Hypertherm Command THC Instruction Manual Download Page 120

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POWERMAX SETUP

CommandTHC for X-Y Table

Instruction Manual

3g-1

Section 3g

POWERMAX SYSTEM INTERCONNECTIONS

Verify power supply machine interface

(Powermax800, Powermax900 and Powermax 1100)

Power supply machine interface kits

If your power supply is not equipped with the machine interface option, install one of the following kits:

Look at the back of the power supply and verify that
it is equipped with the machine interface option.

Machine Interface Panel

Power Supply

Voltage

Machine Interface Kit

Powermax800

208/240/480

028905

200/230/400

128035

400 CE

128036

Powermax900

208/240/480

128241

200/230/400

128242

230/400 CE

128286

Powermax1100

208/240/480

128144

200/230/400

128168

400 CE

128169

Summary of Contents for Command THC

Page 1: ...Command THC X Y Table Torch Height Control THC System Instruction Manual 802780 Revision 11 EN50199 EN60974 1...

Page 2: ..._____________________________________ ___________________________________________________________________ ___________________________________________________________________ Maintenance notes ________...

Page 3: ...erm 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 Command THC X Y Table Tor...

Page 4: ...ervice Hypertherm S Pte Ltd 82 Genting Lane Media Centre Annexe Block A01 01 Singapore 349567 Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax 65 6841 2489 Technical Service Hypertherm Shanghai...

Page 5: ...er shall ensure that other equipment being used in the environment is compatible This may require additional protection measures h Time of day that cutting or other activities are to be carried out Th...

Page 6: ...where direct connection is not permitted the bonding should be achieved by suitable capacitances selected according to national regulations Note the cutting circuit may or may not be earthed for safe...

Page 7: ...eu of all other warranties express implied statutory or otherwise with respect to the Products or as to the results which may be obtained therefrom and all implied warranties or conditions of quality...

Page 8: ...les are subject to oil dust or water contaminants hard usage ratings may be required When external interconnecting cables are subject to continuous movement constant flexing ratings may be required It...

Page 9: ...ights you may have hereunder only in connection with the sale of all or substantially all of your assets or capital stock to a successor in interest who agrees to be bound by all of the terms and cond...

Page 10: ...rit 1a 2 Suivre les instructions de s curit 1a 2 Le coupage peut provoquer un incendie ou une explosion 1a 2 Les chocs lectriques peuvent tre fatals 1a 3 L lectricit statique peut endommager les carte...

Page 11: ...de polvo seco 1b 11 Section 2 DESCRIPTION SPECIFICATIONS 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 bre...

Page 12: ...perator 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 Typi...

Page 13: ...8 Power cords 6 8 Ohmic contact wire 6 9 Recommended spare parts 6 10 Interface cables See Section 3a through 3j Section 7 WIRING DIAGRAMS 7 1 Introduction 7 1 Wiring diagrams 7 5 Appendix A PARTS LIS...

Page 14: ...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 Compressed gas equipment safety 1 6 Gas cylinders can explode...

Page 15: ...in this manual that may result in minor injury or damage to equipment if not followed correctly Fire prevention Be sure the area is safe before doing any cutting Keep a fire extinguisher nearby Remove...

Page 16: ...Install and ground this equipment according to the instruction manual and in accordance with national and local codes Inspect the input power cord frequently for damage or cracking of the cover Replac...

Page 17: ...e equipment is used and to ensure that the air quality in the workplace meets all local and national standards and regulations The air quality level in any relevant workplace depends on site specific...

Page 18: ...d by ultraviolet light sparks and hot metal Gauntlet gloves safety shoes and hat Flame retardant clothing to cover all exposed areas Cuffless trousers to prevent entry of sparks and slag Remove any co...

Page 19: ...use Never allow electrical contact between the plasma arc and a cylinder Never expose cylinders to excessive heat sparks slag or open flame Never use a hammer wrench or other tool to open a stuck cyl...

Page 20: ...near any plasma arc cutting and gouging operations To reduce magnetic field hazards Keep both the work cable and the torch lead to one side away from your body Route the torch leads as close as possib...

Page 21: ...rg technical facts 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 m...

Page 22: ...perator and persons in the work area Consult manual before operating Failure to follow all these safety instructions can result in death AVERTISSEMENT Le coupage plasma peut tre pr judiciable pour l o...

Page 23: ...tection 3 Hazardous voltage Risk of electric shock or burn 3 1 Wear insulating gloves Replace gloves when wet or damaged 3 2 Protect from shock by insulating yourself from work and ground 3 3 Disconne...

Page 24: ...nitions and explanations of regulatory terms such as deflagration AHJ adopted by reference the Kst value deflagration index and other terms Note 1 Hypertherm s interpretation of these new requirements...

Page 25: ...ent provoquer des blessures ou la mort 1a 4 L arc plasma peut provoquer des blessures ou des br lures 1a 5 Les rayons de l arc peuvent br ler les yeux et la peau 1a 5 Mise la masse et la terre 1a 6 S...

Page 26: ...s curit ATTENTION pr c dent les directives associ es dans le manuel qui si elles ne sont pas suivies scrupuleusement peuvent entra ner des blessures secondaires ou endommager l quipement Pr vention d...

Page 27: ...codes lectriques locaux et nationaux LES CHOCS LECTRIQUES PEUVENT TRE FATALS Inspecter fr quemment le cordon d alimentation primaire pour s assurer qu il n est ni endommag ni fendu Remplacer imm diat...

Page 28: ...et r glementation locales et nationales Le niveau de qualit de l air dans tout lieu de travail d pend des variables propres au site comme Type de table humide s che sous l eau Composition du mat riau...

Page 29: ...es tincelles et le m tal br lant Gants crispin chaussures et casque de s curit V tements ignifuges couvrant toutes les parties expos es du corps Pantalon sans revers pour viter que des tincelles ou de...

Page 30: ...tion ou connect e pour utilisation viter tout prix le contact lectrique entre l arc plasma et une bouteille Ne jamais exposer des bouteilles une chaleur excessive aux tincelles aux scories ou aux flam...

Page 31: ...age ou le gougeage plasma Pour r duire les risques associ s aux champs magn tiques Garder loin de soi et du m me c t du corps le c ble de retour et le faisceau de la torche Faire passer le faisceau de...

Page 32: ...rs Laboratories Incorporated UL ou T V Marque CE La marque CE signifie la d claration de conformit du fabricant aux directives et normes europ ennes applicables Seules les versions des produits Hypert...

Page 33: ...to operator and persons in the work area Consult manual before operating Failure to follow all these safety instructions can result in death AVERTISSEMENT Le coupage plasma peut tre pr judiciable pour...

Page 34: ...emplacer les gants quand ils sont humides ou endommag s 3 2 Se prot ger contre les chocs en s isolant de la pi ce et de la terre 3 3 Couper l alimentation avant l entretien Ne pas toucher les pi ces s...

Page 35: ...ent locaux Voir le document NFPA68 pour obtenir des d finitions et des explications des termes r glementaires tels que d flagration autorit comp tente adopt par r f rence valeur du pire cas indice de...

Page 36: ...sar 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 Segurid...

Page 37: ...muerte Los mensajes de seguridad de CUIDADO o PRECAUCI N preceden mensajes relacionados con instrucciones en el manual que puede resultar en lesiones menores o da o a equipo si no se siguen correctame...

Page 38: ...MUERTE Instale este equipo y con ctelo a tierra seg n el manual de instrucciones y de conformidad con los c digos locales y nacionales Inspeccione el cord n de alimentaci n primaria con frecuencia par...

Page 39: ...de trabajo cumpla con todas las normas y reglamentos locales y nacionales El nivel de la calidad del aire en cualquier lugar de trabajo relevante depende en variables espec ficas al sitio tales como...

Page 40: ...aduras causadas por la radiaci n ultravioleta de alta intensidad por las chispas y por el metal caliente Guantes largos zapatos de seguridad y gorro Roipa de combusti n retardada y que cubra todas las...

Page 41: ...os a calor excesivo chispas escorias o llamas No emplee nunca martillos llaves u otro tipo de herramientas para abrir de golpe la v lvula del cilindro Cable de trabajo La pinza del cable de trabajo de...

Page 42: ...anurado por plasma Para reducir los peligros de los campos magn ticos Mantenga el cable de trabajo y la manguera de la antorcha a un lado lejos del cuerpo Dirija la manguera antorcha lo m s cerca posi...

Page 43: ...writers Laboratories Incorporated UL T V Marcas CE Las marcas CE significan una declaraci n del fabricante de conformidad a las directivas y est ndares aplicables Europeos S lo aquellas versiones del...

Page 44: ...ng can be injurious to operator and persons in the work area Consult manual before operating Failure to follow all these safety instructions can result in death AVERTISSEMENT Le coupage plasma peut tr...

Page 45: ...provocados por la antorcha o el cableado pueden ser fatales Prot jase del electrochoque 3 1 Col quese guantes aislantes No utilice guantes da ados o mojados 3 2 A slese de la pieza de trabajo y de la...

Page 46: ...digos de construcci n locales Rem tase a la NFPA 68 para definiciones y explicaciones de los t rminos reguladores como deflagraci n AHJ adoptada por referencia el valor Kst ndice de deflagraci n y otr...

Page 47: ...e Instruction Manual 2 1 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 l...

Page 48: ...S 5 2 2 CommandTHC for X Y Table Instruction Manual Figure 2 1 X Y CommandTHC system interfaced with plasma cutting system and CNC X Y lifter assembly Plasma interface assembly THC control module Oper...

Page 49: ...ng Note HyPerformance HPR plasma systems do not have an interface assembly HPR systems have an interface board that mounts in the power supply X Y lifter assembly Figure 2 4 The torch lifter station u...

Page 50: ...ions 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 Figur...

Page 51: ...VDC Voltage divider function 41 1 Arc voltage isolated THC 90 3 1 78 mm 2 2 56 mm 10 7 271 mm 6 6 168 mm 4 6 lb 2 kg HT4400 and HPR installation Note Instructions to install the plasma interface PCB i...

Page 52: ...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...

Page 53: ...CommandTHC for X Y Table Instruction Manual 2 7 Figure 2 5 Operator pendant Operator pendant Electrical Input power 12 VDC Serial digital I O RS 422 5 VDC THC 69 7 oz 0 2 kg 25 7 6 m 8 25 210 mm 4 1...

Page 54: ...ir 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 in...

Page 55: ...ace cable 3 14 THC selectable responses 3 16 DIP switch positions 3 17 CommandTHC serial protocol 3 18 Grounding requirements 3 20 Power cord grounding 3 20 Protective earth ground 3 20 Lifter I O Cab...

Page 56: ...on manual Optional components Operator pendant with 25 ft 7 5 m cable Pendant extension cable 9 pin Torch mounting block kit Torch breakaway kit Claims Claims for damage during shipment If your unit w...

Page 57: ...pecifications for unit dimensions THC control module Mount the THC control module close to the CNC controller for easy access to the THC system power and to provide easy access for routing and connect...

Page 58: ...ce 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 3i The plasma interface enclosure is n...

Page 59: ...X Y lifter assembly on the cutting table See Figure 3 3 THC 68 3 5 89 mm 3 5 89 mm 3 5 89 mm 22 4 570 mm 2 875 73 mm 4 5 114 mm 5 0 127 mm 2 8 71 mm 1 4 20 2 12 54 mm 1 75 44 5 mm 1 26 32 mm 1 42 36...

Page 60: ...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 Figure 3 4 X Y lifte...

Page 61: ...SETUP CommandTHC for X Y Table Instruction Manual 3 7 5 Blank...

Page 62: ...and force the breakaway to trip to simulate a crash Manually reposition breakaway to the lock position 10 Adjust air pressure until the desired trip force is achieved 11 Enable the emergency stop circ...

Page 63: ...circuit Tubing 6 screws Collar Collar Block Brown 4 1 5 16 inch 33 34 mm Filter regulator Breakaway Breakaway pressure switch Normally Open Moisture drain Inlet port 1 4 in NPTF 100 psi 6 9 bar Custom...

Page 64: ...al 7 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 2 1 Figur...

Page 65: ...3 11 7 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 2 1 Figur...

Page 66: ...e 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 3i The plasma interface enclosure is no...

Page 67: ...Control Module Plasma Interface Assembly Optional Operator Pendant shown with optional extension cable Lifter I O interface cable Motor drive cable IHS ohmic contact wire Plasma interface cable HT440...

Page 68: ...stop signal See Figure 3 10 The machine interface cable provides a signal for emergency stop Continuity must be provided through pins 16 and 35 so that the signal is not interrupted Install a normall...

Page 69: ...wn in Figure 3 11 Figure 3 11 Machine interface cable Figure 3 12 Machine interface cable grounding 4 If installation requires removal of a cable connector all wires must be properly terminated includ...

Page 70: ...motor drive board Note The DIP switch positions are set to ON default settings at Hypertherm DANGER ELECTRIC SHOCK CAN KILL Turn off all electrical power before removing the power supply cover Press...

Page 71: ...ximately one half in both up and down directions OFF enables normal or fast response 2 Conventional HyDefinition resolution ON enables the THC to respond to larger voltage error changes OFF enables th...

Page 72: ...ata Query Notes Pierce Delay PD 0 9000 0 to 9 000 seconds yes Delay before motion output Pierce Height Factor PH 50 300 50 to 300 yes Used to set pierce height Preflow During IHS PF 0 1 0 off 1 on yes...

Page 73: ...d RI return the decimal representations of the revisions that are stored as ASCII characters in the firmware 5 Setting the Retract distance RH only applies when the THC is in partial retract Retract 1...

Page 74: ...module must be properly grounded through the power cord according to national or local electrical codes Protective earth ground Install protective earth PE grounding cables to the 3 THC components as...

Page 75: ...t Brown Home Switch 24V Home switch power 30 Input 16 Output Green Lifter Down Active when lifter is moving down 16 Input 35 Brown Lifter Down 35 17 Output Green Lifter Brake Out Powers electro mechan...

Page 76: ...sfer In 28 10 Output Red Nozzle H V Relay Relay active during arc initiation to isolate the THC interface PCB from 10 Input 29 Yellow Nozzle H V Relay high voltage 29 13 Input Green Pierce Complete Pi...

Page 77: ...multiple torch 10 Input 1 29 Yellow IHS Complete installations When all connected torches are in position 29 IHS Sync In signal is deactivated to proceed with torch ignition 12 Output Red Retract Com...

Page 78: ...atings of 24 VDC and 10 mA Note 2 All THC inputs are optically isolated 12 VDC signals Signals are made active by sinking 3 mA per input Note 3 Jumper required in CNC See instructions on page 3 14 Not...

Page 79: ...r TX 1 Output 2 Green RX RS 422 serial non inverting receiver TX 2 6 Output Black TX RS 422 serial inverting transmitter output RX 6 Input 3 White TX RS 422 serial non inverting transmitter output RX...

Page 80: ...50 ft 45 6 m THC 83 Pin Pin number Color Signal name Function number 5 Output Red Motor Phase A Powers lifter motor phase A 5 Input 4 Black Motor Phase A 4 9 Output Red Motor Phase A Powers lifter mot...

Page 81: ...HD3070 SETUP CommandTHC for X Y Table Instruction Manual 3a 1 5 Section 3a HD3070 SYSTEM INTERCONNECTIONS...

Page 82: ...ct one of the wires to the 1XPCB1 PC board where wire No 126 is connected Label this wire positive Connect the other wire to the 1XPCB1 PC board where wire No 140 is connected Label this wire negative...

Page 83: ...SETUP CommandTHC for X Y Table Instruction Manual 3a 3 11 A B 126 140 2 3 1 4 5 J5 D C THC 80 Plasma interface assembly 1XPCB1 PC board Figure 3a 1 HD3070 electrode and work lead arc voltage wires con...

Page 84: ...3070 instruction manual See Figure 3a 2 Connect the interface cable plug to the 1X1 receptacle on the back of the power supply Connect the other plug of the interface cable to the CNC Install the 5 pa...

Page 85: ...anual 3a 5 5 Figure 3a 2 HD3070 Power supply interface cable connections Plasma interface assembly Plasma Interface assembly Power supply CNC Green wire Black wire Orange wire Black wire Black wire Wh...

Page 86: ...power supply front panel Drain Drain 26 Dry contact closure Power Off Black 4 4 Not Power Off Blue 8 8 Connected Drain Drain 13 13 External Interlock Red 16 16 Not External Interlock Blue 17 17 Conne...

Page 87: ...opriate 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 C A THC 76...

Page 88: ...HT2000 SETUP CommandTHC for X Y Table Instruction Manual 3b 1 6 Section 3b HT2000 SYSTEM INTERCONNECTIONS...

Page 89: ...onnect one of the wires to the WORK LEAD connection of the input output panel Label this wire positive Connect the other wire to the NEGATIVE LEAD connection of the input output panel Label this wire...

Page 90: ...0 SETUP CommandTHC for X Y Table Instruction Manual 3b 3 11 2 3 1 4 5 J5 THC 75 A B C D Plasma interface assembly Input Output panel Figure 3b 1 HT2000 electrode and work Lead arc voltage wires connec...

Page 91: ...t 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 pla...

Page 92: ...tion Plasma Start Plasma Start 24V 24V 8 7 6 5 4 3 2 1 J4 A B C C THC 79 4 3 2 1 J3 Pilot Arc Pilot Arc Transfer IN Transfer IN Figure 3b 2 HT2000 power supply interface cable connections Plasma inter...

Page 93: ...e use Power Plasma Supply CNC Interface Signal Name Color End 1X6 End End Function Hold Black 5 Not J4 6 Optional Hold Ignition I O signal used for preflow during Hold White 1 Connected J4 5 IHS Also...

Page 94: ...20837 Figure 3b 4 HT2000 ohmic contact wire connection Ohmic contact wire See Figure 3b 4 Install the ohmic contact wire through the strain relief of the plasma interface assembly Install appropriate...

Page 95: ...HT2000LHF SETUP CommandTHC for X Y Table Instruction Manual 3c 1 5 Section 3c HT2000LHF SYSTEM INTERCONNECTIONS...

Page 96: ...nds Connect one of the wires to the WORK LEAD connection of the input output panel Label this wire positive Connect the other wire to the NEGATIVE LEAD connection of the input output panel Label this...

Page 97: ...F SETUP CommandTHC for X Y Table Instruction Manual 3c 3 11 2 3 1 4 5 J5 THC 75 A B C D Plasma interface assembly Input Output panel Figure 3c 1 HT2000LHF electrode and work lead arc voltage wires con...

Page 98: ...ct 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 pl...

Page 99: ...tion Plasma Start Plasma Start 24V 24V 8 7 6 5 4 3 2 1 J4 A B C C THC 79 4 3 2 1 J3 Pilot Arc Pilot Arc Transfer IN Transfer IN Figure 3c 2 HT2000LHF power supply interface cable connections Plasma in...

Page 100: ...t to the CNC Refer to Not Used Brown 3 3 Connected HT2000 LHF Instruction manual for signal information Drain Drain 12 12 Not Used Black 16 16 Not Not Used Green 17 17 Connected Drain Drain 18 18 HT20...

Page 101: ...20837 Figure 3c 4 HT2000LHF ohmic contact wire connection Ohmic contact wire See Figure 3c 4 Install the ohmic contact wire through the strain relief of the plasma interface assembly Install appropria...

Page 102: ...HT4001 SETUP CommandTHC for X Y Table Instruction Manual 3d 1 5 Section 3d HT4001 SYSTEM INTERCONNECTIONS...

Page 103: ...nnect one of the wires to the top bus bar where wire No 42 is connected Label this wire positive Connect the other wire to the bottom bus bar where wire No 45 is connected Label this wire negative At...

Page 104: ...HT4001 SETUP CommandTHC for X Y Table Instruction Manual 3d 3 11 Figure 3d 1 HT4001 electrode and work lead arc voltage wires connection 2 3 1 4 5 J5 THC 74 42 45 A B C D Plasma interface assembly...

Page 105: ...t 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 pla...

Page 106: ...tion Plasma Start Plasma Start 24V 24V 8 7 6 5 4 3 2 1 J4 A B C C THC 79 4 3 2 1 J3 Pilot Arc Pilot Arc Transfer IN Transfer IN Figure 3d 2 HT4001 power supply interface cable connections Plasma inter...

Page 107: ...s connect to the CNC Refer to HT4001 Arc Voltage Yellow 37 37 Connected Instruction manual for signal information Drain Drain 26 26 Spare Black 16 16 Not Spare Green 17 17 Connected Drain Drain 18 18...

Page 108: ...MAX100 SETUP CommandTHC for X Y Table Instruction Manual 3e 1 5 Section 3e MAX100 SYSTEM INTERCONNECTIONS...

Page 109: ...ect one of the wires to the 1XPCB1 PC board where wire No 42 is connected Label this wire positive Connect the other wire to the 1XPCB1 PC board where wire No 39 is connected Label this wire negative...

Page 110: ...SETUP CommandTHC for X Y Table Instruction Manual 3e 3 11 2 3 1 4 5 J5 THC 73 A B 42 39 C D Plasma interface assembly 1XPCB1 PC board Figure 3e 1 MAX100 electrode and work lead arc voltage wires conn...

Page 111: ...G 0 9 mm2 double pair shielded wire rated for 600V or greater Wire length As required from the power supply to the plasma interface assembly After installing the wires into the power supply install ap...

Page 112: ...n Manual 3e 5 5 Figure 3e 2 MAX100 power supply interface cable connections A B Plasma Start Plasma Start 24V 24V 5 4 3 2 1 J4 TB1 35 36 33 34 C 34 33 35 36 C C 4 3 2 1 J3 Pilot Arc Pilot Arc Transfer...

Page 113: ...MAX200 SETUP CommandTHC for X Y Table Instruction Manual 3f 1 6 Section 3f MAX200 SYSTEM INTERCONNECTIONS...

Page 114: ...onnect one of the wires to the WORK LEAD connection of the input output panel Label this wire positive Connect the other wire to the NEGATIVE LEAD connection of the input output panel Label this wire...

Page 115: ...0 SETUP CommandTHC for X Y Table Instruction Manual 3f 3 11 2 3 1 4 5 J5 THC 75 A B C D Plasma interface assembly Input Output panel Figure 3f 1 MAX200 electrode and work lead arc voltage wire connect...

Page 116: ...e 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...

Page 117: ...e cable connections Pierce Complete Pierce Complete Hold Ignition Hold Ignition Plasma Start Plasma Start 24V 24V 8 7 6 5 4 3 2 1 J4 A B THC 78 B 4 3 2 1 J3 Pilot Arc Pilot Arc Transfer IN Transfer IN...

Page 118: ...5 Relay signal is lost system must be restarted Output signal Drain Drain 14 Arc Transfer Delayed Black 31 J3 2 Arc Transfer signal Contact closes after arc transfer and Arc Transfer Delayed Red 36 J3...

Page 119: ...ntact Wire Torch retaining cap with IHS tab P N 120837 Ohmic contact wire See Figure 3f 4 Install the ohmic contact wire through the strain relief of the plasma interface assembly Install appropriate...

Page 120: ...s not equipped with the machine interface option install one of the following kits Look at the back of the power supply and verify that it is equipped with the machine interface option Machine Interfa...

Page 121: ...5 terminal of the machine interface board for the powermax 1000 1250 and 1650 Label the wire positive Connect the other arc voltage wire to the J1 8 terminal of the machine interface board for the pow...

Page 122: ...ble Instruction Manual 3g 3 11 Figure 3g 1 Powermax800 Powermax900 and Powermax 1100 electrode and work lead arc voltage wire connections A B ARC VOLTAGE J1 1 8 6 C THC 72 2 3 1 4 5 J5 D Plasma interf...

Page 123: ...HC for X Y Table Instruction Manual 11 Figure 3g 2 Powermax1000 Powermax1250 and Powermax 1650 electrode and work lead arc voltage wire connections A B C THC 72G3 2 3 1 4 5 J5 D Plasma interface assem...

Page 124: ...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 3...

Page 125: ...upply interface cable connections Pierce Complete Pierce Complete Hold Ignition Hold Ignition Plasma Start Plasma Start 24V 24V 8 7 6 5 4 3 2 1 J4 A B THC 78 B 4 3 2 1 J3 Pilot Arc Pilot Arc Transfer...

Page 126: ...HT4400 SETUP CommandTHC for X Y Table Instruction Manual 3h 1 5 Section 3h HT4400 SYSTEM INTERCONNECTIONS...

Page 127: ...ure 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 int...

Page 128: ...HT4400 SETUP CommandTHC for X Y Table Instruction Manual 3h 3 11 THC 102 A B C D Figure 3h 1 Plasma interface PC board preparation...

Page 129: ...screws that were removed from the plasma interface assembly Install the plasma interface PC board into the HT4400 power supply DANGER ELECTRIC SHOCK CAN KILL Turn off all electrical power before remo...

Page 130: ...HT4400 SETUP CommandTHC for X Y Table Instruction Manual 3h 5 5 Figure 3h 2 Install the plasma interface PC board THC 104 mid plane mid plane A B C...

Page 131: ...rd 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 Connect wire No 42 to the plasma interface board J5 2 terminal label...

Page 132: ...HT4400 SETUP CommandTHC for X Y Table Instruction Manual 3h 7 5 Figure 3h 3 Plasma interface PC board connection THC 105 mid plane mid plane 2 3 1 4 5 J5 A B C D 45 42 42 45 J3 J4...

Page 133: ...l 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 inte...

Page 134: ...T4400 SETUP CommandTHC for X Y Table Instruction Manual 3h 9 5 THC 106 2 3 1 4 5 J5 A B C Ohmic contact wire Torch retaining cap with IHS tab P N 120907 Figure 3h 4 HT4400 ohmic contact wire connectio...

Page 135: ...HPR SETUP CommandTHC for X Y Table Instruction Manual 3i 1 9 Section 3i HPR SYSTEM INTERCONNECTIONS...

Page 136: ...er supplies A Figure 3i 1 Right side panel removal DANGER ELECTRIC SHOCK CAN KILL Turn off all electrical power before removing the power supply cover Press the power supply OFF 0 pushbutton switch an...

Page 137: ...TUP CommandTHC for X Y Table Instruction Manual 3i 3 9 Figure 3i 2 Install the plasma interface PC board B Figure 3i 3 Plasma interface and control PC board connections inside the power supply C Femal...

Page 138: ...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 par...

Page 139: ...er 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 Connect wire Number 25 to the bus bar marked WORK Con...

Page 140: ...HPR SETUP 3i 6 CommandTHC for X Y Table Instruction Manual C Figure 3i 7 I O board connections Figure 3i 6 I O wire location D 25 26 11...

Page 141: ...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 termin...

Page 142: ...rd 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...

Page 143: ...HPR SETUP CommandTHC for X Y Table Instruction Manual 3i 9 Figure 3i 10 Plasma interface and control PC board connections C Female Male 11...

Page 144: ...e 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 pa...

Page 145: ...s with fork terminals Attach wire number 25 to the terminal marked WORK and wire number 26 to the terminal marked ELECTRODE Make the connections to the I O board using the wire ends with ring terminal...

Page 146: ...HPR SETUP 3i 12 CommandTHC for X Y Table Instruction Manual 11 C Figure 3i 13 I O board connections B Figure 3i 12 Plasma interface PC board connection 25 26 25 26...

Page 147: ...to the terminal labeled SHIELD on the plasma interface PC board See figure 3i 14 B A 1 Slide the end of the ohmic contact wire with the connector attached through the opening in the braided cover and...

Page 148: ...HPR SETUP 3i 14 CommandTHC for X Y Table Instruction Manual Figure 3i 14 Ohmic contact wire connection B B 11...

Page 149: ...HSD130 SETUP CommandTHC for X Y Table Instruction Manual 3j 1 11 Section 3j HSD SYSTEM INTERCONNECTIONS...

Page 150: ...tton 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 In other countries follow appropriate local or nation...

Page 151: ...wires Fabricate the wires as follows Use 18AWG 0 9 mm2 single pair unshielded wire rated for 600V or greater Wire length As required from the power supply to the plasma interface assembly After deter...

Page 152: ...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 Install the...

Page 153: ...ire 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...

Page 154: ...HSD130 SETUP 3j 6 CommandTHC for X Y Table Instruction Manual 11 1X4 Install the machine interface cable see page 3 22 for part numbers from the power supply to the plasma interface assembly B...

Page 155: ...odule 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...

Page 156: ...ammable 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 thicke...

Page 157: ...e 4 2 Operator pendant key pad 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 F...

Page 158: ...ic or manual control mode Selects the height the torch retracts after completing a cut FULL full retract MID programmable dimension Initiates IHS test Torch moves to plate and then retracts to cutting...

Page 159: ...Pull back SETUP A Press Can view and adjust detailed operating parameters Press to return to main operation screen DIAGNOSTIC B Press Can perform limited on site testing of the THC controls cabling an...

Page 160: ...mmandTHC for X Y Table Instruction Manual 4 5 5 Automatic Operation Screen Manual Operation Screen Diagnostic Screen B Remote Mode Screen Maintenance Mode Screen Setup Screen A Figure 4 3 Pendant disp...

Page 161: ...djusts the torch height during a cut to maintain the Set Arc Volts Small change 0 5 V Large change 5 V Setpoint range 50 300 V Sets the initial cutting height before AVC is activated Also sets the pie...

Page 162: ...test the IHS without firing the torch When IHS TEST is selected the torch will sense the workpiece with ohmic contact sensing or limited force stall sensing and then retract to the piercing height Th...

Page 163: ...Manual Operation Screen 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 Torch Position Note IHS an...

Page 164: ...t in the least plate deflection and the greatest IHS accuracy This limited force stall sensing is the backup mode to the ohmic contact plate sensing System will default to limited force stall sensing...

Page 165: ...te 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 cont...

Page 166: ...ierce Height 0 150 inch THC system performs this calculation Sets the lifter retract homing speed This value is a compromise between machine speed and the amount of weight on the lifter At lower speed...

Page 167: ...ng piercing Application Set the cut height to 2X the desired pierce height and enter a pierce height factor of 50 These are initial settings which may be adjusted to obtain cut improvements After the...

Page 168: ...rcing thicker materials EVENT Figure 4 6 Pierce height factor for thicker materials sequence of events 1 2 4 3 Cut Height Plate Plate 5 Molten metal accumulated on top of plate during piercing Plate P...

Page 169: ...ms that can occur during a typical operating cycle in the automatic mode as well as solutions that can be done by the operator The numbers shown in an operating cycle correspond to the numbers in the...

Page 170: ...al to plasma power supply 8 If Preflow During IHS is enabled THC releases arc HOLD IGNITION OUT signal 9 Preflow completes if it has not already completed 10 Torch ignites 11 Arc transfers to workpiec...

Page 171: ...movement Inaccurate IHS with nozzle ohmic contact Check that THC is in Automatic Mode If not press AUTO MAN key on keypad to select Automatic Mode Check that Nozzle Ohmic Contact is ON enabled on Setu...

Page 172: ...erce Delay on Automatic Operating Screen the delay is set too short Torch dives below cutting height immediately after pierce delay and before AVC begins Increase Set Cut Height on Automatic Operating...

Page 173: ...lay signal elapses THC issues PIERCE COMPLETE OUT signal to plasma power supply and THC issues MACHINE MOTION OUT signal to CNC to begin profiling part 8 At end of part profile CNC releases CYCLE STAR...

Page 174: ...ing 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 dist...

Page 175: ...s 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...

Page 176: ...TENANCE CommandTHC for X Y Table Instruction Manual 5 3 7 Figure 5 1 Sealing band Remove VIEW 1 VIEW 2 VIEW 3 Retaining block Left side cover screws 5 Left side cover Retaining block Retainer Sealing...

Page 177: ...re the band sits in the channel View 1 3 Secure the ends of the band to the retaining block with retainers and hex screws Make sure the band is in the groove Views 2 and 3 4 Install the lifter left si...

Page 178: ...MAINTENANCE CommandTHC for X Y Table Instruction Manual 5 5 7 Figure 5 2 Sealing band install 2 of 2 Retaining block Retainer VIEW 2 VIEW 3 Groove Left side cover screws 5 Left side cover...

Page 179: ...gure 5 3 Diagnostic screen B Error messages The error messages in Table 5 1 are displayed on the pendant or on the CNC via the RS 422 serial interface The error messages for the RS 422 serial interfac...

Page 180: ...h retracted to the Home Limit Reposition lifter torch or workpiece Stall Force and IHS speed in combination or separately are improperly set Try a lower speed or a higher stall force Select Diagnostic...

Page 181: ...ervice Nozzle Contact at Home Press OPR SCRN Key Nozzle contact is being sensed with lifter at Home position Check ohmic contact wire connections at shield and inside plasma interface assembly Check o...

Page 182: ...itch On THC control PCB Motor Drive Interface D49 should illuminate Diag FAIL Repower Torch inhibited from reaching Lower Limit position during diagnostic test Place THC in Manual Position Mode and jo...

Page 183: ...y Power Fuses AC Power In Ground chassis TB1 1 115 VAC N 3 15A 250V TB1 2 115 VAC L 3 15A 250V TB1 3 Ground chassis TB1 1 230 VAC N 3 15A 250V TB1 2 230 VAC L 3 15A 250V TB1 3 Figure 5 4 AC power and...

Page 184: ...board 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 LED Signal function Status D1 Drive active...

Page 185: ...CommandTHC for X Y Table Instruction Manual 10 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 P...

Page 186: ...B2 3 J8 4 D42 TP5 12 VDC Blue TB2 2 J1 3 TP4 Common White TB2 4 J1 4 TP2 24 VDC Blue TB2 5 J8 5 D41 TP4 Ground White TB2 7 J8 6 TP3 Ground 24 VDC Blue TB2 6 J8 7 24 VDC Blue J1 5 TP6 J8 8 Ground White...

Page 187: ...pilot arc output Off D28 retract complete On D29 spare out Off D30 IHS complete Off D31 error 1 Not functional On D32 plasma start output Off D33 hold ignition output Off D34 pierce complete out Off...

Page 188: ...MAINTENANCE CommandTHC for X Y Table Instruction Manual 5 15 6 Figure 5 7 Control board...

Page 189: ...nts TP1 ground and TP2 allow the measurement of the isolated electrode to work voltage divided by 82 Interface board status lights during normal power up The following LEDs and test points are located...

Page 190: ...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 Ohm...

Page 191: ...k THC 3 005186 Module power entry fused filter 1 4 008971 Fuse T 3 15 Amp H 250V 5 mm x 20 mm 2 5 229070 Power source 130W see Figure 6 2 1 6 041511 PCB assembly motor driver see Figure 6 2 1 7 128407...

Page 192: ...PARTS LIST CommandTHC for X Y Table Instruction Manual 6 3 10 Figure 6 2 THC control module interior...

Page 193: ...1 3 041842 HPR PC Board Assembly plasma interface 1 THC 94 for HPR Figure 6 3 Plasma interface assembly HT4400 and HPR installation Note Instructions to install the plasma interface PCB into the HT440...

Page 194: ...726 Encoder replacement kit 1 2 128727 Motor Encoder replacement kit 1 3 027550 Brake power off 1 4 129699 Assembly leadscrew standard 1 127154 Drive nut 1 5 128607 Band seal kit length 32 3125 1 6 02...

Page 195: ...ch mounting block 1 3 4 Inch diameter torch 1 128279 Kit torch mounting block 2 inch diameter torch 1 1 004775 Spacer Command THC mounting block 1 2 075127 Socket cap 1 4 20 X 1 1 2 inch hex BTN S Z 4...

Page 196: ...6 Cable CMD THC lifter torch breakaway 1 3b 127155 Proximity switch 1 3c 127156 Collar 1 4 015317 Connector male 10 32 X 1 4 inch push In tube 1 5 046078 Tubing 1 4 inch O D Synflex 10 ft 3m 129361 Re...

Page 197: ...Description Quantity 1 008960 Domestic power cord 115 VAC 1 2 008961 International power cord 230 VAC not shown 1 1 Operator pendant Index no Part no Description Quantity 1 053019 Operator pendant wit...

Page 198: ...3 m 1 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 123226 125 ft 38 m 123227 150 ft 45 6 m 2 123983 HPR400XD...

Page 199: ...d replacement rollers 1 X Y lifter assembly 1 rail 128050 old style Part No Description Quantity 128189 Kit torch lifter band seal replacement 1 128190 Kit lifter band replacement rollers 1 X Y lifter...

Page 200: ...r Page 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 o...

Page 201: ...oor interlock 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...

Page 202: ...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 Center Off S...

Page 203: ...ld Preflow Plasma Cutflow Shield Cutflow 123022 Command I O Cable THC Command Machine I O Cable 023018 Pendant Ext Cable 053019 Optional Unit Operator Pendant Lifter Torch Atm Vent Gas Valve Cable Pos...

Page 204: ...8 9 10 11 12 13 14 15 16 COM 120 Vac 2 TB1 1 4 3 5 24V 5V TB2 120 Vac GND 005186 Pwr Entry Mdl 3 1A 008971 Fuse 009858 3 4D A 6 4D E 3 4C D 6 4C F 3 4C B 3 4D C 6 4D G 008960 Pwr Cord 008961 or L1 BLK...

Page 205: ...LL PART RETRACT IN D13 IHS SYNC IN IHS SYNC IN D14 IHS TEST IN IHS TEST IN D15 MACHINE CABLE IN MACHINE CABLE IN TX TX RX RX 24V D23 PLASMA CABLE IN PLASMA CABLE IN ARC VOLTS ARC VOLTS D32 PLASMA STAR...

Page 206: ...5 7 6 RX 4 TX 3 RX 1 J1 SPARE RS 422 TX 12V 50 49 48 47 46 45 44 43 42 41 40 39 38 D53 DRIVE ID1 OUT D54 DRIVE ID2 OUT D55 DRIVE ID4 OUT ENCODER A ENCODER A ENCODER B ENCODER B 9 8 2 5 7 6 4 3 1 J5 9...

Page 207: ...44 43 42 41 40 39 38 DRIVE ID1 DRIVE ID2 DRIVE ID4 ENCODER A ENCODER A ENCODER B ENCODER B 8 2 5 7 6 4 3 1 J5 9 MOTOR POWER PHASE A TO LIFTER 123020 SPEED RESPONSE LIMIT DOWN D13 HOME POSITION MOTOR C...

Page 208: ...OWER ENCODER POWER 8 2 5 7 6 WHT BLU 12V 4 12V 3 5V 1 J1 WHT 24V WHT BLU BLU 2 4C G 2 4C E 3 4C H TO LIFTER 123022 ENCODER A ENCODER A SPARE IN SPARE IN DRIVE ID4 DRIVE ID4 DRIVE ID2 DRIVE ID2 DRIVE I...

Page 209: ...1 PIERCE PIERCE HOLD HOLD START IN START IN 8 2 5 7 6 RX 4 TX 3 RX 1 J1 OPTIONAL RS 422 TX 12V 9 LED 1 POWER LED 2 SHIELD RELAY LED 5 PLASMA START RELAY LED 6 OHMIC CONTACT 1 2 3 24VDC 4 5 6 7 8 9 10...

Page 210: ...OMPLETE TORCH FIRES MACHINE MOTION MANUAL MODE CNC START PLASMA HOLD IHS COMPLETE ARC TRANSFER PIERCE DELAY PIERCE COMPLETE MACHINE MOTION MACHINE ACCEL AVC CORNER HOLD RETRACT DELAY RETRACT RETRACT C...

Page 211: ...CommandTHC for X Y Table Instruction Manual a 1 11 In this section 1 Rail Lifter a 2 Plasma interface assembly a 3 THC control module a 4 Appendix A PARTS LIST FOR OLDER SYSTEMS...

Page 212: ...cement Kit 1 2 128727 Motor Encoder replacement Kit 1 3 027550 Brake power off 1 4 027552 Driving block 1 5 027551 Rail and block bearing 1 6 129266 Assembly leadscrew standard 1 7 128189 Band seal ki...

Page 213: ...terface assembly 1 128503 Kit plasma interface upgrade 1 1 002266 Enclosure plasma interface 1 2 041521 PCB assembly plasma interface 1 3 001603 Panel plasma interface 1 3 1 2 Note 128048 can only be...

Page 214: ...filter 1 4 008971 Fuse T 3 15 Amp H 250 V 5 mm x 20 mm 2 5 041507 PCB control see figure on next page 1 6 081029 Firmware real time microprocessor 1 7 081030 Firmware interface microprocessor 1 8 0415...

Page 215: ...APPENDIX A PARTS LIST FOR OLDER SYSTEMS CommandTHC for X Y Table Instruction Manual a 5 11 8 9 Control module interior 5 7 6...

Page 216: ...default settings are listed in case it becomes necessary to reset other parameters The following keys on the keypad represent the function keys F1 F5 Appendix B PENDANT CONTRAST ADJUSTMENT PROCEDURE n...

Page 217: ...INT MODE button to acknowledge that the change has been saved The screen may freeze at this time but will return to normal after about 15 seconds or after a function key has been pressed Default penda...

Page 218: ...24 Global Changed sensing wires to arc voltage wires everywhere it appeared 3g Updated section to include the G3 series 3i Added the 260 and 400XD to the HPR setup section Added section 3j Added inst...

Page 219: ...page Rev changed from 9 to 10 Art on cover updated to show new encoder 2 3 Added note to Plasma interface assembly with voltage divider bullet 3 16 5 12 and 6 3 Changed part number in 130 W power sup...

Page 220: ...CommandTHC for X Y Table Instruction Manual...

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