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Hypertherm ArcGlide Torch Height Control, Instruction Manual

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Hypertherm ArcGlide Torch Height Control Instruction Manual Download Page 205

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ArcGlide Motor Controller Processor PCB

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Summary of Contents for ArcGlide Torch Height Control

Page 1: ...Instruction Manual 806450 Revision 3 November 2010 ArcGlide THC...

Page 2: ......

Page 3: ...ion 3 November 2010 Copyright 2010 Hypertherm Inc All Rights Reserved ArcGlide EDGE Pro Hypertherm HPR and Sensor THC are trademarks of Hypertherm Inc and may be registered in the United States and or...

Page 4: ...Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax 65 6841 2489 Technical Service Hypertherm Shanghai Trading Co Ltd Unit A 5th Floor Careri Building 432 West Huai Hai Road Shanghai 200052 PR Chi...

Page 5: ...55 1 7 Discrete plasma interface 090052 1 8 Ethernet switch 1 9 ArcGlide communication 1 11 Hypernet communication configurations 1 12 Discrete communication configurations 1 13 Mixed communication co...

Page 6: ...h CNC and MAX200 HT2000 or HT2000 LHF plasma system 2 20 ArcGlide plasma interface with discrete connection to MAX200 HT2000 or HT2000 LHF plasma system 2 21 ArcGlide plasma interface connection to Po...

Page 7: ...9 Operation 3 1 Operator controls 3 2 Control module 3 2 Lifter 3 3 HMI 3 4 Daily operations 3 5 Startup procedure 3 5 Shutdown procedure 3 5 ArcGlide THC operating modes 3 6 Manual mode 3 6 Automatic...

Page 8: ...software 4 14 Download from a laptop 4 14 Operator tests 4 15 Problems and solutions 4 16 Troubleshooting routines 4 19 Edge Pro will not communicate with HPR power supply 4 19 Error message troublesh...

Page 9: ...llowed correctly WARNING safety messages precede related instructions in this manual that may result in injury or death if not followed correctly CAUTION safety messages precede related instructions i...

Page 10: ...workpiece in place or on the workbench with the work cable attached during the cutting process Before checking cleaning or changing torch parts disconnect the main power or unplug the power supply Ne...

Page 11: ...drogen Cutting under water with fuel gases containing hydrogen can result in an explosive condition that can detonate during plasma cutting operations WARNING Hydrogen Detonation with Aluminum Cutting...

Page 12: ...ality level in any relevant workplace depends on site specific variables such as Table design wet dry underwater TOXIC FUMES CAN CAUSE INJURY OR DEATH Material composition surface finish and compositi...

Page 13: ...with dark colors to reduce reflection Use protective screens or barriers to protect others from flash and glare Warn others not to watch the arc Use placards or signs ARC RAYS CAN BURN EYES AND SKIN...

Page 14: ...plosion Protection by Deflagration Venting provides requirements for the design location installation maintenance and use of devices and systems to vent combustion gases and pressures after any deflag...

Page 15: ...ection American National Standards Institute 1430 Broadway New York NY 10018 4 AWS F4 1 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held H...

Page 16: ...English Hypertherm Safety and Compliance S 8...

Page 17: ...Language requirements Electromagnetic compatibility requirements These differences in national or other standards may make it impossible or impractical for all certification test marks to be placed on...

Page 18: ...with both fixed and adjustable trip currents between 6 to 40 milliamperes and a range of trip times up to 300 milliseconds selected for the equipment installation application and intended use Where RC...

Page 19: ...heck all federal state and local laws In the European Union check the EU directives national and local laws For more information visit www hypertherm com weee In other countries check national and loc...

Page 20: ...uipment will be installed and operated In the USA the National Institute for Occupational Safety and Health NIOSH Manual of Analytical Methods NMAM is a collection of methods for sampling and analyzin...

Page 21: ...lasma interface 1 4 Industrial Ethernet switch 1 4 Specifications 1 5 System 1 5 Control module 090054 1 5 Lifter assembly 090053 1 6 Optional HMI 090055 1 7 Discrete plasma interface 090052 1 8 Ether...

Page 22: ...ith a plasma system and CNC Note The ArcGlide control module and Ethernet switch should be located in an electrical cabinet that is electrically grounded and environmentally clean Plasma system CNC Ar...

Page 23: ...torch lifter station under control of the control module positions a torch head vertically above the workpiece The lifter has the following features Ability to detect the workpiece using Ohmic contac...

Page 24: ...convenient control signal interface to the ArcGlide THC Hypertherm offers two types of plasma interface HPR Hypernet communication factory installed All other plasma systems discrete communication fi...

Page 25: ...e output 70 VDC 6 A Hypernet communication Shielded RJ 45 Cat 5e Control module Control module 090054 Input power 115 VAC or 230 VAC 1 Phase 50 60 Hz Operating temperature 10 C to 40 C 14 F to 104 F O...

Page 26: ...sembly 78 7 mm 3 1 151 0 mm 5 9 268 1 mm 10 6 743 2 mm 29 3 127 0 mm 5 0 85 5 mm 3 4 11 11 kg 24 50 lb 238 8 mm 9 4 50 8 mm 2 0 Part number Torch mounting and breakaway options 090082 51 mm 2 in mount...

Page 27: ...vals CE CSA Input power 100 VAC to 240 VAC 50 60 Hz 40 mA to 20 mA 1 Phase Hypernet communication Shielded RJ 45 Cat 5e Operating temperature 10 C to 40 C 14 F to 104 F Operating humidity 95 relative...

Page 28: ...ace is required for configurations that use discrete communication Electrical Input power 24 V AC or DC Parallel digital I O 12 VDC to 24 VDC Serial digital I O 5 VDC Voltage divider ratio 50 1 Arc vo...

Page 29: ...numbers and details about each model A plasma arc cutting system can be configured with 1 CNC up to 4 plasma systems 4 THC controllers 4 lifters and 4 optional HMIs The total number of ports your sys...

Page 30: ...and current information about installing and operating these switches If your cutting system does not include one of these Advantech Ethernet switches use the specifications in the following table to...

Page 31: ...crete I O and serial data A dedicated cable to each component from the ArcGlide control module within each cable there is a dedicated wire for each signal Hypernet Ethernet data packets A standard Cat...

Page 32: ...igured Ethernet port for these connections In addition a Hypernet configuration must include an industrial grade Ethernet switch to route communication from the CNC to the other units in the system No...

Page 33: ...ion is used between the ArcGlide THC and CNC or plasma system and discrete communication is used for the alternate link from the ArcGlide THC Whenever the HMI is used it must be connected to the contr...

Page 34: ...1 14 ArcGlide THC Instruction Manual Specifications...

Page 35: ...em 2 14 ArcGlide THC with discrete connection to a Picopath CNC and HPR or HPR XD plasma system 2 15 ArcGlide THC with discrete connection to a generic CNC and HPR or HPR XD plasma system 2 16 ArcGlid...

Page 36: ...6 Cables 2 38 Lifter interface cable 2 38 Hypernet and HMI interface cable 2 39 Operator console I O cable 2 40 ArcGlide motor control CNC interlock kit 228594 2 41 CNC I O cable 2 42 Plasma interface...

Page 37: ...em 2 14 ArcGlide THC with discrete connection to a Picopath CNC and HPR or HPR XD plasma system 2 15 ArcGlide THC with discrete connection to a generic CNC and HPR or HPR XD plasma system 2 16 ArcGlid...

Page 38: ...6 Cables 2 38 Lifter interface cable 2 38 Hypernet and HMI interface cable 2 39 Operator console I O cable 2 40 ArcGlide motor control CNC interlock kit 228594 2 41 CNC I O cable 2 42 Plasma interface...

Page 39: ...erm distributor Claims for defective or missing merchandise If any of the merchandise is defective or missing contact your supplier If you need additional assistance call Customer Service listed in th...

Page 40: ...the plasma system and other systems such as the CNC controller and the motor drivers as well as the supplemental ground rod connected to the work table In the plasma circuits the ground is carried fro...

Page 41: ...e ground bus can be steel Under no circumstances should aluminum or steel hardware be used 6 AC power PE and service grounds must be connected to all equipment according to local and national codes 7...

Page 42: ...d If the 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 type 1800F or equivalent The...

Page 43: ...above shows the connection from the gantry ground bus the connection from the ground rod the plasma system positive lead the RHF console the CNC enclosure the torch holder and the plasma system chass...

Page 44: ...l ground cables from the components mounted on the gantry go to the bus except those from the RHF console and the torch holder A single heavy cable then goes from the gantry ground bus to the ground b...

Page 45: ...ve systems It also limits the amount of noise that is received by the CNC and other control and measurement circuits ArcGlide Chassis and RFI ground AC earth or service ground Driven ground RHF consol...

Page 46: ...ernet HMI optional Lifter Control module System description for a Hypernet configuration The following diagram illustrates the cable and signal connections in a Hypernet communication configuration No...

Page 47: ...rete communication configuration Note For information on multidrop configurations refer to the instruction manual for your plasma system Discrete control and signal cables Customer supplied operator c...

Page 48: ...2 12 ArcGlide THC Instruction Manual INSTALLATION...

Page 49: ...port industrial Ethernet switch Hypernet plasma interface 141161 installed in plasma system below Rotary address switch set to 1 HPR130 HPR260 HPR130XD HPR260XD HPR400XD with a built in Ethernet adap...

Page 50: ...RNET Plasma interface assembly 090052 EDGE Pro CNC DB37 to DB37 cable 123760 HPR or HPRXD plasma system with discrete plasma interface 090052 Plasma interface I O cable Interlock Lifter interface cabl...

Page 51: ...Cable 223192 without serial with red heatshrink Plasma interface 090052 CNC I O cable Shielded Ethernet cable ArcGlide control module address 1 Plasma interface cable Arc voltage sense wires Lifter i...

Page 52: ...d Ethernet cable ArcGlide control module address 1 Plasma interface cable Arc voltage sense wires Lifter interface cable ArcGlide lifter To plasma interface assembly Cable 223192 without serial with r...

Page 53: ...1 ArcGlide HMI address 1 To CNC RS 422 port terminate as required CNC I O cable Plasma interface cable Lifter interface cable ArcGlide lifter DB50 male Cable 223192 without serial with red heatshrink...

Page 54: ...3 24V PULL UP PULL UP 24V PULL UP 24V FUTURE USE NO CONNECT NO CONNECT FOR I O USE IF NEEDED 500MA MAX ARC XFER D3 D4 THC ON D2 PLASMA STRT PLASMA ON D1 16 1 16 Interface cable 123760 DB37 to DB37 To...

Page 55: ...NC with Picopath interface HSD130 Plasma interface mounted externally by customer Plasma interface I O cable Interface cable 123209 Arc voltage sense wires Use 0 9 mm squared 18 AWG twisted pair wire...

Page 56: ...erface cable ArcGlide control module address set to 1 ArcGlide HMI address set to 1 CNC with Picopath interface Plasma interface I O cable CNC I O cable Shielded Ethernet cable ArcGlide lifter To plas...

Page 57: ...ernally by the customer No connection Electrode Work Remove Replace with bushing 008245 Refer to HT2000 HT2000LHF manual for the 1x6 connection 1x6 Machine interface cable Plasma interface termination...

Page 58: ...wisted pair wire rated 600 V or greater Plasma interface I O cable CNC I O cable ArcGlide lifter No connection Powermax G3 CAT 5e shielded Ethernet cable Plasma interface 090052 mounted by the custome...

Page 59: ...ol Red 1 Cycle start input 31 Output 11 Hold ignition Blue 7 IHS sync input 30 Output 10 Torch height disable Green 5 AVC disable input 12 Input 12 Cut sense 1 Green 17 Machine motion output A Jumper...

Page 60: ...ULL UP 24V PULL UP 24V FUTURE USE NO CONNECT NO CONNECT FOR I O USE IF NEEDED 500MA MAX ARC XFER D3 D4 THC ON D2 PLASMA STRT PLASMA ON D1 16 1 16 24V PULL UP To plasma system WORK J3 Outputs J2 Inputs...

Page 61: ...LLATION Install the lifter 17 8 mm 7 114 3 mm 4 5 44 45 mm 1 75 6 7 mm 0 266 in diameter 44 45 mm 1 75 44 45 mm 1 75 44 45 mm 1 75 44 45 mm 1 75 44 45 mm 1 75 44 45 mm 1 75 44 45 mm 1 75 44 45 mm 1 75...

Page 62: ...cally along the side of the lifter to verify that it is mounted vertically e Tighten the screws using a maximum torque of 0 9 newton meter 8 0 inch pounds f When they are tightened the tops of the scr...

Page 63: ...the terminal end off the Ohmic wire from the HPR XD torch and strip 5 mm 0 2 in of the covering 5 Insert the end of the Ohmic wire from the HPR XD system through the grommet in the bottom of the moto...

Page 64: ...not splice Ohmic wires If your plasma system is not an HPR XD system connect the ArcGlide Ohmic wire to the torch 1 Unfasten the tywrap around the coiled Ohmic wire and straighten the Ohmic wire 2 Ins...

Page 65: ...lifter 2 Fit the ground wire terminal on the ground wire over the grounding post 3 Replace the bottom nut and washer on the ground post and finger tighten it so the ground terminal is in contact with...

Page 66: ...6 56 157 23 mm 6 19 168 91 mm 6 65 358 65 mm 14 12 381 00 mm 15 37 71 63 mm 2 82 107 95 mm 4 25 25 40 mm 1 00 Control module front Control module right side 127 00 mm 5 00 371 35 mm 14 62 Control modu...

Page 67: ...cables for more information on connecting cables to the control module 3 Attach one end of the power cord to the AC Power connector on the front of the control module Prepare the other end for the 120...

Page 68: ...d level or tilted 101 60 mm 4 00 130 58 mm 5 14 19 43 mm 0 77 9 55 mm 0 38 20 00 mm 0 79 298 00 mm 11 73 117 60 mm 4 63 65 00 mm 2 50 10 32 x 9 52 mm 3 8 Phillips head screw 63 50 mm 2 50 203 20 mm 2...

Page 69: ...le you want it and tighten the screws 5 Attach one end of the power cord to the AC Power connector on the back of the HMI Prepare the other end for the 120 240 VAC power outlet Ground the HMI To groun...

Page 70: ...on on the requirements for this switch see Specifications In this type of configuration the Hypernet links are made from the ArcGlide directly to the Ethernet switch and from there to the CNC or plasm...

Page 71: ...net cable to connect the CNC to the Ethernet switch a Insert one end of the Hypernet cable into the Hypernet port on the back of an EDGE Pro CNC or to a Hypernet configured dedicated Ethernet port on...

Page 72: ...is color coded to match the connector on the interface cable that connects to it as shown in the illustrations for each cable later in this section 1 Connect the HMI to the control module a Insert on...

Page 73: ...appropriate connectors on the custom operator console For more information see the description of the operator console I O cable later in this section 3 Connect the plasma system to the control modul...

Page 74: ...nse bias 12 VDC 9 Black 22 AWG Encoder common 10 Red 22 AWG Lifter station active 11 White Blue 22 AWG Encoder input B 12 Blue 22 AWG Encoder input B 13 White Yellow 22 AWG Encoder input A 14 Yellow 2...

Page 75: ...Not connected 5 Not connected 6 RX receive data 7 Not connected 8 Not connected Hypernet and HMI interface cable Connect this end to the ArcGlide HMI Connect this end to the control module or Ethernet...

Page 76: ...t this end to the connector on the control module with the green circle Add the appropriate connector for your console on this end Contact your console supplier for additional information Pin number C...

Page 77: ...n This interlock must be wired correctly and according to the appropriate national and local codes to allow the quick stop of motion The interlock must be closed pins 25 and 26 to enable the Z axis mo...

Page 78: ...ol Notes All ArcGlide CNC inputs can be configured for dry contact closures or 12 24 V sourced inputs For more information about discrete CNC I O signals see ArcGlide discrete interface signals Pin nu...

Page 79: ...way output B 23 Brown CNC Spare output A 24 Red CNC Spare output B 25 Orange Motion interlock input 26 Red Motion interlock input 27 White Interlock output A 28 Green Interlock output B 29 Blue Common...

Page 80: ...Note For more information about discrete plasma I O signals see ArcGlide discrete interface signals Pin numbers are the same on both ends of the cable Pin number Color Signal name Dry contact circuit...

Page 81: ...ed Spare output A 25 Orange Spare output B 26 Red Remote on output A 27 White Remote on output B 28 Green Common 29 Blue Common 30 Green Common 31 Yellow 24 VDC output 32 Green 24 VDC output 33 Brown...

Page 82: ...ol board Part number Length Used in 223192 61 cm 2 ft HPR130 XD HPR260 XD 223193 2 3 m 7 5 ft HPR400 XD Pin number Color Signal name 1 Not connected 2 Not connected 3 Not connected 4 Not connected 5 N...

Page 83: ...Hold output A 21 Yellow Hold output B 22 Red Start output A 23 Brown Start output B 24 Red Spare output A 25 Orange Spare output B 26 Red Remote on output A 27 White Remote on output B 28 Green Commo...

Page 84: ...er Signal Pin number Signal 1 HPR RX 20 HPR Rx 2 HPR TX 21 HPR Tx 3 RS422 Com 22 HPR powered on 4 Ground 23 Motion 5 Ground 24 Error 6 Ground 25 Rampdown error 7 Ground 26 HPR NR 8 Not connected 27 No...

Page 85: ...or dry contacts no external voltage the default or for positive voltage sourced inputs The inputs have two different modes that are selected using switches behind the calibration and setup door on the...

Page 86: ...against currents above 100 mA The 24 V supply is limited to a total of 2 Amps for all outputs The figure below shows the simplified schematic of the ArcGlide THC outputs Relay outputs Relay Relay Rela...

Page 87: ...y a retract at the end of the cut when this signal is removed This signal must be maintained during the plasma cut Low Gain Input This input automatically reduces the AVC gain for marking This improve...

Page 88: ...and to clear any tip ups This signal is optional Cut Sense This is a required output from the ArcGlide to the CNC This signal is issued after plasma torch ignition and the Pierce Delay Time has expir...

Page 89: ...he serial interface to the HPR power supplies If connected to an HPR auto gas system then all plasma related parameters can be set using this interface For both HPR auto and manual systems this interf...

Page 90: ...configuration have completed their IHS sequence and are in position and ready to fire At this point all active torches will return an active IHS Complete signal to the CNC and the CNC should remove al...

Page 91: ...Torch UP Switch This is a switch contact input signal that raises the torch This input raises the torch manually if the torch is not cutting The manual motion starts as a 0 01 inch jog after a 1 2 se...

Page 92: ...ArcGlide and Hypertherm Ethernet To select the ArcGlide THC and Hypernet 1 Select Setups Password and enter the Machine password 2 On the Machine setup screen use the scroll box next to ArcGlide THCs...

Page 93: ...an one ArcGlide axis the screen displays a numbered soft key for each axis 2 Press or click the soft key for the ArcGlide axis you want to set up Use the information in the table in this section to se...

Page 94: ...nd enter the Station password 3 Click Reset if ArcGlide THC does not appear in the Lifter dropdown list 4 On the Station Configuration screen select ArcGlide THC for each station on which you want to...

Page 95: ...priate If this value is set too high the lifter positioning will become unstable and prone to oscillation If this value is set too low the positioning can become slow and inaccurate This gain can be t...

Page 96: ...s 25 4 in mm 5 mm 5 08 revolutions to travel one linear inch This results in a value of 5 08 revolutions x 4 000 counts revolution 20 320 counts per linear inch of travel Example 20 320 counts per lin...

Page 97: ...for fine tuning in multiple ArcGlide installations or for long leads How to use The measured input value is multiplied by the value of this parameter before being used for either voltage control or di...

Page 98: ...e sub optimal For the Hypertherm 24 13 cm 9 5 inch lifter this value is 0 1524 centimeters 600 inches per minute At the low input line voltage limit the motor drive is capable of supplying about 45 VD...

Page 99: ...e between the torch center and the laser pointer when looking from the side of the cutting machine When to use During installation How to use Use the precise distance between the laser spot and the ce...

Page 100: ...2 64 ArcGlide THC Instruction Manual INSTALLATION...

Page 101: ...edure 3 5 ArcGlide THC operating modes 3 6 Manual mode 3 6 Automatic modes 3 6 Arc voltage control AVC disabled 3 7 Set arc voltage mode 3 7 Sampled arc voltage mode 3 7 Operating the HMI 3 9 HMI scre...

Page 102: ...odule Item Control Description 1 LEDs These LEDs show the status of system operations 2 Display window This window displays status error and diagnostic messages 3 Display select Press the UP or DOWN a...

Page 103: ...s off the brake is locked and the lifter is disabled 2 Station enable disable switch Press this switch up to enable the lifter for operation Press the switch down to disable the lifter before maintena...

Page 104: ...not have a CNC connected to Hypernet the operator can also make changes to parameter values 4 Scroll and selection button Allows the user to select set and view values for parameters in the parameter...

Page 105: ...trol module In a Hypernet configuration if the Hypernet link between the ArcGlide and the plasma system is not active the plasma system will not power ON 2 Return the lifter to the Home position 3 Cal...

Page 106: ...the programmed Slow Speed Manual mode is used to Cut a flat workpiece when cut quality is not a primary concern The torch cuts at the same height regardless of consumable wear Make rip cuts Mark on a...

Page 107: ...ng thin material at low torch heights Cutting complex shapes where lead ins are short Cutting or marking under conditions where an accurate IHS is not possible Some of these conditions include A dirty...

Page 108: ...Cut height delay AVC delay Auto kerf detect Torch height disable Cut off time Stop time Retract height CNC cut control active Plasma torch active Cutting X Y motion AVC active Cut height Time CNC cycl...

Page 109: ...ay provides information about the process setup of the ArcGlide The Diagnostics display shows the latest error message and control state of the system The Installation display provides access to lifte...

Page 110: ...S Stall Force Ohmic Plate sense Kerf Detect Kerf Level Diagnostics screen Error message Control state Hypernet status Switch diagnostics Test IHS Auto manual mode Enabled disabled Manual up Manual dow...

Page 111: ...Errors The latest and currently active error condition sent from the control module Set Volts 50 V to 300 V with 0 1 volt resolution This line displays only if Sampled Arc Voltage is not enabled Cut H...

Page 112: ...ting the pierce puddle that forms when cutting thicker workpieces IHS Start Height This is the height above the workpiece at which the torch speed slows to the IHS speed before contacting the workpiec...

Page 113: ...detected AVC is disabled and the torch position is fixed for a short period to avoid diving into the workpiece Kerf Level This parameter sets a sensitivity threshold to detect kerf The range is 1 mor...

Page 114: ...seconds ERR 4 PLATE CONTACT AT HOME Ohmic contact with the workpiece at home position an invalid condition ERR 5 HOME LIM DURING OPR The Lifter reached the Home limit during auto operation ERR 6 LOWE...

Page 115: ...The Transfer signal was not received from the plasma system within 60 seconds ERR 13 LOST TRANSFER The plasma arc was lost during the cut ERR 14 FAILED MOVE TO PIERCE The lifter failed to reach Pierce...

Page 116: ...rlock was removed ERR 28 BREAKAWAY TRIPPED Torch breakaway was removed ERR 29 FIELD SUPPLY FAILED The 5 V 12 V or 12 V supply has failed ERR 30 LIFTER CALIBRATION Lifter Calibration down motion failed...

Page 117: ...torch up at the programmed Slow Speed till the Upper Limit Switch or a stall is detected Then the lifter enters the Upper Limit state LIFTER CALIBRATION The control module calibrates the lifter immed...

Page 118: ...or the IHS Sync input signal from the CNC to synchronize multiple torches Then the THC enters the Start Plasma state START PLASMA The lifter holds the torch at the IHS Transfer position waits for the...

Page 119: ...act state MANUAL UP The lifter initially jogs up 0 254 mm 0 01 inch After 0 5 second it begins continuous upward motion at the IHS Speed After 2 seconds the lifter increases the speed to the programme...

Page 120: ...feedback Maximum Speed per min This parameter sets the maximum linear speed that the THC can achieve Fast Speed per min This speed is used for all automatic rapid moves such as the End of Cut Retract...

Page 121: ...loop positioning Relative ARC Volts Gain This gain is used when the THC is operating closed loop arc voltage control Arc Voltage Calibration This value is used to finely calibrate the measured arc vol...

Page 122: ...y errors and pierce delay information is displayed HMI Parameter Value Error The most recent error condition Pierce Delay 0 to 10 seconds with 0 01 second resolution Setup Parameters Return to the Set...

Page 123: ...that display HMI Parameter Value Arc Starts The number of times the arc has started since the last time consumables were changed and the counter was restated Arc Minutes The number of minutes of acti...

Page 124: ...n in the Phoenix software determine the operation of an ArcGlide THC that is configured with a Hypertherm CNC Many of these parameters interact with other parameters on this screen or on other screens...

Page 125: ...constant position during the cut that is independent of the Arc Voltage Setting OFF ON Sample Voltage Description The Height Control must be in Automatic Mode and the Voltage Control must be ON When S...

Page 126: ...erce Height Description This value determines the height at which the torch pierces the workpiece This value originates in the plasma process cut charts and can be temporarily fine tuned on this scree...

Page 127: ...ion To set this parameter the Height Control must be in Automatic Mode When Auto Kerf Detect is active the THC looks for a rapid rise in the measured arc voltage that indicates that the torch is cutti...

Page 128: ...previous cut the THC skips the IHS When this happens the torch goes directly to the Transfer Height and skips contact with the workpiece This setting can improve the overall machine production rate b...

Page 129: ...t the torch is raised to clear the top dross puddle that can form during the pierce It is the torch height after Pierce This height is entered as a percentage of the Cut Height The torch remains at th...

Page 130: ...achine motion With a value of up to 2 seconds the plasma arc turns off after motion stops This parameter is generally used to help compensate for the plasma torch ramp down Setting 1 2 seconds Arc Off...

Page 131: ...ze cut quality 4 11 Plasma set up tips 4 11 Maximize the life of consumable parts 4 11 Additional factors of cut quality 4 12 Additional improvements 4 13 Update ArcGlide software 4 14 Download throug...

Page 132: ...lide PCBs 4 43 HMI processor 228581 4 43 HMI 7 segment display interface 228582 4 45 THC controller interface 228577 4 46 THC processor 228578 4 51 Discrete plasma interface 228576 4 55 Hypernet plasm...

Page 133: ...iage The carriage on the slide within the ArcGlide lifter requires lubrication at regular intervals that are based on the number of hours of operation or the distance that the slide travels Under norm...

Page 134: ...brication interval To oil the sealing strip 1 Remove the front panel to access the carriage and sealing strip 2 Apply a few drops of oil Shell Tellus 100 heavy hydraulic fluid is recommended to the se...

Page 135: ...shielding practices in the Installation section of this manual Check the work lead connection particularly where the work lead connects to the cutting table This must be a good clean connection becau...

Page 136: ...arrows on the front of the control module to restore defaults or to enter built in test modes Power OFF then power ON to end test mode Power OFF then power ON to end test mode Power ON reset Initializ...

Page 137: ...Critical errors must be corrected before power is turned on again Encoder overflow or underflow Field supply failure Interlock activated Lifter breakaway activated AC voltage low or high Max processor...

Page 138: ...e HMI operating parameters Use CNC discrete wire operating signals Station disabled Critical error Plasma remote power ON Plasma remote power OFF Plasma system Hypernet link active Use Hypernet Plasma...

Page 139: ...date motor drive and lifter brake outputs Update CNC interface and plasma supply outputs front panel status LEDS Set desired torch position ion Reset state timer Not the first time in this state Error...

Page 140: ...rward motion of the torch 2 Torch to work distance is not correct check Cut chart information 3 Cutting speed is not correct check Cut chart information 4 Arc current is not correct check Cut chart in...

Page 141: ...p on the workpiece The torch should never fire into the air Start the cut at the edge of the workpiece is acceptable as long as the arc is not fired in the air To start with a pierce use a pierce heig...

Page 142: ...nd It forms as a thin linear bead of solid metal attached very close to the cut It is welded to the bottom of the cut and is difficult to remove To reduce high speed dross Decrease the cutting speed D...

Page 143: ...quires a 50 mm lead in To avoid damage to the shield from the build up of molten material created by the pierce do not allow the torch to descend to cut height until it has cleared the puddle of molte...

Page 144: ...t on the dialog box Select 0 to exit without updating 8 When the update process is complete the program returns the network settings to their original settings and exits Update ArcGlide software Downl...

Page 145: ...he torch between the transfer and retract heights On a Hypertherm CNC the Test IHS soft key on the Process screen performs the same function Operator tests The operator can perform several tests to te...

Page 146: ...PCB 5 Verify that the corresponding station is enabled and that the green Enable light on the lifter is illuminated Arc ignites before IHS is complete 1 Check that the Hold signal is reaching the plas...

Page 147: ...naccurate IHS with Stall Force sensing 1 Check that Nozzle Ohmic Contact is OFF disabled 2 Check Transfer Height 3 Check that Stall Force is not set too high 4 Check that workpiece is not deflecting e...

Page 148: ...o short Torch dives below cutting height immediately after pierce delay and before AVC begins 1 Increase Set Cut Height on Automatic Operating Screen and decrease Pierce Height Factor 2 Increase Machi...

Page 149: ...s Edge Pro will not communicate with HPR power supply Verify that all units are wired and powered up Check for software update or protocol mismatch On the ArcGlide controller scroll down 4 screens and...

Page 150: ...take to correct it Also see Troubleshooting routines Normal errors are cleared with the next plasma cycle Critical errors must be corrected before the next plasma cycle Error Description Possible Cau...

Page 151: ...ually jog the lifter down while watching the LCD on the HMI or control module and verify that the position being displayed increases as the torch moves downward If the lifter is not a Hypertherm lifte...

Page 152: ...ing properly Check the condition of the Ohmic contact wire replace it if it is faulty A loose connection to the lifter can cause this problem Check the torch tip for an electrical short between the sh...

Page 153: ...e plasma interface PCB as well as cables to and from the board If a Hypernet plasma interface is used check Hypernet communications to the board from the control module display If Arc Voltage is read...

Page 154: ...ation and perform a test IHS Do the test twice During the first test the ArcGlide will calculate the travel distance on the first IHS During the second test the ArcGlide will use the programmed Start...

Page 155: ...een the shield and nozzle Check the consumables for damage and for the correct combination Disable Nozzle Contact in the Plasma process screen if a water table is used or water injection plasma system...

Page 156: ...are going in the right direction lower torch positive direction 11 The IHS_Sync input to the control module was not released within a reasonable time and after the IHS was complete The error can occur...

Page 157: ...C Hypernet only The transfer time needs to be long enough to allow the plasma system to purge gases In an HPR this could be up to 10 seconds Check the plasma system for an error Make sure the plasma s...

Page 158: ...erce height setting in the Plasma Process screen or in the plasma menu in the control module Do an IHS test and verify that the torch is retracting to the pierce height listed in the plasma system cut...

Page 159: ...ule See ArcGlide Setup Parameters in the Installation section Check for other mechanical binds that can be preventing the lifter from moving properly 15 Failed to reach the cut height after motion sta...

Page 160: ...the plasma interface board to the plasma system control module Check the transfer output on the plasma system control board If the plasma arc actually extinguishes check the transfer current sensor i...

Page 161: ...is off The workpiece is lying unevenly on the table The lifter is stalling before reaching the plate Possible problem with plasma system Damaged or the wrong consumables in the torch The wrong consuma...

Page 162: ...torch height disable while cutting and verify that this parameter is turning off in corners and in a radius and verify that it is not turning on while piercing or immediately after motion starts Check...

Page 163: ...nnection between the shield cap and Ohmic wire connection on the back of the torch Perform a test IHS and verify that the torch is reaching the plate If the torch is firing in the air Increase the Sta...

Page 164: ...rature Allow the control module to cool down to within the normal operating temperature before continuing operating the ArcGlide The ambient temperature has exceeded the specified maximum temperature...

Page 165: ...mounted within a cabinet check the ambient temperate within the cabinet and verify that air is continuously being circulating inside the cabinet If fans or a cooler is present verify that these compon...

Page 166: ...ifter I O cable for damage 29 The 5 V 12 V or 24 V supplies are not within their normal operating range 120 VAC is applied to the control module and control module is configured for 220 VAC A damaged...

Page 167: ...and position encoder for proper operation 31 The control module is unable to communicate with either the CNC or the HMI If an HMI is part of the ArcGlide system a Hypernet connection is required to th...

Page 168: ...e properly configured Check the Ethernet cables connecting to HMI or CNC Verify that the Ethernet switch is properly powered Check that all related units are powered and addressed to the unit number C...

Page 169: ...ter interface cable for damage Check the operation of the motor and encoder from within the diagnostic screen of the CNC or at control module 35 The internal position counter has counted below its min...

Page 170: ...that dropped out exceeded the maximum number The Hypernet components are not addressed properly The Ethernet cable is loose or damaged Check the unit addresses on all the Hypernet devices and verify...

Page 171: ...ace Op con interface Plasma interface Board interconnect Lifter interface PCB Lifter interface Motor brake encoder interface Upper lower limit switches Tip touch Station enable switch Manual up down s...

Page 172: ...et connector THC interface PCB CNC interface Lifter interface Op con interface Discrete plasma interface Board interconnect Lifter interface PCB Motor brake encoder interface Upper lower limit switche...

Page 173: ...haracter module J8 Front panel LEDs J11 Rotary encoder input J12 Power input J10 IHS Test pushbutton J9 Display backlight SW6 Unit address switch default setting 1 SW2 UNIT ADDRESS Note In a Hypernet...

Page 174: ...LED 8 Contact LED 9 Spare1 LED 10 Spare1 LED J10 IHS Test pushbutton Pin number Signal 1 Ground 2 IHS test J11 Front panel rotary encoder input Pin number Signal 1 Ground 2 Ground 3 Pushbutton A 4 Ou...

Page 175: ...decimal point 2 LED V 20 Hundreds G 3 Ones decimal point 21 Hundreds F 4 Ones G 22 Hundreds E 5 Ones F 23 Hundreds D 6 Ones E 24 Hundreds C 7 Ones D 25 Hundreds B 8 Ones C 26 Hundreds A 9 Ones B 27 Th...

Page 176: ...to Transformer J6 CNC I O male J4 Lifter I O male J7 Op Con I O female J5 Plasma I O female 4 37 1 34 4 24 1 34 4 37 1 21 1 12 3 14 Motor drive J3 to Transformer Pin number Signal 1 115 V input 1 2 1...

Page 177: ...connected 18 Not connected 19 5 VDC 20 Ground 21 Plasma Motion input 22 Plasma Corner output 23 Plasma Error input 24 Plasma Pierce output 25 Plasma Ramp Error input 26 Plasma Hold output 27 Plasma No...

Page 178: ...put 64 1 50 Arc V 65 Op Con Torch Up input 66 Ohmic contact sense 67 Op Con Torch Down input 68 Ohmic contact sense common 69 5 VDC 70 Ground 71 Op Con Spare input 72 Power good low active 73 Not conn...

Page 179: ...n 12 Encoder input B 24 Not connected J5 Plasma interface Pin number Signal Pin number Signal 1 RS422 RX 20 Hold output A 2 RS422 RX 21 Hold output B 3 RS422 Tx 22 Start output A 4 RS422 Tx 23 Start o...

Page 180: ...Input 1 29 Common 11 Spare Input 2 30 Common 12 Spare Input 2 31 Common 13 IHS Complete output A 32 Common 14 IHS Complete output B 33 24 VDC output 15 Retract complete output A 34 24 VDC output 16 R...

Page 181: ...interconnects J2 Front panel LEDs J5 LCD character module J11 LCD B L J8 Hypernet 52 51 2 1 100 99 50 49 J4 LCD B L SW3 Unit address switch default setting 1 SW2 UNIT ADDRESS Note In a Hypernet config...

Page 182: ...number Signal 1 5 V 2 Ground 3 Not connected J11 Power connector Pin number Signal 1 5 VDC 2 Ground 3 Common 4 Not connected J8 Hypernet Pin number Signal 1 TX transmit data 2 TX transmit data 3 RX r...

Page 183: ...connected 18 Not connected 19 5 VDC 20 Ground 21 Plasma Motion input 22 Plasma Corner output 23 Plasma Error input 24 Plasma Pierce output 25 Plasma Ramp Error input 26 Plasma Hold output 27 Plasma No...

Page 184: ...Arc V 65 Op Con Torch Up input 66 Ohmic contact sense 67 Op Con Torch Down input 68 Ohmic contact sense common 69 5 VDC 70 Ground 71 Op Con Spare input 72 Power good low active 73 Not connected 74 Lin...

Page 185: ...HPR Interface J2 Contact closure inputs to THC J3 Contact closure outputs from THC J5 THC discrete cable J4 Arc voltage 1 18 34 17 33 50 Electrode Work If the THC controller interface is configured wi...

Page 186: ...Motion 24 Error 25 Rampdown error 26 HPR NR 27 Not connected 28 Not connected 29 Not connected 30 Not connected 31 Corner B 32 Pierce B 33 Hold B 34 Plasma station relay B 35 Rem on B 36 Ground 37 HPR...

Page 187: ...B 13 Common 14 Common 15 24 V output 16 24 V output J4 Arc voltage Pin number Signal 1 Electrode 2 Work Note Pins 11 and 12 on connector J3 must be connected to locations 1 and 3 on terminal block 2 i...

Page 188: ...11 Input common 12 Not ready input 13 Input common 14 Spare input 15 Input common 16 Corner output A 17 Corner output B 18 Pierce output A 19 Pierce output B 20 Hold output A 21 Hold output B 22 Star...

Page 189: ...lasma supply Note In a Hypernet configuration the Unit address switch SW1 on the Hypernet interface PCB must have the same address as the Unit address switch on the HMI processor and the THC processor...

Page 190: ...ror 7 HPR not ready 8 Not connected 9 Not connected 10 Not connected 11 Not connected 12 Spare 13 Pierce A 14 Hold A 15 Start A 16 Not connected 17 Not connected 18 Ground 19 Not connected 20 HPR RX 2...

Page 191: ...number Signal 1 12 VDC 2 Upper limit switch 3 Common J2 Station Active LED Pin number Signal 1 5 VDC 2 Common J3 Lower limit switch Pin number Signal 1 12 VDC 2 Lower limit switch 3 Common J4 Breakaw...

Page 192: ...r input A 15 Field common 16 Change consumable switch 17 Lifter down switch 18 Lifter up switch 19 Breakaway switch 20 Upper limit switch 21 Lower limit switch 22 Not connected 23 Common 24 Not connec...

Page 193: ...ArcGlide THC Instruction Manual 5 1 Section 5 PARTS LIST In this section Lifter parts 5 2 THC controller parts 5 4 HMI parts 5 5 Plasma interface PCB 5 6...

Page 194: ...it Laser pointer diode 1 5 228608 Kit Breakaway cable 1 6 228593 Kit 11 34 kg 25 lb Magnetic breakaway 1 7 228607 Kit 4 54 kg 10 lb Magnetic breakaway 1 8 228597 Kit Pneumatic breakaway 1 9 128277 Kit...

Page 195: ...tion Manual 5 3 PARTS Item Part number Description Quantity 1 228580 Kit Lifter interface PCB 1 2 228591 Kit Lifter slide 1 3 228587 Kit Upper limit proximity switch 1 4 228586 Kit Lower limit proximi...

Page 196: ...Part number Description Quantity 1 228589 Kit LCD display 1 2 228578 Kit THC Processor PCB 1 3 228577 Kit THC Control interface PCB 1 4 228590 Kit 120 VAC 5 V 5 amp 25 W power source 1 5 228579 Kit 23...

Page 197: ...iption Quantity 1 228589 Kit LCD display 1 2 228583 Kit Momentary pushbutton switch 1 3 228590 Kit 120 VAC 5 V 5 amp 25 W power source 1 4 228579 Kit 230 V Surge PCB 1 5 228581 Kit HMI processor PCB 1...

Page 198: ...5 6 ArcGlide THC Instruction Manual PARTS Item Part number Description Quantity 1 228576 Kit Plasma interface PCB 1 Plasma interface PCB 1...

Page 199: ...ge to page referencing is done in the following manner C SHEET 4 D3 C SHEET 4 D3 Destination and Source Coordinates refer to letters A D on the Y axis of each sheet and numbers 1 4 on the X axis of ea...

Page 200: ...erlock Fan Feedthru LC Filter AC DC supply Fuse Ground Clamp Ground Chassis Ground Earth IGBT Inductor LED Lamp Pin Socket Plug PNP Transistor Potentiometer Push Button Normally Closed MOV Push Button...

Page 201: ...mer Coil Valve Solenoid Voltage Source Zener Diode VAC Source Triac Switch Pressure Normally Closed Switch Pressure Normally Open Switch 1 Pole 1 Throw Switch 1 Pole 2 Throw Switch 1 Pole 1 Throw Cent...

Page 202: ...6 4 ArcGlide THC Instruction Manual Wiring Diagrams...

Page 203: ...turn 5 Vdc Phase A Phase A Phase B Phase B Common 12 Vdc 12 Vdc 12 Vdc Common Common Common Common Lower Limit Sw Upper Limit Sw Breakaway Sw Up Sw Dwn Sw Common Enable 5 Vdc Common 5 Vdc Common ULMT...

Page 204: ...B Error Output B Input Common Input Common Input Common Input Common Input Common Common 24 VDC OUTPUT Remote On Output A Remote On Output B Spare Input RS422 Tx RS422 Tx RS422 Rx RS422 Rx RS422 Comm...

Page 205: ...erface PCB RESERVED RESERVED D E V R E S E R D E V R E S E R OPTIONS SWITCH 223003 LCD Display 229298 RIBBON CABLE 123999 J5 LCD J2 101037 LED J8 123998 HYPERNET ETHERNET CABLE FRONT PANEL WITH OVERLA...

Page 206: ...upply 229234 223053 223003 F B AC ENTRY 229248 IHS PUSHBUTTON 229241 FRONT PANEL WITH OVERLAY 101037 OVERLAY FLEX CIRCUIT ROTARY ENCODER 005630 ROTARY INPUT J11 ArcGlide HMI PCB 141082 ATTACHED RIBBON...

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