual...
Page 175: Routine Maintenance
MAINTENANCE Routine maintenance Every 3 months complete the following: DANGER ELECTRIC SHOCK CAN KILL Turn off all electrical power before removing the power supply cover. Press the power supply OFF (0) pushbutton switch and set the line disconnect switch to OFF. In the U.S., use a “lock-out and tag-out”...
Page 176 MAINTENANCE VIEW 1 Retaining block Left side cover screws (5) Left side cover Retainer VIEW 2 Retaining block VIEW 3 Sealing band Figure 5-1 Sealing band – Remove CommandTHC for X-Y Table Instruction Manual...
Page 177 MAINTENANCE Sealing band — install (Figure 5-2) 1. Install the new band from the back of the lifter (View 1). 2. Route the band through the top and bottom slots. Make sure the band sits in the channel (View 1). 3.
Page 178 MAINTENANCE VIEW 2 Retainer Retaining block VIEW 3 Groove Left side cover screws (5) Left side cover Figure 5-2 Sealing band – install (2 of 2) CommandTHC for X-Y Table Instruction Manual...
Page 179: Troubleshooting
MAINTENANCE Troubleshooting DANGER ELECTRIC SHOCK CAN KILL Turn off all electrical power before removing the power supply cover. Press the power supply OFF (0) pushbutton switch and set the line disconnect switch to OFF. In the U.S., use a “lock-out and tag-out” procedure until the service or maintenance is complete.
Page 180 Table 5-1 X-Y THC error messages Error Message* Clear Error Description of Error Corrective Action • Reposition lifter, torch or workpiece. • Select Diagnostic Screen B by pressing <B> on keypad. Then press <SHIFT-B> to start tests. Check for the following: –...
Page 181 • Check Home Limit switch and cable, replace if required. A processor on THC control PCB Watch Dog Timeout FAIL Repower • Call Hypertherm Technical Service. has failed. Changed real-time processor to a • Check ﬁrmware revisions in both processors for compatibility.
Page 182 Table 5-1 X-Y THC error messages Error Message* Clear Error Description of Error Corrective Action • Place THC in Manual Position Mode and jog torch to Home Torch inhibited from reaching position to activate switch. Diag FAIL Repower Home Limit position during •...
Page 183: Ac Power Distribution
MAINTENANCE AC power distribution Check fuses. Remove fuses by gently prying out the fuse holder. See Figure 5-4 and Table 5-2. Figure 5-4 AC power and fuses Table 5-2 AC power and fuses Input Filter Power Supply Power Fuses AC Power In Ground (chassis) —...
Page 184: Motor Drive Board Status Lights During Normal Power-Up
MAINTENANCE Motor drive board status lights during normal power-up The following LEDs are located on the motor drive PCB inside the control module. See Figure 5-5. Signal function Status Drive active Brake released Down * On = brake is unlocked Off = brake is on Figure 5-5 Motor drive board...
Page 185: Dc Power Distribution
MAINTENANCE DC power distribution The following connections are located on the power supply board inside the control module. See Figure 5-6 and Table 5-3. Figure 5-6 Power supply board 5-12 CommandTHC for X-Y Table Instruction Manual...
Page 186 MAINTENANCE Table 5-3 DC power, LEDs and test points Wire Connection Points/LEDs and Test Points Wire Power Supply PCB Motor Drive PCB Control PCB Power Color DC Power Out DC Power In DC Power In + 12 VDC Blue TB2-1 J8-3/D43 &...
Page 187: Control Board Status Lights During Normal Power-Up
MAINTENANCE Control board status lights during normal power-up The following LEDs are located on the control board inside the control module. See Figure 5-7. Signal function Status Signal function Status cycle start input +24v auto height on/off –12v spare input +12v spare input IHS sync input...
Page 188 MAINTENANCE Figure 5-7 Control board CommandTHC for X-Y Table Instruction Manual 5-15...
Page 189: Interface Board Status Lights During Normal Power-Up
MAINTENANCE Interface board status lights during normal power-up The following LEDs and test points are located on the interface board. See Figure 5-8. Signal function Status Power Shield Relay Normally On – Off when arc initiates. Plasma Start On when plasma start signal to the power supply is active. Ohmic Contact Normally Off –...
Page 190: Parts List
Section 6 PARTS LIST In this section: THC control module ....................................6-2 Plasma interface assembly..................................6-4 2 rail X-Y lifter assembly ....................................6-5 X-Y lifter torch mounting block kits .................................6-6 X-Y lifter breakaway kit – optional ................................6-7 Operator pendant.......................................6-8 Power cords ........................................6-8 Ohmic contact wire....................................6-9 Recommended spare parts ...................................6-10 Interface cables..............................See Section 3a through 3j CommandTHC for X-Y Table Instruction Manual...
Page 191: Thc Control Module
PARTS LIST THC control module Index no. Part no. Description Quantity 053018 THC control module 002261 Enclosure, THC control module 129067 Heatsink SA, THC control module 004705 Heatsink, THC 005186 Module, power entry, fused filter 008971 Fuse, T,3.15 Amp H 250V 5 mm x 20 mm 229070 Power source, 130W (see Figure 6-2) 041511...
Page 192 PARTS LIST Figure 6-2 THC control module interior CommandTHC for X-Y Table Instruction Manual...
Page 193: Plasma Interface Assembly
PARTS LIST Plasma interface assembly Index no. Part no. Description Quantity 128494 Plasma interface assembly 128408 PC Board Assembly, plasma interface 041842 HPR PC Board Assembly, plasma interface HT4400 and HPR installation Note: Instructions to install the plasma interface PCB into the HT4400 power supply are included in section 3h.
Page 194: Rail X-Y Lifter Assembly
PARTS LIST 2 rail X-Y lifter assembly Index no. Part no. Description Quantity 128606 X-Y lifter assembly 128726 Encoder replacement kit 128727 Motor/Encoder replacement kit 027550 Brake, power off 129699 Assembly: leadscrew standard 127154 Drive nut 128607 Band seal kit (length 32.3125”) 027903 Block, driving 128190...
Page 195: X-Y Lifter Torch Mounting Block Kits
Kit, torch mounting block, 1-3/4 Inch diameter torch 128279 Kit, torch mounting block, 2 inch diameter torch 004775 Spacer, Command THC mounting block 075127 Socket cap, 1/4-20 X 1-1/2 inch hex BTN S/Z 075583 Socket cap, 1/4-20 X 1-3/4 inch hex SST...
Page 196: X-Y Lifter Breakaway Kit - Optional
128281 Kit, X-Y lifter torch breakaway 004774 Bracket, breakaway X-Y fiberglass Screw 075509 Socket cap, 1/4-20 X 1/2 inch hex BTN S/Z 027574 Breakaway, Command THC 123596 Cable: CMD THC lifter torch breakaway 127155 Proximity switch 127156 Collar 015317 Connector, male 10-32 X 1/4 inch, push In tube 046078 Tubing, 1/4 inch O.D.
Page 197: Operator Pendant
PARTS LIST Operator pendant Index no. Part no. Description Quantity 053019 Operator pendant, with 25 ft. cable 027665 Protective cover (not shown) 228057 Kit: cable replacement Figure 6-7 Operator pendant Power cords Index no. Part no. Description Quantity 008960 Domestic power cord, 115 VAC 008961 International power cord, 230 VAC (not shown) Figure 6-9...
Page 198: Ohmic Contact Wire
PARTS LIST Ohmic contact wire Index no. Part no. Description Length Quantity 123464 Ohmic contact wire 10 ft./3 m 123465 20 ft./6.1 m 123221 25 ft./7.6 m 123222 30 ft./9.1 m 123223 40 ft./12.2 m 123039 50 ft./15.2 m 123224 75 ft./23 m 123225 100 ft./30.5 m...
Page 199: Recommended Spare Parts
PARTS LIST Recommended spare parts X-Y lifter assembly - 2 rail (128606) Part No. Description Quantity 128607 Kit: torch lifter band-seal replacement 128190 Kit: lifter band replacement rollers X-Y lifter assembly - 1 rail (128050 - old style) Part No. Description Quantity 128189...
Page 200: Wiring Diagrams
Section 7 WIRING DIAGRAMS Introduction This section contains the wiring diagrams for the system. When tracing a signal path or ref er enc ing with the Parts List or Troubleshooting sections, please be aware of the following format to assist you in un der stand ing the wiring diagrams' organization: •...
Page 201: Wiring Diagrams
WIRING DIAGRAMS CommandTHC for X-Y Table Instruction Manual...
Page 202 WIRING DIAGRAMS CommandTHC for X-Y Table Instruction Manual...
Page 203 Machine Interface I/O Cable Operator Pendant (053019 Optional Unit) Interface 123022 Machine I/O Cable Pendant Ext. Cable 023018 Command Plasma Interface Command I/O Cable Command I/O Cable Module 123022 123022 123022 053018 128494 THC Motor Drive Cable 123020 ELEC SCHEM:COMMAND THC 013369...
Page 204 6-4D +12V –12V SHEET 3-4C +24V L1 BLK SHEET 120 Vac 3-4C L2 BLK SHEET 120 Vac 6-4C SHEET GRN/YEL 3-4D SHEET 6-4D GRN/YEL Fuse 3.1A Pwr Entry Mdl 008971 005186 009858 Pwr Cord 008960 008961 ELEC SCHEM:COMMAND THC 013369...
Page 205 1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 2911 3012 1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 TO CNC 123022 TO PLASMA INTERFACE 123022 SHEET 7-4A ELEC SCHEM:COMMAND THC 013369...
Page 206 SPARE RS-422 PENDANT RS-422 TX– TX– OPTIONAL PENDANT RS-422 (053019) +12V +12V 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 23 SHEET 5-3A ELEC SCHEM:COMMAND THC 013369...
Page 207 SW2 - ON - STD PLASMA RESOLUTION SW3 - ON - LIMIT DOWN SW4 - HPR PEIRCE COMPLETE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1617 18 19 20 21 22 23 SHEET ELEC SCHEM:COMMAND THC 4-3A 013369...
Page 208 2-4C –12V +24V SHEET 3-4C SHEET 2-4C LIFTER INTERFACE 1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 TO LIFTER 123022 ELEC SCHEM:COMMAND THC 013369 7-10...
Page 209 1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 TO THC 123022 TO PLASMA SYSTEM 123022 SHEET 3-2A ELEC SCHEM:COMMAND THC 013369 7-11...
Page 210 MACHINE ACCEL MACHINE MOTION MACHINE ACCEL CORNER HOLD RETRACT DELAY CORNER HOLD RETRACT RETRACT DELAY RETRACT COMPLETE RETRACT TORCH MACHINE START FIRES MOTION REMOVED RETRACT COMPLETE START TORCH MACHINE FIRES MOTION REMOVED AUTO VOLTAGE TRANSFER CONTROL ELEC SCHEM:COMMAND THC 013369 7-12...
Page 211 Appendix A PARTS LIST FOR OLDER SYSTEMS In this section 1 Rail Lifter ........................................a-2 Plasma interface assembly ..................................a-3 THC control module....................................a-4 CommandTHC for X-Y Table Instruction Manual...
Page 212: Appendix Aparts List For Older Systems
APPENDIX A – PARTS LIST FOR OLDER SYSTEMS 1 rail lifter Index no. Part no. Description Quantity 128050 X-Y lifter assembly 128726 Encoder replacement Kit 128727 Motor/Encoder replacement Kit 027550 Brake, power off 027552 Driving block 027551 Rail and block, bearing 129266 Assembly, leadscrew standard 128189...
Page 213: Plasma Interface Assembly
APPENDIX A – PARTS LIST FOR OLDER SYSTEMS Plasma interface assembly Note: 128048 can only be used if the control module (see next page) has the older control PCB and software. If the control module is updated the plasma interface upgrade kit (128503) must be installed. Index no.
Page 214: Thc Control Module
APPENDIX A – PARTS LIST FOR OLDER SYSTEMS THC control module Index no. Part no. Description Quantity 053018 Control module 002261 Enclosure: control module 129067 Heatsink assembly 004705 Heatsink 005186 Power entry module: fused filter 008971 Fuse: T, 3.15 Amp, H 250 V, 5 mm x 20 mm *041507 PCB: control (see figure on next page) *081029...
Page 215 APPENDIX A – PARTS LIST FOR OLDER SYSTEMS Control module interior CommandTHC for X-Y Table Instruction Manual...
Page 216 The following options will APPEAR on the change settings menu: F1 – CHANGE THE SETTINGS F2 – NEXT OPTION F3 – PREVIOUS OPTIONS F4 – QUIT WITHOUT SAVING F5 – SAVE & EXIT Command THC for X-Y Table Instruction Manual...
Page 217: Appendix Bpendant Contrast Adjustment Procedure
APPENDIX B – PENDANT CONTRAST ADJUSTMENT PROCEDURE 2. Press F2 (AUTO/MAN button) until you get to the VIEWING ANGLE parameter. 3. Press F1 (MAINT/MODE button) to change the contrast setting until the display is easy to see. 4. Press F5 (IHS TEST/RUN button) to save the changes, and then press F1 (MAINT/MODE button) to acknowledge that the change has been saved.
Page 218 Page of Description of Change Rev 10 to 11 2/2009 Change Global Updated formats to current style for TOCs and converted font from Helvetica to Akzidenz. i and ii Updated the EMC and Warranty sections to new format Added section 1c (Spanish safety section) and updated 1a and 1b. Updated graphics of the plasma interface assembly to show the addition of a second I/O, DB Global connector.
Page 219 Page of Change Description of Change Rev 9 to 10 1/31/05 Cover & Title Rev changed from 9 to 10. Art on cover updated to show new encoder. page Added note to Plasma interface assembly with voltage divider, bullet. 3.16, 5.12 Changed part number in 130 W power supply art from 041509 to 229070 and 6.3 Changed part number for item number 5 (power source, 130W) from 041509 to...
Page 220 CommandTHC for X-Y Table Instruction Manual...