®

command THC
X-Y Table
Torch Height Control
(THC) System
Instruction Manual
802780 – Revision 10

EN50199
EN60974-1
 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

2.3 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
6.2 229070

Command THC for X-Y Table Instruction Manual

Command THC for X-Y Table Instruction Manual
 ®
Command THC
X-Y Table
Torch Height Control
(THC) System

Instruction Manual
(P/N 802780)

Revision 10 – January 2005

Hypertherm, Inc.
Hanover, NH USA
www.hypertherm.com

© Copyright 2005 Hypertherm, Inc.

All Rights Reserved

Hypertherm and Command THC are trademarks of Hypertherm, Inc., and

may be registered in the United States and/or other countries
Hypertherm, Inc. France
Etna Road, P.O. Box 5010 15 Impasse des Rosiers
Hanover, NH 03755 USA 95610 Eragny, France
603-643-3441 Tel (Main Office) 00 800 3324 9737 Tel
603-643-5352 Fax (All Departments) 00 800 4973 7329 Fax
info@hypertherm.com (Main Office Email)
800-643-9878 Tel (Technical Service) Hypertherm S.r.l.
technical.service@hypertherm.com (Technical Service Email) Via Torino 2
800-737-2978 Tel (Customer Service) 20123 Milano, Italia
customer.service@hypertherm.com (Customer Service Email) 39 02 725 46 312 Tel
39 02 725 46 400 Fax
Hypertherm Automation, LLC 39 02 725 46 314 (Technical Service)
5 Technology Drive, Suite 300
West Lebanon, NH 03755 USA Hypertherm Europe B.V.
603-298-7970 Tel Vaartveld 9
603-298-7977 Fax 4704 SE Roosendaal, Nederland
31 165 596907 Tel
Hypertherm Plasmatechnik, GmbH 31 165 596901 Fax
Technologiepark Hanau 31 165 596908 Tel (Marketing)
Rodenbacher Chaussee 6 31 165 596900 Tel (Technical Service)
D-63457 Hanau-Wolfgang, Deutschland 00 800 49 73 7843 Tel (Technical Service)
49 6181 58 2100 Tel
49 6181 58 2134 Fax Japan
49 6181 58 2123 (Technical Service) 1952-14 Yata-Natsumegi
Mishima City, Shizuoka Pref.
Hypertherm (S) Pte Ltd. 411-0801 Japan
No. 19 Kaki Bukit Road 2 81 0 559 75 7387 Tel
K.B. Warehouse Complex 81 0 559 75 7376 Fax
Singapore 417847, Republic of Singapore
65 6 841 2489 Tel HYPERTHERM BRASIL LTDA.
65 6 841 2490 Fax Rua Jati, 33
65 6 841 2489 (Technical Service) CEP 07180-350 Cumbica
Guarulhos, SP - Brasil
Hypertherm (Shanghai) Consulting Co., Ltd. 55 11 6482 1087 Tel
Suite 305, CIMIC Towers 55 11 6482 0591 Fax
1090 Century Boulevard, Pudong
Shanghai 200120
P.R. China
86-21-5835-5362 /3 Tel
86-21-5835 5220 Fax
86-21-5835-5362 /3 (Technical Service)

Hypertherm
Branch of Hypertherm, UK, UC
PO Box 244
Wigan, Lancashire, England WN8 7WU
00 800 3324 9737 Tel
00 800 4973 7329 Fax
00 800 4973 7843 (Technical Service)

11/30/04
 ELECTROMAGNETIC COMPATIBILITY (EMC)

EMC INTRODUCTION The size of the surrounding area to be Earthing of Workpiece

considered will depend on the structure of
Hypertherm's CE-marked equipment is built Where the workpiece is not bonded to earth
the building and other activities that are tak-
in compliance with standard EN50199. The for electrical safety, nor connected to earth
ing place. The surrounding area may extend
equipment should be installed and used in because of its size and position, for example,
beyond the boundaries of the premises.
accordance with the information below to ship's hull or building steelwork, a connection
achieve electromagnetic compatibility. bonding the workpiece to earth may reduce
METHODS OF REDUCING EMISSIONS
emissions in some, but not all instances.
The limits required by EN50199 may not be Care should be taken to prevent the earthing
adequate to completely eliminate interfer- Mains Supply
of the workpiece increasing the risk of injury
ence when the affected equipment is in Cutting equipment must be connected to the to users, or damage to other electrical equip-
close proximity or has a high degree of mains supply according to the manufactur- ment. Where necessary, the connection of
sensitivity. In such cases it may be neces- er's recommendations. If interference the workpiece to earth should be made by a
sary to use other measures to further occurs, it may be necessary to take direct connection to the workpiece, but in
reduce interference. additional precautions such as filtering of some countries where direct connection is
This plasma equipment is designed for use the mains supply. Consideration should be not permitted, the bonding should be
only in an industrial environment. given to shielding the supply cable of per- achieved by suitable capacitances selected
manently installed cutting equipment, in according to national regulations.
INSTALLATION AND USE metallic conduit or equivalent. Shielding
Note. The cutting circuit may or may not be
should be electrically continuous throughout
The user is responsible for installing and earthed for safety reasons. Changing the
its length. The shielding should be connect-
using the plasma equipment according to earthing arrangements should only be au-
ed to the cutting mains supply so that good
the manufacturer's instructions. If electro- thorized by a person who is competent to
electrical contact is maintained between the
magnetic disturbances are detected then it assess whether the changes will increase
conduit and the cutting power source
shall be the responsibility of the user to re- the risk of injury, for example, by allowing
enclosure.
solve the situation with the technical assis- parallel cutting current return paths which
tance of the manufacturer. In some cases may damage the earth circuits of other
Maintenance of Cutting Equipment
this remedial action may be as simple as equipment. Further guidance is given in
earthing the cutting circuit, see Earthing of The cutting equipment must be routinely IEC/TS 62081 Arc Welding Equipment
Workpiece. In other cases it could involve maintained according to the manufacturer's Installation and Use.
constructing an electromagnetic screen recommendations. All access and service
enclosing the power source and the work doors and covers should be closed and Screening and Shielding
complete with associated input filters. In all properly fastened when the cutting
Selective screening and shielding of other
cases electromagnetic disturbances must equipment is in operation. The cutting
cables and equipment in the surrounding
be reduced to the point where they are no equipment should not be modified in any
area may alleviate problems of interference.
longer troublesome. way except for those changes and adjust-
Screening of the entire plasma cutting
ments covered in the manufacturer's
installation may be considered for special
ASSESSMENT OF AREA instructions. In particular, the spark gaps of
applications.
arc striking and stabilizing devices should
Before installing the equipment the user be adjusted and maintained according to
shall make an assessment of potential elec- the manufacturer's recommendations.
tromagnetic problems in the surrounding
area. The following shall be taken into Cutting Cables
account:
a. Other supply cables, control cables, The cutting cables should be kept as short
signalling and telephone cables; above, as possible and should be positioned close
below and adjacent to the cutting equip- together, running at or close to the floor
ment. level.
b. Radio and television transmitters and
receivers. Equipotential Bonding
c. Computer and other control equipment. Bonding of all metallic components in the
d. Safety critical equipment, for example cutting installation and adjacent to it should
guarding of industrial equipment. be considered. However, metallic compo-
e. Health of the people around, for nents bonded to the workpiece will increase
example the use of pacemakers and hear- the risk that the operator could receive a
ing aids. shock by touching these metallic
f. Equipment used for calibration or mea- components and the electrode at the same
surement. time. The operator should be insulated from
g. Immunity of other equipment in the en- all such bonded metallic components.
vironment. User shall ensure that other
equipment being used in the environment is
compatible. This may require additional
protection measures.
h. Time of day that cutting or other activities
are to be carried out.

Hypertherm Plasma Systems i

01/25/05
WARRANTY

WARNING Hypertherm, infringes any patent of any third party. You shall
Genuine Hypertherm parts are the factory-recommended notify Hypertherm promptly upon learning of any action or
replacement parts for your Hypertherm system. Any damage threatened action in connection with any such alleged
caused by the use of other than genuine Hypertherm parts may infringement, and Hypertherm’s obligation to indemnify shall be
not be covered by the Hypertherm warranty. conditioned upon Hypertherm’s sole control of, and the
indemnified party’s cooperation and assistance in, the defense
WARNING of the claim.
You are responsible for the safe use of the Product.
Hypertherm does not and cannot make any guarantee or
LIMITATION OF LIABILITY
warranty regarding the safe use of the Product in your In no event shall Hypertherm be liable to any person or
environment. entity for any incidental, consequential, indirect, or
punitive damages (including but not limited to lost profits)
GENERAL regardless of whether such liability is based on breach of
Hypertherm, Inc. warrants that its Products shall be free from contract, tort, strict liability, breach of warranties, failure of
defects in materials and workmanship, if Hypertherm is notified essential purpose or otherwise and even if advised of the
of a defect (i) with respect to the power supply within a period possibility of such damages.
of two (2) years from the date of its delivery to you, with the
exception of Powermax Series power supplies, which shall be
LIABILITY CAP
within a period of three (3) years from the date of delivery to In no event shall Hypertherm’s liability, whether such
you, and (ii) with respect to the torch and leads within a period liability is based on breach of contract, tort, strict liability,
of one (1) year from its date of delivery to you. This warranty breach of warranties, failure of essential purpose or
shall not apply to any Product which has been incorrectly otherwise, for any claim action suit or proceeding arising
installed, modified, or otherwise damaged. Hypertherm, at its out of or relating to the use of the Products exceed in the
sole option, shall repair, replace, or adjust, free of charge, any aggregate the amount paid for the Products that gave rise
defective Products covered by this warranty which shall be to such claim.
returned with Hypertherm’s prior authorization (which shall not
be unreasonably withheld), properly packed, to Hypertherm’s INSURANCE
place of business in Hanover, New Hampshire, or to an At all times you will have and maintain insurance in such
authorized Hypertherm repair facility, all costs, insurance and quantities and types, and with coverage sufficient and
freight prepaid. Hypertherm shall not be liable for any repairs, appropriate to defend and to hold Hypertherm harmless in
replacement, or adjustments of Products covered by this the event of any cause of action arising from the use of the
warranty, except those made pursuant to this paragraph or with Products.
Hypertherm’s prior written consent. The warranty above is
exclusive and is in lieu of all other warranties, express, NATIONAL AND LOCAL CODES
implied, statutory, or otherwise with respect to the National and Local codes governing plumbing and electrical
Products or as to the results which may be obtained installation shall take precedent over any instructions
therefrom, and all implied warranties or conditions of contained in this manual. In no event shall Hypertherm be
quality or of merchantability or fitness for a particular liable for injury to persons or property damage by reason of any
purpose or against infringement. The foregoing shall code violation or poor work practices.
constitute the sole and exclusive remedy for any breach
by Hypertherm of its warranty. Distributors/OEMs may offer TRANSFER OF RIGHTS
different or additional warranties, but Distributors/OEMs are You may transfer any remaining rights you may have
not authorized to give any additional warranty protection to you hereunder only in connection with the sale of all or substantially
or make any representation to you purporting to be binding all of your assets or capital stock to a successor in interest who
upon Hypertherm. agrees to be bound by all of the terms and conditions of this
Warranty.
PATENT INDEMNITY
Except only in cases of products not manufactured by
Hypertherm or manufactured by a person other than
Hypertherm not in strict conformity with Hypertherm’s
specifications and in cases of designs, processes, formulae, or
combinations not developed or purported to be developed by
Hypertherm, Hypertherm will defend or settle, at its own
expense, any suit or proceeding brought against you alleging
that the use of the Hypertherm product, alone and not in
combination with any other product not supplied by

ii Hypertherm Plasma Systems

9-01
 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
Cutting Can Produce Toxic Fumes..................................................................................................................1-3
Plasma Arc Can Cause Injury and Burns........................................................................................................1-4
Arc Rays Can Burn Eyes and Skin .................................................................................................................1-4
Grounding Safety ............................................................................................................................................1-4
Compressed Gas Equipment Safety...............................................................................................................1-5
Gas Cylinders Can Explode if Damaged.........................................................................................................1-5
Noise Can Damage Hearing ...........................................................................................................................1-5
Pacemaker and Hearing Aid Operation...........................................................................................................1-5
A Plasma Arc Can Damage Frozen Pipes ......................................................................................................1-5
Additional Safety Information ..........................................................................................................................1-5
Warning Lable .................................................................................................................................................1-6

SECTION 1a SÉCURITÉ .......................................................................................................................... 1a-1

IIdentifier les consignes de sécurité ..............................................................................................................1a-2
Suivre les instructions de sécurité.................................................................................................................1a-2
Danger Avertissement Précaution...............................................................................................................1a-2
Le coupage peut provoquer un incendie ou une explosion...........................................................................1a-2
Prévention des incendies, Prévention des explosions .........................................................................1a-2
Risque d’explosion argon-hydrogène et méthane ................................................................................1a-2
Détonation de l’hydrogène lors du coupage de l’aluminium .................................................................1a-2
Les chocs électriques peuvent être fatals .....................................................................................................1a-3
Prévention des chocs électriques.........................................................................................................1a-3
Le coupage peut produire des vapeurs toxiques ..........................................................................................1a-3
L’arc plasma peut provoquer des blessures ou des brûlures........................................................................1a-4
Torches à allumage instantané.............................................................................................................1a-4
Les rayons de l’arc peuvent brûler les yeux et la peau .................................................................................1a-4
Protection des yeux, Protection de la peau, Zone de coupage ..........................................................1a-4
Mise à la masse et à la terre .........................................................................................................................1a-4
Câble de retour, Table de travail, Alimentation .....................................................................................1a-4
Sécurité des bouteilles de gaz comprimé .....................................................................................................1a-5
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages....................................................1a-5
Le bruit peut provoquer des problèmes auditifs ............................................................................................1a-5
Pacemakers et prothèses auditives ..............................................................................................................1a-5
Un arc plasma peut endommager les tuyaux gelés ......................................................................................1a-5
Étiquette de sécurité .....................................................................................................................................1a-6

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
THC breakaway option....................................................................................................................................2-8

Command THC for X-Y Table Instruction Manual iii

6
TABLE OF CONTENTS

SECTION 3 SETUP
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 torch (without torch breakaway option) ......................................................................................3-10
Install torch (with torch breakaway option) ...........................................................................................3-11
System interconnections ...............................................................................................................................3-12
THC system cables ..............................................................................................................................3-12
Machine interface cable........................................................................................................................3-14
THC selectable responses ............................................................................................................................3-16
Dipswitch positions ...............................................................................................................................3-17
Command THC serial protocol......................................................................................................................3-18
Grounding requirements ...............................................................................................................................3-20
Power cord grounding ..........................................................................................................................3-20
Protective earth ground ........................................................................................................................3-20
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
HPR130 system interconnections ..................................................................................................................3i-1

SECTION 4 OPERATION
Operating controls ..........................................................................................................................................4-2
THC control module................................................................................................................................4-2
Operator pendant ..................................................................................................................................4-2
Pendant display screens ........................................................................................................................4-4
Pendant programmable fields.................................................................................................................4-6
Automatic screen operation ..............................................................................................................4-6
Manual screen operation ...................................................................................................................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
Problems and solutions ........................................................................................................................4-16
Manual mode time-line .........................................................................................................................4-18
THC selectable responses (DIP switch)...............................................................................See section 3 Setup

iv Command THC for X-Y Table Instruction Manual

9
 TABLE OF CONTENTS

SECTION 5 MAINTENANCE
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 drive board status lights during normal power-up ....................................................................5-14
Interface board status lights during normal power-up ..........................................................................5-16

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
Ohmic contact wire..........................................................................................................................................6-9
Power cords ....................................................................................................................................................6-9
Recommended spare parts...........................................................................................................................6-10
Interface cables...........................................................................................................See Section 3a through 3i

APPENDIX
APPENDIX A 1 rail lifter parts list ..............................................................................................................a-1

Command THC for X-Y Table Instruction Manual v

9
TABLE OF CONTENTS

vi Command THC for X-Y Table Instruction Manual

6
 Section 1

SAFETY

In this section:

Recognize Safety Information...................................................................................................................................1-2

Follow Safety Instructions .........................................................................................................................................1-2
Cutting Can Cause Fire or Explosion .......................................................................................................................1-2
Electric Shock Can Kill..............................................................................................................................................1-3
Cutting Can Produce Toxic Fumes ...........................................................................................................................1-3
A Plasma Arc Can Cause Injury and Burns ..............................................................................................................1-4
Arc Rays Can Burn Eyes and Skin ...........................................................................................................................1-4
Grounding Safety ......................................................................................................................................................1-4
Compressed Gas Equipment Safety ........................................................................................................................1-5
Gas Cylinders Can Explode If Damaged ..................................................................................................................1-5
Noise Can Damage Hearing .....................................................................................................................................1-5
Pacemaker and Hearing Aid Operation ....................................................................................................................1-5
A Plasma Arc Can Damage Frozen Pipes ................................................................................................................1-5
Additional Safety Information ....................................................................................................................................1-5
Warning Label...........................................................................................................................................................1-6

Hypertherm Plasma Systems 1-1

SAFETY

RECOGNIZE SAFETY INFORMATION • Keep your machine in proper working condition.

Unauthorized modifications to the machine may
The symbols shown in this section are used to identify affect safety and machine service life.
potential hazards. When you see a safety symbol in this
manual or on your machine, understand the potential
for personal injury, and follow the related instructions to
avoid the hazard. DANGER WARNING CAUTION

A signal word DANGER or WARNING is used with a

FOLLOW SAFETY INSTRUCTIONS safety symbol. DANGER identifies the most serious
hazards.

Read carefully all safety messages in this manual and • DANGER and WARNING safety labels are located
safety labels on your machine. on your machine near specific hazards.
• WARNING safety messages precede related
• Keep the safety labels on your machine in good
instructions in this manual that may result in injury
condition. Replace missing or damaged labels
or death if not followed correctly.
immediately.
• CAUTION safety messages precede related
• Learn how to operate the machine and how to use
instructions in this manual that may result in
the controls properly. Do not let anyone operate it
damage to equipment if not followed correctly.
without instruction.

CUTTING CAN CAUSE FIRE OR EXPLOSION

Fire Prevention WARNING

• Be sure the area is safe before doing any cutting. Explosion Hazard
Keep a fire extinguisher nearby. Argon-Hydrogen and Methane
• Remove all flammables within 35 feet (10 m) of the
cutting area. Hydrogen and methane are flammable gases that
• Quench hot metal or allow it to cool before handling present an explosion hazard. Keep flames away from
or before letting it touch combustible materials. cylinders and hoses that contain methane or hydrogen
• Never cut containers with potentially flammable mixtures. Keep flames and sparks away from the torch
materials inside – they must be emptied and when using methane or argon-hydrogen plasma.
properly cleaned first.
• Ventilate potentially flammable atmospheres before
cutting. WARNING
• When cutting with oxygen as the plasma gas, an Hydrogen Detonation with Aluminum Cutting
exhaust ventilation system is required.
• When cutting aluminum underwater, or with the
Explosion Prevention water touching the underside of the aluminum, free
• Do not use the plasma system if explosive dust or hydrogen gas may collect under the workpiece and
vapors may be present. detonate during plasma cutting operations.
• Do not cut pressurized cylinders, pipes, or any • Install an aeration manifold on the floor of the water
closed container. table to eliminate the possibility of hydrogen
• Do not cut containers that have held combustible detonation. Refer to the Appendix section of this
materials. manual for aeration manifold details.

1-2 Hypertherm Plasma Systems

11-98
 SAFETY

ELECTRIC SHOCK CAN KILL

Touching live electrical parts can cause a fatal shock • Install and ground this equipment according to the
or severe burn. instruction manual and in accordance with national
and local codes.
• Operating the plasma system completes an
• Inspect the input power cord frequently for damage
electrical circuit between the torch and the
or cracking of the cover. Replace a damaged power
workpiece. The workpiece and anything touching
cord immediately. Bare wiring can kill.
the workpiece are part of the electrical circuit.
• Inspect and replace any worn or damaged torch
• Never touch the torch body, workpiece or the water
leads.
in a water table when the plasma system is
• Do not pick up the workpiece, including the waste
operating.
cutoff, while you cut. Leave the workpiece in place
or on the workbench with the work cable attached
Electric Shock Prevention
during the cutting process.
All Hypertherm plasma systems use high voltage • Before checking, cleaning or changing torch parts,
in the cutting process (200 to 400 VDC are disconnect the main power or unplug the power
common). Take the following precautions when supply.
operating this system: • Never bypass or shortcut the safety interlocks.
• Wear insulated gloves and boots, and keep your • Before removing any power supply or system
body and clothing dry. enclosure cover, disconnect electrical input power.
• Do not stand, sit or lie on – or touch – any wet Wait 5 minutes after disconnecting the main power
surface when using the plasma system. to allow capacitors to discharge.
• Insulate yourself from work and ground using dry • Never operate the plasma system unless the power
insulating mats or covers big enough to prevent any supply covers are in place. Exposed power supply
physical contact with the work or ground. If you must connections present a severe electrical hazard.
work in or near a damp area, use extreme caution. • When making input connections, attach proper
• Provide a disconnect switch close to the power grounding conductor first.
supply with properly sized fuses. This switch allows • Each Hypertherm plasma system is designed to be
the operator to turn off the power supply quickly in used only with specific Hypertherm torches. Do not
an emergency situation. substitute other torches which could overheat and
• When using a water table, be sure that it is correctly present a safety hazard.
connected to earth ground.

CUTTING CAN PRODUCE TOXIC FUMES

Cutting can produce toxic fumes and gases that beryllium, unless the area is well ventilated and the
deplete oxygen and cause injury or death. operator wears an air-supplied respirator. The
coatings and any metals containing these elements
• Keep the cutting area well ventilated or use an can produce toxic fumes when cut.
approved air-supplied respirator. • Never cut containers with potentially toxic materials
• Do not cut in locations near degreasing, cleaning or inside – they must be emptied and properly cleaned
spraying operations. The vapors from certain first.
chlorinated solvents decompose to form phosgene • This product, when used for welding or cutting,
gas when exposed to ultraviolet radiation. produces fumes or gases which contain chemicals
• Do not cut metal coated or containing toxic materi- known to the State of California to cause birth
als, such as zinc (galvanized), lead, cadmium or defects and, in some cases, cancer.

Hypertherm Plasma Systems 1-3

8-99
SAFETY

A PLASMA ARC CAN CAUSE INJURY AND BURNS

Instant-On Torches The plasma arc will cut quickly through gloves and
Plasma arc comes on immediately when the torch skin.
switch is activated. • Keep away from the torch tip.
• Do not hold metal near the cutting path.
• Never point the torch toward yourself or others.

ARC RAYS CAN BURN EYES AND SKIN

Eye Protection Plasma arc rays produce intense Skin Protection Wear protective clothing to protect
visible and invisible (ultraviolet and infrared) rays that against burns caused by ultraviolet light, sparks and
can burn eyes and skin. hot metal.
• Use eye protection in accordance with applicable • Gauntlet gloves, safety shoes and hat.
national or local codes. • Flame-retardant clothing to cover all exposed areas.
• Wear eye protection (safety glasses or goggles with • Cuffless trousers to prevent entry of sparks and
side shields, and a welding helmet) with appropriate slag.
lens shading to protect your eyes from the arc’s • Remove any combustibles, such as a butane lighter
ultraviolet and infrared rays. or matches, from your pockets before cutting.

Lens Shade Cutting Area Prepare the cutting area to reduce

Arc Current AWS (USA) ISO 4850 reflection and transmission of ultraviolet light:
Up to 100 A No. 8 No. 11 • Paint walls and other surfaces with dark colors to
100-200 A No. 10 No. 11-12 reduce reflection.
200-400 A No. 12 No. 13 • Use protective screens or barriers to protect others
Over 400 A No. 14 No. 14 from flash and glare.
• Warn others not to watch the arc. Use placards or
signs.

GROUNDING SAFETY Input Power

• Be sure to connect the power cord ground wire to
the ground in the disconnect box.
Work Cable Attach the work cable securely to the • If installation of the plasma system involves
workpiece or the work table with good metal-to-metal connecting the power cord to the power supply, be
contact. Do not connect it to the piece that will fall sure to connect the power cord ground wire
away when the cut is complete. properly.
• Place the power cord's ground wire on the stud first,
Work Table Connect the work table to an earth then place any other ground wires on top of the
ground, in accordance with appropriate national or power cord ground. Fasten the retaining nut tightly.
local electrical codes. • Tighten all electrical connections to avoid excessive
heating.

1-4 Hypertherm Plasma Systems

5/6/02
 SAFETY

COMPRESSED GAS EQUIPMENT SAFETY GAS CYLINDERS CAN

EXPLODE IF DAMAGED
• Never lubricate cylinder valves or regulators with oil
or grease. Gas cylinders contain gas under high pressure. If
• Use only correct gas cylinders, regulators, hoses damaged, a cylinder can explode.
and fittings designed for the specific application. • Handle and use compressed gas cylinders in
• Maintain all compressed gas equipment and accordance with applicable national or local codes.
associated parts in good condition. • Never use a cylinder that is not upright and secured
• Label and color-code all gas hoses to identify the in place.
type of gas in each hose. Consult applicable • Keep the protective cap in place over valve except
national or local codes. when the cylinder is in use or connected for 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 cylinder valve.

NOISE CAN DAMAGE HEARING PACEMAKER AND HEARING

AID OPERATION

Pacemaker and hearing aid operation can be affected

Prolonged exposure to noise from cutting or gouging
by magnetic fields from high currents.
can damage hearing.
Pacemaker and hearing aid wearers should consult a
• Use approved ear protection when using plasma
doctor before going near any plasma arc cutting and
system.
gouging operations.
• Warn others nearby about the noise hazard.
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 possible to the
A PLASMA ARC CAN work cable.
DAMAGE FROZEN PIPES • Do not wrap or drape the torch lead or work cable
around your body.
• Keep as far away from the power supply as
Frozen pipes may be damaged or can burst if you possible.
attempt to thaw them with a plasma torch.

ADDITIONAL SAFETY INFORMATION 5. AWS F5.2, Recommended Safe Practices for Plasma Arc
Cutting, American Welding Society
1. ANSI Standard Z49.1, Safety in Welding and Cutting, American 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135
Welding Society, 550 LeJeune Road 6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in
P.O. Box 351020, Miami, FL 33135 Cylinders, Compressed Gas Association
2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and 1235 Jefferson Davis Highway, Arlington, VA 22202
Welding Processes, American National Standards Institute 7. CSA Standard W117.2, Code for Safety in Welding and Cutting,
1430 Broadway, New York, NY 10018 Canadian Standards Association Standard Sales
3. ANSI Standard Z87.1, Safe Practices for Occupation and 178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada
Educational Eye and Face Protection, American National 8. NFPA Standard 51B, Cutting and Welding Processes, National
Standards Institute, 1430 Broadway, New York, NY 10018 Fire Protection Association
4. AWS F4.1, Recommended Safe Practices for the Preparation for 470 Atlantic Avenue, Boston, MA 02210
Welding and Cutting of Containers and Piping That Have Held 9. NFPA Standard 70–1978, National Electrical Code, National Fire
Hazardous Substances, American Welding Society Protection Association, 470 Atlantic Avenue, Boston, MA 02210
550 LeJeune Road, P.O. Box 351040, Miami, FL 33135 10. OSHA, Safety and Health Standards, 29FR 1910
U.S. Government Printing Office, Washington, D.C. 20402

Hypertherm Plasma Systems 1-5

11-98
SAFETY

WARNING LABEL
This warning label is affixed to some power supplies. It is
important that the operator and maintenance technician
understand the intent of these warning symbols as described.

1-6 Hypertherm Plasma Systems

8-99
 Section 1a

SÉCURITÉ

Dans cette section :

Identifier les consignes de sécurité.........................................................................................................................1a-2

Suivre les instructions de sécurité ..........................................................................................................................1a-2
Danger Avertissement Précaution ........................................................................................................................1a-2
Le coupage peut provoquer un incendie ou une explosion ....................................................................................1a-2
Prévention des incendies, Prévention des explosions ...................................................................................1a-2
Risque d’explosion argon-hydrogène et méthane..........................................................................................1a-2
Détonation de l’hydrogène lors du coupage de l’aluminium...........................................................................1a-2
Les chocs électriques peuvent être fatals...............................................................................................................1a-3
Prévention des chocs électriques ..................................................................................................................1a-3
Le coupage peut produire des vapeurs toxiques....................................................................................................1a-3
L’arc plasma peut provoquer des blessures ou des brûlures .................................................................................1a-4
Torches à allumage instantané ......................................................................................................................1a-4
Les rayons de l’arc peuvent brûler les yeux et la peau...........................................................................................1a-4
Protection des yeux, Protection de la peau, Zone de coupage ....................................................................1a-4
Mise à la masse et à la terre...................................................................................................................................1a-4
Câble de retour, Table de travail, Alimentation ...............................................................................................1a-4
Sécurité des bouteilles de gaz comprimé ...............................................................................................................1a-5
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .............................................................1a-5
Le bruit peut provoquer des problèmes auditifs......................................................................................................1a-5
Pacemakers et prothèses auditives ........................................................................................................................1a-5
Un arc plasma peut endommager les tuyaux gelés................................................................................................1a-5
Étiquette de sécurité ...............................................................................................................................................1a-6

Hypertherm Systèmes plasma 1a-1

2/12/01
SÉCURITÉ

IDENTIFIER LES CONSIGNES • Garder la machine en bon état. Des modifications non
DE SÉCURITÉ autorisées sur la machine peuvent engendrer des
problèmes de sécurité et raccourcir la durée d’utilisation
Les symboles indiqués dans cette section sont utilisés pour de l’équipement.
identifier les risques éventuels. Si vous trouvez un symbole
de sécurité, que ce soit dans ce manuel ou sur
l’équipement, soyez conscient des risques de blessures et
DANGER AVERTISSEMENT PRÉCAUTION
suivez les instructions correspondantes afin d’éviter ces
risques. Les signaux DANGER ou AVERTISSEMENT sont utilisés
avec un symbole de sécurité, DANGER correspondant aux
SUIVRE LES INSTRUCTIONS risques les plus sérieux.
DE SÉCURITÉ • Les étiquettes de sécurité DANGER et AVERTISSEMENT
Lire attentivement toutes les consignes de sécurité dans le sont situées sur la machine pour signaler certains
présent manuel et sur les étiquettes de sécurité se trouvant dangers spécifiques.
sur la machine. • Les messages d’AVERTISSEMENT précèdent les
instructions d’utilisation expliquées dans ce manuel et
• Les étiquettes de sécurité doivent rester lisibles. signalent les risques de blessures ou de mort au cas où
Remplacer immédiatement les étiquettes manquantes ou ces instructions ne seraient pas suivies correctement.
abîmées. • Les messages de PRÉCAUTION précèdent les
• Apprendre à faire fonctionner la machine et à utiliser instructions d’utilisation contenues dans ce manuel et
correctement les commandes. Ne laisser personne utiliser signalent que le matériel risque d’être endommagé si les
la machine sans connaître son fonctionnement. instructions ne sont pas suivies correctement.

LE COUPAGE PEUT PROVOQUER UN INCENDIE

OU UNE EXPLOSION

Prévention des incendies AVERTISSEMENT

• Avant de commencer, s’assurer que la zone de coupage Risque d’explosion
ne présente aucun danger. Conserver un extincteur à argon-hydrogène et méthane
proximité.
• Éloigner toute matière inflammable à une distance d’au L’hydrogène et le méthane sont des gaz inflammables et
moins 10 m du poste de coupage. potentiellement explosifs. Conserver à l’écart de toute
• Tremper le métal chaud ou le laisser refroidir avant de flamme les bouteilles et tuyaux contenant des mélanges à
le manipuler ou avant de le mettre en contact avec des base d’hydrogène ou de méthane. Maintenir toute flamme
matériaux combustibles. et étincelle à l’écart de la torche lors de l’utilisation d’un
• Ne jamais couper des récipients pouvant contenir des plasma d’argon-hydrogène ou de méthane.
matières inflammables avant de les avoir vidés et
nettoyés correctement. AVERTISSEMENT
• Aérer toute atmosphère potentiellement inflammable Détonation de l’hydrogène lors du
avant d’utiliser un système plasma. coupage de l’aluminium
• Lors de l’utilisation d’oxygène comme gaz plasma, un
système de ventilation par aspiration est nécessaire. • Lors du coupage de l’aluminium sous l’eau, ou si l’eau
touche la partie inférieure de la pièce d’aluminium, de
Prévention des explosions l’hydrogène libre peut s’accumuler sous la pièce à couper
• Ne pas couper en présence de poussière ou de vapeurs. et détonner lors du coupage plasma.
• Ne pas couper de bouteilles, de tuyaux ou autres • Installer un collecteur d’aération au fond de la table à eau
récipients fermés et pressurisés. afin d’éliminer les risques de détonation de l’hydrogène.
• Ne pas couper de récipients contenant des matières Se référer à l’annexe du manuel pour plus de
combustibles. renseignements sur les collecteurs d’aération.

1a-2 Hypertherm Systèmes plasma

2/12/01
 SÉCURITÉ

LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS

• Installer et mettre à la terre l’équipement selon les

Toucher une pièce électrique sous tension peut provoquer instructions du présent manuel et conformément aux
un choc électrique fatal ou des brûlures graves. codes électriques locaux et nationaux.
• Inspecter fréquemment le cordon d’alimentation primaire
• La mise en fonctionnement du système plasma ferme un pour s’assurer qu’il n’est ni endommagé, ni fendu.
circuit électrique entre la torche et la pièce à couper. La Remplacer immédiatement un cordon endommagé.
pièce à couper et tout autre élément en contact avec cette Un câble dénudé peut tuer.
pièce font partie du circuit électrique. • Inspecter et remplacer les câbles de la torche qui sont
• Ne jamais toucher le corps de la torche, la pièce à couper usés ou endommagés.
ou l’eau de la table à eau pendant le fonctionnement du • Ne pas saisir la pièce à couper ni les chutes lors du
système plasma. coupage. Laisser la pièce à couper en place ou sur la
table de travail, le câble de retour connecté lors du
Prévention des chocs électriques coupage.
Tous les systèmes plasma Hypertherm utilisent des hautes • Avant de vérifier, de nettoyer ou de remplacer les pièces
tensions pour le coupage (souvent de 200 à 400 V). On de la torche, couper l’alimentation ou débrancher la prise
doit prendre les précautions suivantes quand on utilise le de courant.
système plasma : • Ne jamais contourner ou court-circuiter les verrouillages
• Porter des bottes et des gants isolants et garder le corps de sécurité.
et les vêtements au sec. • Avant d’enlever le capot du système ou de la source de
• Ne pas se tenir, s’asseoir ou se coucher sur une surface courant, couper l’alimentation électrique. Attendre ensuite
mouillée, ni la toucher quand on utilise le système plasma. 5 minutes pour que les condensateurs se déchargent.
• S’isoler de la surface de travail et du sol en utilisant des • Ne jamais faire fonctionner le système plasma sans que
tapis isolants secs ou des couvertures assez grandes les capots de la source de courant ne soient en place.
pour éviter tout contact physique avec le travail ou le sol. Les raccords exposés de la source de courant sont
S’il s’avère nécessaire de travailler dans ou près d’un extrêmement dangereux.
endroit humide, procéder avec une extrême prudence. • Lors de l’installation des connexions, attacher tout d’abord
• Installer un sectionneur avec fusibles appropriés, à la prise de terre appropriée.
proximité de la source de courant. Ce dispositif permet à • Chaque système plasma Hypertherm est conçu pour être
l’opérateur d’arrêter rapidement la source de courant en utilisé uniquement avec des torches Hypertherm
cas d’urgence. spécifiques. Ne pas utiliser des torches inappropriées qui
• En cas d’utilisation d’une table à eau, s’assurer que cette pourraient surchauffer et présenter des risques pour la
dernière est correctement mise à la terre. sécurité.

LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES

Le coupage peut produire des vapeurs et des gaz toxiques soit très bien ventilée et que l’opérateur porte un masque
qui réduisent le niveau d’oxygène dans l’air et peuvent respiratoire. Les revêtements et métaux contenant ces
provoquer des blessures, voire la mort. matières peuvent produire des vapeurs toxiques lors du
• Conserver le poste de coupage bien aéré ou utiliser un coupage.
masque respiratoire homologué. • Ne jamais couper de récipients pouvant contenir des
• Ne pas procéder au coupage près d’endroits où matières inflammables avant de les avoir vidés et
s’effectuent le dégraissage, le nettoyage ou la vapori- nettoyés correctement.
sation. Certains solvants chlorés se décomposent sous • Quand on utilise ce produit pour le soudage ou le
l’effet des rayons ultraviolets et forment du phosgène. coupage, il dégage des fumées et des gaz qui
• Ne pas couper des métaux peints ou contenant des contiennent des produits chimiques qui, selon l’État de
matières toxiques comme le zinc (galvanisé), le plomb, le Californie, provoquent des anomalies congénitales et,
cadmium ou le béryllium, à moins que la zone de travail dans certains cas, le cancer.

Hypertherm Systèmes plasma 1a-3

2/12/01
SÉCURITÉ

L’ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURES

Torches à allumage instantané L’arc plasma coupe facilement les gants et la peau.
L’arc plasma s’allume immédiatement après que la torche • Rester éloigné de l’extrémité de la torche.
soit mise en marche. • Ne pas tenir de métal près de la trajectoire de coupe.
• Ne jamais pointer la torche vers soi ou d’autres
personnes.

LES RAYONS DE L’ARC PEUVENT BRÛLER LES YEUX ET LA PEAU

Protection des yeux Les rayons de l’arc plasma • Gants à crispin, chaussures et casque de sécurité.
produisent de puissants rayons visibles ou invisibles • Vêtements ignifuges couvrant toutes les parties exposées
(ultraviolets et infrarouges) qui peuvent brûler les yeux et la du corps.
peau. • Pantalon sans revers pour éviter que des étincelles ou
• Utiliser des lunettes de sécurité conformément aux codes des scories puissent s’y loger.
locaux ou nationaux en vigueur. • Avant le coupage, retirer de ses poches tout objet
• Porter des lunettes de protection (lunettes ou masque combustible comme les briquets au butane ou les
muni d’écrans latéraux et encore masque de soudure) allumettes.
avec des verres teintés appropriés pour protéger les yeux
des rayons ultraviolets et infrarouges de l’arc. Zone de coupage Préparer la zone de coupage afin de
réduire la réverbération et la transmission de la lumière
Puissance des verres teintés ultraviolette :
Courant de l’arc AWS (É.-U.) ISO 4850 • Peindre les murs et autres surfaces de couleur sombre
Jusqu’à 100 A No 8 No 11 pour réduire la réflexion de la lumière.
100-200 A o
N 10 No 11-12 • Utiliser des écrans et autres dispositifs de protection afin
200-400 A o
N 12 No 13 de protéger les autres personnes de la lumière et de la
Plus de 400 A o
N 14 No 14 réverbération.
• Prévenir les autres personnes de ne pas regarder l’arc.
Protection de la peau Porter des vêtements de sécurité Utiliser des affiches ou des panneaux.
pour se protéger contre les brûlures que peuvent causer les
rayons ultraviolets, les étincelles et le métal brûlant :

MISE À LA MASSE ET À LA TERRE Alimentation

• S’assurer que le fil de terre du cordon d’alimentation est
connecté à la terre dans le coffret du sectionneur.
Câble de retour Bien fixer le câble de retour (ou de • S’il est nécessaire de brancher le cordon d’alimentation à
masse) à la pièce à couper ou à la table de travail de façon la source de courant lors de l’installation du système,
à assurer un bon contact métal-métal. Ne pas fixer le câble s’assurer que le fil de terre est correctement branché.
de retour à la partie de la pièce qui doit se détacher. • Placer tout d’abord le fil de terre du cordon d’alimentation
sur le plot de mise à la terre puis placer les autres fils de
Table de travail Raccorder la table de travail à la terre, terre par-dessus. Bien serrer l’écrou de retenue.
conformément aux codes de sécurité locaux ou nationaux • S’assurer que toutes les connexions sont bien serrées
appropriés. pour éviter la surchauffe.

1a-4 Hypertherm Systèmes plasma

5/6/02
 SÉCURITÉ

SÉCURITÉ DES BOUTEILLES DE LES BOUTEILLES DE GAZ

GAZ COMPRIMÉ COMPRIMÉ PEUVENT EXPLOSER
EN CAS DE DOMMAGES
• Ne jamais lubrifier les robinets des bouteilles ou les
régulateurs avec de l’huile ou de la graisse. Les bouteilles de gaz contiennent du gaz à haute pression.
• Utiliser uniquement les bouteilles, régulateurs, tuyaux et Si une bouteille est endommagée, elle peut exploser.
accessoires appropriés et conçus pour chaque application • Manipuler et utiliser les bouteilles de gaz comprimé
spécifique. conformément aux codes locaux ou nationaux.
• Entretenir l’équipement et les pièces d’équipement à gaz • Ne jamais utiliser une bouteille qui n’est pas placée à la
comprimé afin de les garder en bon état. verticale et bien assujettie.
• Étiqueter et coder avec des couleurs tous les tuyaux de • Le capuchon de protection doit être placé sur le robinet
gaz afin d’identifier le type de gaz contenu dans chaque sauf si la bouteille est en cours d’utilisation ou connectée
tuyau. Se référer aux codes locaux ou nationaux en pour utilisation.
vigueur. • Éviter à tout prix le contact électrique entre l’arc plasma et
une bouteille.
• 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.

LE BRUIT PEUT PROVOQUER DES PACEMAKERS ET

PROBLÈMES AUDITIFS PROTHÈSES AUDITIVES

Les champs magnétiques produits par les courants à haute

Une exposition prolongée au bruit du coupage ou du
tension peuvent affecter le fonctionnement des prothèses
gougeage peut provoquer des problèmes auditifs.
auditives et des pacemakers. Les personnes portant ce
• Utiliser un casque de protection homologué lors de
type d’appareil doivent consulter un médecin avant de
l’utilisation du système plasma.
s’approcher d’un lieu où s’effectue le coupage ou le
• Prévenir les personnes aux alentours des risques
gougeage plasma.
encourus en cas d’exposition au bruit.
Pour réduire les risques associés aux champs magnétiques :
• Garder loin de soi et du même côté du corps le câble de
retour et le faisceau de la torche.
• Faire passer le faisceau de la torche le plus près possible
UN ARC PLASMA du câble de retour.
PEUT ENDOMMAGER • Ne pas s’enrouler le faisceau de la torche ou le câble de
LES TUYAUX GELÉS retour autour du corps.
• Se tenir le plus loin possible de la source de courant.

Les tuyaux gelés peuvent être endommagés ou éclater

si l'on essaie de les dégeler avec une torche plasma.

Hypertherm Systèmes plasma 1a-5

2/12/01
SÉCURITÉ

Étiquette de sécurité
Cette étiquette est affichée sur la source de courant. Il est important
que l’utilisateur et le technicien de maintenance comprennent la
signification des symboles de sécurité.

1a-6 Hypertherm Systèmes plasma

2/12/01
 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
THC breakaway option ...........................................................................................................................2-8

Command THC for X-Y Table Instruction Manual 2-1

6
SPECIFICATIONS

X-Y Lifter Assembly

Plasma THC
Interface Assembly Control Module

Operator
Pendant

Figure 2-1 X-Y Command THC system

interfaced with plasma cutting system and CNC

2-2 Command THC for X-Y Table Instruction Manual

5
 SPECIFICATIONS

General

Hypertherm’s X-Y Command THC 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. The system includes the following:

• THC control module (Figure 2-2) The THC control module houses 2 microcontrollers, a realtime controller
and an interface controller. This unit provides initial height sensing, arc voltage control and interfaces with
the torch lifter, the CNC machine, operator pendant and the plasma power supply through standard discrete
I/O interfaces and optional extended RS-422 serial interfaces.

• Plasma interface assembly with voltage divider (Figure 2-3) The plasma interface houses an interface
PCB which provides a communications link between the THC control module and the plasma power supply.
The voltage divider provides a 41 : 1 signal which is derived from the cutting arc voltage. For example, if the
arc voltage is 150 volts, the resultant 3.66-volt output signal is used to control the stand-off distance
between the torch and workpiece during plasma cutting.
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, under control of the THC control module, positions
a torch head vertically above the workpiece. Its maximum stroke is 8 inches (200 mm) between the home
and lower limit switches. It is driven by a stepper motor attached to a leadscrew. An encoder is provided for
stall IHS sensing, and to detect gross errors during normal operation. A lower limit switch detects maximum
travel in the downward direction. A home switch is provided to detect when the lifter is in the uppermost
position. A power-off brake is energized after power up, and allows controlled motion of the torch. It is
powered off during "Maintenance Mode" to prevent the torch from being accidentally moved. An optional
torch breakaway kit is also available.

• Operator pendant (optional) (Figure 2-5) The operator pendant is a remote control which includes an
LCD display and keypad used for THC setup and control (parameter entry and menu selection). The main
functions provided are: maintenance mode; arc voltage control/manual position mode; retract mid/full;
IHS test/run; and voltage, cut height, and pierce delay setpoints; and access to setup and diagnostic
screens.

• Torch Breakaway Kit (optional) (Figure 2-6) The torch breakaway (collision sensor) provides a level of
protection for the torch, lifter and X-Y table. Air pressure locks the torch to the THC lifter assembly. The air
pressure can be adjusted to change the force required to trip the breakaway. Upon side impact, the
breakaway releases from the lock position and allows the torch to float. See Figure 2-4 for torch mounting
dimensions with and with out the breakaway.

Command THC for X-Y Table Instruction Manual 2-3

10
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"
(142 mm)

18"
(457 mm)
9
C.8
TH

Figure 2-2 THC control module

2-4 Command THC for X-Y Table Instruction Manual

5
 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 HPR130 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 HPR130 power supply are included in
section 3i.
The plasma interface enclosure is not used for the HT4400.

2.2"
(56 mm)

4.6 lb
(2 kg)

3.1"
(78 mm)

10.7"
(271 mm) 0
C.9
TH
6.6"
(168 mm)

Figure 2-3 Plasma interface assembly

Command THC for X-Y Table Instruction Manual 2-5

9
SPECIFICATIONS

X-Y lifter assembly

Electrical
Motor ....................................................................+ 2.48 VDC, 2- phase (3.3 amp per ph.)
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

21.8"
(554 mm)

6a
C.6
TH

5"
(127 mm)
2.8"
(71 mm)
4.67"
119 mm 5.78"
164 mm

18 lb Without Breakaway With Breakaway

(8.2 kg)

Figure 2-4 X-Y lifter assembly

2-6 Command THC for X-Y Table Instruction Manual

7
 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)
C.69
TH

25’
(7.6 m)

Figure 2-5 Operator pendant

Command THC for X-Y Table Instruction Manual 2-7

5
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
Breakaway ..........................................................1.9 pounds (0.86 kg)
Air filter/regulator..................................................1.0 pounds (0.45 kg)

Air Filter/Regulator
Pressure Switch

Air Pressure
Inlet Port

Breakaway Unit

Figure 2-6 X-Y lifter breakaway option

2-8 Command THC for X-Y Table Instruction Manual

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 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 torch (without torch breakaway option) ......................................................................................3-10
Install torch (with torch breakaway option) ...........................................................................................3-11
System interconnections ...............................................................................................................................3-12
THC system cables ..............................................................................................................................3-12
Machine interface cable........................................................................................................................3-14
THC selectable responses ............................................................................................................................3-16
Dipswitch positions ...............................................................................................................................3-17
Command THC serial protocol......................................................................................................................3-18
Grounding requirements ...............................................................................................................................3-20
Power cord grounding ..........................................................................................................................3-20
Protective earth ground ........................................................................................................................3-20
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
HPR130 system interconnections ..................................................................................................................3i-1
HD4070 system interconnections ................................................................................................See IM 803760

Command THC for X-Y Table Instruction Manual 3-1

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SETUP

Upon receipt

The THC system is shipped in two containers: one container holds the units; the other holds the cables.
The containers should include the following standard and optional components, if ordered:

Standard components

• THC control module

• 2 Power cords, 6.5 ft./2 m
• Plasma interface assembly
• X-Y lifter assembly
• Interface cables
– Lifter motor drive cable (9 pin)
– 3 Interface cables (37 pin)
– Ohmic contact wire
– Power supply interface cable (for Hypertherm power supplies only)
• Command X-Y THC system instruction 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 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.

Claims for defective or missing merchandise — If any of the merchandise is defective or missing, call your
authorized Hypertherm distributor. If you need additional assistance, call Customer Service listed in the front of this
manual.

Power requirements

See THC control module in Section 2.

3-2 Command THC for X-Y Table Instruction Manual

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 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

• 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 connecting cables. The unit can be mounted in any position
except with the power module (AC receptacle and switch) facing up. Four mounting holes, requiring
1/4-inch (6 mm) fasteners, are provided. See Figure 3-1.

17.25 in.
(438 mm)

12 in.
(305 mm)

THC.70

Figure 3-1 THC control module mounting

Command THC for X-Y Table Instruction Manual 3-3

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SETUP

Plasma interface assembly

HT4400 AND HPR130 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 HPR130 power supply are included in
section 3i.
The plasma interface enclosure is not used for the HT4400.

• Mount the plasma interface assembly close to the plasma power supply for easy connection of control and
process signal wires between the units. The unit can be mounted in any position. The mounting holes
require #8 (4 mm) fasteners. See Figure 3-2.

1.25" 7.0"
(32 mm) (178 mm)

0.25"
(6 mm)

4.6"
(117 mm)

THC.99

9.5"
(241 mm)

Figure 3-2 Plasma interface assembly mounting

3-4 Command THC for X-Y Table Instruction Manual

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 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" 2.12" 1.42"

(89 mm) (54 mm) (36 mm)

1.75"
(44.5 mm) 1/4-20
3.5"
(89 mm)

2.25"
(57 mm)

1.41"
(36 mm)
2.8"
(71 mm)
4.5"
(114 mm)

8.0"
5.0" (203 mm)
(127 mm)

3.25"
(82.6 mm)
THC.68

Figure 3-3 X-Y lifter assembly mounting

Command THC for X-Y Table Instruction Manual 3-5

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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.

Figure 3-4 X-Y lifter assembly torch mounting block

3-6 Command THC for X-Y Table Instruction Manual

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 SETUP

Blank

Command THC for X-Y Table Instruction Manual 3-7

5
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. Attach the torch mounting block to the breakaway with the collar and 2 screws.

4. Wire the electrical output of the breakaway to the emergency stop circuit at CNC.

5. Mount the filter/regulator.

6. Connect tubing between regulator and breakaway.

7. Install air supply to the regulator inlet port at 100 psi (6.9 bar) (recommended maximum pressure).

8. Adjust the regulator to indicate 30 psi (2 bar) (recommended starting pressure) on the gauge.

9. By hand, 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 circuit at CNC after the breakaway is installed.

Notes:

• Installing the torch breakaway kit to the X-Y lifter assembly also requires using parts of the torch mounting
block kit of the proper diameter. Refer to Section 6, Part List for details.
• The maximum pressure regulator inlet pressure is 150 psi (10.2 bar). Typically, the maximum inlet pressure
should be set at 100 psi (6.9 bar).
• The routing of the leads, stall force, IHS speed, and acceleration/deceleration movements can affect the
pressure setting required to achieve reliable operation.
• If air pressure is removed (for example, overnight), the breakaway will have to be manually repositioned when
air is applied. The breakaway will not rest in its position when air pressure is lost.

3-8 Command THC for X-Y Table Instruction Manual

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 SETUP

1
Fiberglass bracket
Tube connector Spacer and 4 hex screws not
used if breakaway is installed.

2
3
6 screws
Collar

1
Hex screws (4)

3
2
Collar
Breakaway

Block
3
X-Y Lifter

Hex screws (2)

8 10

Pin 4

4 Pin 1 Pin 3
6 Wire to emergency stop
circuit
Tubing
1-5/16 inch
(33.34 mm)
Blue = 3
Brown = 4 (Not Connected)

5
Filter/Regulator

Black = 1

7
Inlet Port
1/4 in. NPTF
100 psi (6.9 bar)

Breakaway
pressure switch,
8 10 Normally Open
Breakaway
Pressure Gauge
5
Customer Supplied
Moisture Drain Hex screws (2)
8-32 X 1-1/2 inch
or 4 mm x 40 mm

Figure 3-5 X-Y lifter assembly optional torch breakaway kit mounting details

Command THC for X-Y Table Instruction Manual 3-9

9
SETUP

Install the torch (without torch breakaway option)

1 Mount the torch to the lifter with the mounting block and 2 screws. See Figure 3-6.

2 Install the shield to the mounting block with 4 screws.

Figure 3-6 Torch installed without torch breakaway option

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 SETUP

Install the torch (with torch breakaway option)

1 Install the shield to the mounting block with 4 screws. See Figure 3-7.

2 Mount the torch to the lifter with the mounting block and 2 screws.

Figure 3-7 Torch installed with torch breakaway option

Command THC for X-Y Table Instruction Manual 3-11

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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.

Install system cables as shown in Figure 3-8.

HT4400 AND HPR130 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 HPR130 power supply are included in
section 3i.
The plasma interface enclosure is not used for the HT4400.

3-12 Command THC for X-Y Table Instruction Manual

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 SETUP

Figure 3-8 X-Y THC system diagram

Command THC for X-Y Table Instruction Manual 3-13

9
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.

1 Machine Interface Cable

2 CNC Receptacle
1
To THC
3 Jumper Wire,
Control Customer Supplied
Module
2

3 2 1

CNC 22 21 20
3
THC.86

Figure 3-9 CNC cable-installed signal

2. Emergency 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 normally closed switch in the CNC to provide continuity between pins 16 and 35 when the
machine interface cable is installed to the CNC receptacle.

1 Machine Interface Cable

1 2 CNC Receptacle

3 Stop Switch,
2 Customer Supplied

3
19 18 17 16

CNC 37 36 35

THC.85

Figure 3-10 CNC emergency stop signal

3-14 Command THC for X-Y Table Instruction Manual

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 SETUP

3. Install the machine interface cable as shown in Figure 3-11.

1 Machine interface cable

2 Not used

1
CNC

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.
See Figure 3-12.

Figure 3-12 Machine interface cable grounding

Command THC for X-Y Table Instruction Manual 3-15

5
SETUP

THC selectable responses

The DIP switch, on the motor drive board, provides adjustable arc voltage control response.

WARNING
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. 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.

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 SETUP

DIP switch positions

1 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.

2 Conventional/HyDefinition resolution
• ON enables the THC to respond to larger voltage error changes.
• OFF enables the THC to respond to smaller error voltage changes.

3 Limited down speed

• ON enables lifter to move up at the normal speed, but down at slower speed. This is designed to help where
corner diving is a problem.
• OFF enables the lifter to move up and down at the "normal" speed.

4 HPR pierce complete

1 2 3 4
OFF

As Shipped

DIP Switch ON/OFF Positions

*DIP Switch Settings

1 2 3 4
Plasma Fast/Slow Conv/HyDef Limited Down HPR
Systems Response Resolution Speed pierce
complete
HD3070 OFF OFF OFF OFF
HT2000 OFF ON ON OFF
HT2000LHF OFF ON ON OFF
MAX100 ON ON ON OFF
MAX200 OFF ON ON OFF
HT4001 ON ON ON OFF
HT4400 ON ON ON OFF
HD4070 ON OFF OFF OFF
Powermax ON ON ON OFF
HPR ON ON ON ON

* These are recommended switch settings. Since cutting machine installations vary, these switches can
be adjusted in any combination to achieve desired results.

Command THC for X-Y Table Instruction Manual 3-17

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SETUP

Command THC 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
19200 baud, 8 data bits, 1 stop bit, and no parity. All bytes in a serial message are ASCII characters. A message
consists of a start of message character (>, 0x3E), 2 byte message ID (all message ID’s should be capitalized),
variable length data, 2 byte checksum, and end of message character (<, 0x3C). For example to put the THC into
remote mode >RM1D0<. ‘RM’ is the message ID, ‘1’ is the data field, and 0xD0 is the checksum (2 hex digits sent
as 2 ASCII characters). The response to an accepted command is (^, 0x5E) and the response to an invalid
command is (#, 0x23).

Some of the commands can be queried by using (?, 0x3F) as the data. For example to query the actual arc
voltage >AV?D6<. The response to this query would be >AV100058<, which represents an actual arc voltage of
100.0 volts with a checksum of 0x58.

Errors can be retrieved over the serial link. There is a discrete output on the machine interface cable (THC Error
pins 14,33) which indicates an error has occurred. Using the command >CL8F< errors can be cleared and
retrieved. A typical response might be >ERR-Motor Current Fault46< or if there is no error (^, 0x5E) is returned.

Command listing:
Command ID Data 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 Improves cycle time
IHS Stall Current SC 1 – 10 (1 = least force) yes Used to set stall force
IHS Speed IV 1 – 10 (1= slowest) yes Used to set IHS speed
IHS Test IH 0,1 (0 = run, 1 = test) no Perform IHS test
Nozzle Contact Active NC 0,1 (0 = off, 1 = on) yes Enable nozzle contact IHS
Machine Acceleration MA 0 – 9000 (0 to 9.000 seconds) yes Delay voltage control
Maintenance Mode MT No data no Maintenance mode
Auto Kerf AK 0,1 (0 = off, 1 = on) yes Disable voltage control in kerf
Actual Arc Voltage AV ? (query only) yes Returned value is 1/10 volts
Automatic Voltage Control AA 0,1 (0 = manual, 1 = auto) yes Voltage control or manual
Retract RE 0,1 (0 = full, 1 = partial) yes Full or partial retract
Retract Distance RH 0 – 8000 (0 to 8.000 inches) yes Must be in partial retract
Remote Mode RM 0,1 (0 = off, 1 = on) yes Must be ON to use serial link
IO Rev RI ? (query only) yes IO revision
RT Rev RR ? (query only) yes Real Time revision
Homing Speed HS 1 – 10 (1 = slowest) yes Home speed
Unit Conversion UN 0,1 (0 = inches, 1 = metric) yes Units
Lifter Test LT No data no Perform lifter test
Cut Height CH 0 – 1000 (0 to 1.000 inches) yes Used to set cut height
Arc Voltage Setpoint VS 500 – 3000 (50.0 to 300.0 volts) yes Used to set voltage control
Step Up S+ No data no Move up fixed increment
Step Down S- No data no Move down fixed increment
Jog Up J+ No data no Continuous movement up
Jog Down J- No data no Continuous movement down
Clear Error CL No data no Clear error, send error string
Flush Buffers FL No data no Reset RX and TX buffers
Error code EC ? (query only) yes Send error code number

3-18 Command THC for X-Y Table Instruction Manual

6
 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. To achieve continuous movement the Jog
command must be repeatedly sent faster than once every 50 milliseconds.
3. The Error code command will ONLY retrieve an error code, it will not clear an error. To clear an error the CL
(Clear error command must be sent).
4. The revision commands (RR and 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).
6.To force the lifter station to go home send the following series of commands : RE1, RE0
(partial retract, then full retract this will force a homing sequence).

Error codes:

Code Error string

0 "ERR-Torch is in LOWER LIMIT"
1 "ERR-Torch is in HOME LIMIT"
2 "ERR-EEPROM checksum Error"
3 "ERR-Lifter NOT Installed"
4 "ERR-Motion FAIL"
5 "ERR-Watch Dog Timeout FAIL"
6 "ERR-InterProcessor Comm Fail"
7 "ERR-Nozzle Contact at Home"
8 "ERR-Cycle Start ON at INIT"
9 "ERR-Motor Current Fault"
10 "ERR-Machine Cable Missing"
11 "ERR-Plasma Cable Missing"
12 "ERR-Robotic Limit FAIL"
13 "ERR-DIAG FAIL REPOWER THC"
14 "ERR-IOP CHECKSUM FAIL"
15 "ERR-RTP CHECKSUM FAIL"
16 "ERR-NO ERROR"

Command THC for X-Y Table Instruction Manual 3-19

6
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.

Protective earth ground

• Install protective earth (PE) grounding cables to the 3 THC components as shown in Figure 3-13. Grounding
must comply with national or local electrical requirements.

• The PE cables must be supplied by the customer.

Plasma Interface
Assembly *

THC Control Module

* HT4400: See NOTE on page 3-12.

Figure 3-13 THC component PE grounding

3-20 Command THC for X-Y Table Instruction Manual

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 SETUP

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 75 ft./23 m
123022 25 ft./7.6 m 123218 100 ft./30.5 m
123213 30 ft./9.1 m 123219 125 ft./38 m
123214 35 ft./10.6 m 123220 150 ft./45.6 m

THC Control Module Lifter Assembly

Typical Connector

THC.84

Pin Pin
Number Color Signal Name Function Number

1 Input Black Encoder Power - Encoder power 1 Output

20 Red Encoder Power (5V)+ 20

2 Input Black Encoder B - A quad B position signal. 2 Output

21 Green Encoder B + 21

3 Input Black Encoder A - A quad B position signal. 3 Output

22 Blue Encoder A + 22

5 Input Black Drive ID2 - Lifter ID Most Significant Bit (Binary 3) 5 Output
24 Brown Drive ID2 + 24

6 Input Black Drive ID1 - Lifter ID (Binary 2) 6 Output

25 Orange Drive ID1 + 25

7 Input Red Drive ID0 - Lifter ID Least Significant Bit (Binary 1) – Lifter jumper connection ID Code 7 Output
26 White Drive ID0 + 26

8 Output Red Lifter Up - Active when lifter is moving up. 8 Input

27 Green Lifter Up + 27

9 Input Red Lower Limit Switch Com. Limit switch common. 9 Output
28 Input Blue Lower Limit Switch Signal Logic low between signal and common.
10 Output Red Lower Limit Switch +24V Limit switch power. 10 Input

11 Output Red Home Switch Signal Logic low between signal and common.
29 Output Yellow Home Switch Common Home switch common. 29 Input
30 Output 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-mechanical brake on lifter. 17 Input
36 Orange Lifter Brake Out + 36

4 Input Black Lifter Spare In 5 - Spare 4 Output

23 Yellow Lifter Spare In 5 + 23
12 Output Red Crash Detect - Spare 12 Input
31 Orange Crash Detect + 31
13 Output Green Lifter Spare 3 - Spare 13 Input
32 White Lifter Spare 3 + 32
14 Output Green Reserved Spare 14 Input
33 Blue Reserved 33
15 Output Green Lifter Spare 1 - Spare 15 Input
34 Yellow Lifter Spare 1 + 34
18 White 24 VDC Common Available 24 VDC, 500 mA maximum. 18 Input
37 Black 24 VDC + 37
19 Reserved Not connected 19

Figure 3-14 Lifter I/O cable – Part numbers & signal list
Command THC for X-Y Table Instruction Manual 3-21
6
5
SETUP

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 75 ft./23 m
123022 25 ft./7.6 m 123218 100 ft./30.5 m
123213 30 ft./9.1 m 123219 125 ft./38 m
123214 35 ft./10.6 m 123220 150 ft./45.6 m

THC Control Module Plasma Interface Assembly

Typical Connector

THC.84

Pin Pin
Number Color Signal Name Function Signal Name Number

1 Input Black RX- RS-422 serial inverting receiver. TX- 1 Output

20 Red RX+ RS-422 serial non-inverting receiver. TX+ 20

2 Output Black TX- RS-422 serial inverting transmitter. RX- 2 Input

21 Green TX+ RS-422 serial non-inverting transmitter. RX+ 21

3 Input Black Plasma Cable - Plasma cable recognition used for automatic detection of 3 Output
17 Green Plasma Cable + plasma interface board. 17

7 Input Red Nozzle Contact - Nozzle Contact is active when nozzle or shield is in ohmic 7 Output
26 White Nozzle Contact + contact with the plate. 26

8 Input Red Pilot Arc In - Pilot Arc input verifies that a successful pilot arc has been 8 Output
27 Green Pilot Arc In + established. 27

9 Input Red Transfer In - Transfer In input verifies that a transfer has occurred. 9 Output
28 Blue Transfer 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 - Pierce Complete output verifies that the THC internal pierce 13 Output
32 White Pierce Complete + complete timer has timed out. 32

14 Output Green Hold Ignition - Hold Ignition holds the torch from firing, but allows preflow 14 Input
33 Blue Hold Ignition + gas to flow. 33

15 Output Green Plasma Start - Plasma Start signal is used to initiate the arc. 15 Input
34 Yellow Plasma Start + 34

16 Input Green Arc Volts - Arc Volts is the measured arc voltage between the 16 Output
35 Brown Arc Volts + electrode and work, divided by 41. 35

18 Output White 24 VDC Common Available 24 VDC, 500 mA maximum 18Input

37 Black 24 VDC + 37

36 Output Orange 24 VDC Common Available 24 VDC, 500 mA maximum 36 Input

4 Input Black Torch 2 Select - Spare 4 Output
23 Yellow Torch 2 Select + 23
5 Input Black Torch 1 Select - Spare 5Output
24 Brown Torch 1 Select + 24
6 Input Black Spare 1 - Spare 6Output
25 Orange Spare 1 + 25
11 Output Red Plasma Spare 2 - Spare 11 Input
30 Brown Plasma Spare 2 + 30
12 Output Red Plasma Spare 1 - Spare 12 Input
31 Orange Plasma Spare 1 + 31
19 Not Connected 19
22 Blue Not Used 22

Figure 3-15 Plasma interface cable – Part numbers & signal list

3-22 Command THC for X-Y Table Instruction Manual

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 SETUP

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 75 ft./23 m
123022 25 ft./7.6 m 123218 100 ft./30.5 m
123213 30 ft./9.1 m 123219 125 ft./38 m
123214 35 ft./10.6 m 123220 150 ft./45.6 m

THC Control Module CNC

Typical Connector

THC.84

Pin Signal Pin Notes,

Number Color Signal Name Function Name Number page 3-22

1 Input Black RX- RS-422 serial inverting receiver. TX- 1 Output

20 Red RX+ RS-422 serial non-inverting receiver. TX+ 20

2 Output Black TX- RS-422 serial inverting transmitter. RX- 2 Input

21 Green TX+ RS-422 serial non-inverting transmitter. RX+ 21

3 Input Black Machine Cable - Machine cable recognition used for verifying installation of 3 Output 3
* 22 Blue Machine Cable + Machine interface cable to CNC. 22

5 Input Black IHS Sync - IHS Sync holds torch firing, but allows preflow gas to flow. 5 Output 2
24 Brown IHS Sync + 24

8 Input Red Auto Height On/Off - Auto Height On/Off enables or disables Auto Height. 8 Output 2
* 27 Green Auto Height On/Off + Auto Height is Off when input is active. 27

9 Input Red Cycle Start - Cycle Start (plasma start) initiates start of programmed cycle. 9 Output 2
* 28 Blue Cycle Start + CNC must provide a contact closure to activate this input. 28

10 Output Red IHS Complete - IHS Complete output to CNC to synchronize 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 Complete - Retract Complete output verifies to CNC that the torch has 12 Input 1
31 Orange Retract Complete + retracted and it is safe to move to next start position. 31

13 Output Green Pilot Arc - Pilot Arc output verifies to CNC that a pilot arc has been 13 Input 1
32 White Pilot Arc + established. 32

14 Output Green THC Error - THC Error output alerts CNC that an error has occurred. 14 Input 1
33 Blue THC Error + 33

15 Output Green Machine Motion - Machine Motion output verifies to CNC that a pierce delay 15 Input 1
* 34 Yellow Machine Motion + has been completed and notifies CNC to start movement of 34
the cutting machine.

16 Input Green Ext. Emergency Interlock- Allows installation of an emergency stop switch (normally 16 Output 4
* 35 Brown Ext. Emergency Interlock+ closed). 35

18 Output White 24 VDC Common Available 24 VDC, 500 mA maximum 18 Input 1

37 Black 24 VDC + 37

36 Output Orange 24 VDC Common Available 24 VDC, 500 mA maximum 36 Input 1

4 Input Black Spare 3 - Spare 4 Output
23 Yellow Spare 3 + 23
6 Input Black Spare 2 - Spare 6 Output
25 Orange Spare 2 + 25
7 Input Red Spare 1 - Spare 7 Output
26 White Spare 1 + 26
11 Output Red Spare 1 - Spare 11 Input
30 Brown Spare 1 + 30
17 Green Not Used 17
19 Not Connected 19

* Minimum connections needed for proper operation of Command THC

Figure 3-16 Machine interface cable – Part numbers & signal list

Command THC for X-Y Table Instruction Manual 3-23

6
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. 12 VDC

3,3 K

+
Input
- 12V Return

NOTE 3. Jumper required in CNC. See instructions on page 3-14.

NOTE 4. Stop switch required in CNC. See instructions on page 3-14.

3-24 Command THC for X-Y Table Instruction Manual

5
 SETUP

Part number Length

123018 25 ft./7.6 m
123019 50 ft./15.2 m

THC Control Module Operator Pendant

THC.83

Typical Connector

Pin Pin
Number Color Signal Name Function Signal Name Number

1 Input Black RX- RS-422 serial inverting receiver. 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+ 3

5 Output Black 12 VDC common 12 VDC, 500 mA maximum 5 Input

9 Red 12 VDC + 9

4,7,8 Not Connected 4,7,8

Figure 3-17 Pendant interface cable – Part numbers & signal list

Command THC for X-Y Table Instruction Manual 3-25

6
SETUP

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 123205 75 ft./23 m
123020 25 ft./7.6 m 123206 100 ft./30.5 m
123201 30 ft./9.1 m 123207 125 ft./38 m
123202 35 ft./10.6 m 123208 150 ft./45.6 m

THC Control Module THC Lifter Motor

THC.83

Typical Connector

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 motor, phase A-. 9 Input
8 Black Motor Phase A - 8

3 Not connected 3

7 Output Red Motor Phase B + Powers lifter motor, phase B+. 7 Input
6 Black Motor Phase B - 6

2 Output Red Motor Phase B + Powers lifter motor, phase B-. 2 Input
1 Black Motor Phase B - 1

Figure 3-18 Motor drive cable – Part numbers & signal list

3-26 Command THC for X-Y Table Instruction Manual

6
 HD3070 SETUP

Section 3a

HD3070 SYSTEM INTERCONNECTIONS

Command THC for X-Y Table Instruction Manual 3a-1

5
HD3070 SETUP

Electrode and work lead sensing wires

WARNING
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. In other countries, follow appropriate local or national safety
procedures.

See Figure 3a-1.

1. Remove access covers from the power supply, as required.

2. Locate the 1XPCB1 PC board inside the power supply.

3. Install the sensing wires:

A Fabricate sensing 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 installing the wires from the power supply to the plasma interface assembly, install
appropriate size fork or ring terminals on the wire ends.

B Connect one of the sensing wires to the 1XPCB1 PC board where wire No. 126 is connected. Label
this wire positive (+).

C Connect the other sensing wire to the 1XPCB1 PC board where wire No. 140 is connected. Label
this wire negative (-).

D At the plasma interface assembly, connect the negative (-) wire to the J5-2 terminal labeled
ELECTRODE. Connect the positive (+) wire to the J5-3 terminal labeled WORK.

3a-2 Command THC for X-Y Table Instruction Manual

5
 HD3070 SETUP

Plasma Interface
Assembly
A

126 +
140 -

B
C

-
D

THC.80
J5
5 4 3 2 1

1XPCB1 PC Board

Figure 3a-1 HD3070 electrode and work lead sensing wires connection

Command THC for X-Y Table Instruction Manual 3a-3

5
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.

A Connect the interface cable plug to the 1X1 receptacle on the back of the power supply.

B Connect the other plug of the interface cable to the CNC.

C Install the 5 pairs of wires of the interface cable to the plasma interface assembly as shown
in Figure 3a-2.

D Install the wire with the fork terminal to the plasma interface assembly as shown
in Figure 3a-2.

See Figure 3a-3 for the interface cable part numbers and signal list.

3a-4 Command THC for X-Y Table Instruction Manual

5
6/9/00
 HD3070 SETUP

Plasma Interface
Assembly

Power Supply

CNC

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

Command THC for X-Y Table Instruction Manual 3a-5

5
HD3070 SETUP

Part number Description Length

123270 HD3070 Power Supply Interface Cable 6 ft./1.8 m

1X1
1X1

Power Plasma
Supply CNC Interface
Signal Name Color End (1X1) End End Function

Hold I/O - Black 1 Not J4-6 (Optional) Hold Ignition (I/O) signal used for preflow during
Hold I/O + Red 5 Connected J4-5 IHS. Also used by power unit to synchronize operation of
Drain Drain 10 multiple torch installations.

Pierce Complete + Black 2 Not J4-8 (Optional) Pierce Complete signal used by power unit to
Pierce Complete - White 6 Connected J4-7 time transition from pierce gas flow to cut gas flow. User
Drain Drain 11 enters this time delay into THC.

Pilot Arc Out + Black 3 Not J3-4 (Optional) Pilot Arc Out signal. Maintained during
Pilot Arc Out - Green 7 Connected J3-3 torch ignition. Contact closes after torch ignition. Dry
Drain Drain 12 contact closure.

Plasma Start - Black 9 Not J4-4 Plasma On signal maintained during plasma cut. If signal
Plasma Start + Yellow 15 Connected J4-3 is lost, system must be restarted.
Drain Drain 14

Transfer Out + Black 37 Not J3-2 Arc Transfer signal. Contact closes after arc transfer and
Transfer Out - Orange 32 Connected J3-1 pierce delay (set on power supply front panel). Dry contact
Drain Drain 26 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 Connected
Drain Drain 18 18

Power On Input Black 29 29 Not These signals connect to the CNC. Refer to HD3070
Power On Input Brown 34 34 Connected Instruction manual for signal information.
Drain Drain 23 23

Power Interlocks Red 35 35 Not

Power Interlocks White 30 30 Connected
Drain Drain 24 24

1/50 AC Volts Red 33 33 Not

1/50 AC Volt Green 28 28 Connected
Drain Drain 37 37

Shaded area indicates plasma interface assembly connections.

Plasma Interface Assembly other J3 and J4 connection points:

• J3-5 (+) and J3-6 (-) – Alternate Nozzle Contact. An optically isolated signal that indicates nozzle is in ohmic contact with
work. Ohmic contact is represented by a logic 1.
• J3-7 through J3-12 – Reserved for future use.
• J3-13 and J3-14 – Protective earth ground.
• J4-1 (+) and J4-2 (-) – Available 24 VDC, 500 mA maximum
• J4-9 through J4-12 – Reserved for future use.

Figure 3a-3 HD3070 interface cable – Part number & signal list

3a-6 Command THC for X-Y Table Instruction Manual

9
 HD3070 SETUP

Ohmic contact wire A Install the ohmic contact wire through the strain relief of the
plasma interface assembly.

B Install appropriate size fork terminal on the wire end and

attach the wire to the J5-5 terminal labeled SHIELD.

C Install the other end of the ohmic contact wire to the IHS tab
on the torch retaining cap.

Ohmic Contact Wire Plasma Interface

Assembly
A

12
3

B
4

C
SHIELD
5

J5

THC.76
Torch Retaining Cap with IHS Tab
PAC184 P/N 120543
PAC186 P/N 020687

Figure 3a-4 HD3070 ohmic contact wire connection

Command THC for X-Y Table Instruction Manual 3a-7

5
HD3070 SETUP

Blank

3a-8 Command THC for X-Y Table Instruction Manual

5
 HT2000 SETUP

Section 3b

HT2000 SYSTEM INTERCONNECTIONS

Command THC for X-Y Table Instruction Manual 3b-1

6
HT2000 SETUP

Electrode and work lead sensing wires

WARNING
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. In other countries, follow appropriate local or national safety
procedures.

See Figure 3b-1.

1. Remove access covers from the power supply, as required.

2. Locate the input/output panel on the back of the power supply.

3. Install the sensing wires:

A Fabricate sensing 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 installing the wires from the power supply to the plasma interface assembly, install
appropriate size fork or ring terminals on the wire ends.

B Connect one of the sensing wires to the WORK LEAD (+) connection of the input/output panel. Label
this wire positive (+).

C Connect the other sensing wire to the NEGATIVE LEAD (-) connection of the input/output panel.
Label this wire negative (-).

D At the plasma interface assembly, connect the negative (-) wire to the J5-2 terminal labeled
ELECTRODE. Connect the positive (+) wire to the J5-3 terminal labeled WORK.

3b-2 Command THC for X-Y Table Instruction Manual

6
 HT2000 SETUP

Plasma Interface
Assembly

-
C D

B J5
5 4 3 2 1

THC.75
Input/Output Panel

Figure 3b-1 HT2000 electrode and work Lead sensing wires connection

Command THC for X-Y Table Instruction Manual 3b-3

6
HT2000 SETUP

Power supply interface cable

See Figure 3b-2.

A Connect the interface cable plug to the 1X6 receptacle on the back of the power supply.

B Connect the other plug of the interface cable to the CNC.

C Install the 3 pairs of wires of the interface cable to the plasma interface assembly as shown
in Figure 3b-2.

See Figure 3b-3 for the interface cable part numbers and signal list.

3b-4 Command THC for X-Y Table Instruction Manual

6
 HT2000 SETUP

Plasma Interface
Assembly

B Power Supply

CNC

Plasma Interface
Assembly
J3
Pilot Arc- 4
Pilot Arc+ 3
Transfer IN- 2 Red Wire
Transfer IN+ 1 Black Wire

C
Pierce Complete+ 8
Pierce Complete- 7
Hold Ignition- 6 Black Wire
Hold Ignition+ 5 White Wire
Plasma Start 4 Black Wire
Plasma Start 3 Blue Wire
24V - 2
THC.79 24V + 1
J4
Figure 3b-2 HT2000 power supply interface cable connections

Command THC for X-Y Table Instruction Manual 3b-5

6
HT2000 SETUP

Part number Description Length

123329 HT2000 Power Supply Interface Cable 6 ft./1.8 m

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 used by power unit to synchronize operation of
Drain Drain 10 multiple torch installations. Output signal.

Plasma Start - Black 9 Not J4-4 Plasma Start signal maintained during plasma cut. If signal
Plasma Start + Blue 15 Connected J4-3 is lost, system must be restarted. Output signal.
Drain Drain 14

Arc Transfer - Black 32 Not J3-2 Arc Transfer signal. Contact closes after arc transfer and
Arc Transfer + Red 37 Connected J3-1 pierce delay (set on power supply front panel). Dry contact
Drain Drain 26 closure. Input signal.

Arc Voltage Black 28 28 Not

Arc Voltage Yellow 33 33 Connected
Drain Drain 27 27

Not Used Black 7 7 Not These signals connect to the CNC. Refer to HT2000
Not Used Brown 3 3 Connected 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

Shaded area indicates plasma interface assembly connections.

Plasma Interface Assembly other J3 and J4 connection points:

• J3-5 (+) and J3-6 (-) – Alternate Nozzle Contact. An optically isolated signal that indicates nozzle is in ohmic contact with
work. Ohmic contact is represented by a logic 1.

• J3-7 through J3-12 – Reserved for future use.

• J3-13 and J3-14 – Protective earth ground.

• J4-1 (+) and J4-2 (-) – Available 24 VDC, 500 mA maximum

• J4-7 and J4-8 – Pierce Complete signal used by power supply to time transition from pierce gas flow to cut gas flow. User
enters this time delay into THC. Output signal.

• J4-9 through J4-12 – Reserved for future use.

Figure 3b-3 HT2000 interface cable – Part number & signal list

3b-6 Command THC for X-Y Table Instruction Manual

7
 HT2000 SETUP

Ohmic contact wire A Install the ohmic contact wire through the strain relief of the
plasma interface assembly.
See Figure 3b-4.
B Install appropriate size fork terminal on the wire end and
attach the wire to the J5-5 terminal labeled SHIELD.

C Install the other end of the ohmic contact wire to the IHS tab
on the torch retaining cap.

Plasma Interface
Ohmic Contact Wire Assembly

1
2

C
3

B
4

SHIELD
5

J5

THC.71
Torch Retaining Cap with IHS Tab
P/N 120837

Figure 3b-4 HT2000 ohmic contact wire connection

Command THC for X-Y Table Instruction Manual 3b-7

6
HT2000 SETUP

Blank

3b-8 Command THC for X-Y Table Instruction Manual

6
 HT2000LHF SETUP

Section 3c

HT2000LHF SYSTEM INTERCONNECTIONS

Command THC for X-Y Table Instruction Manual 3c-1

5
HT2000LHF SETUP

Electrode and work lead sensing wires

WARNING
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. In other countries, follow appropriate local or national safety
procedures.

See Figure 3c-1.

1. Remove access covers from the power supply, as required.

2. Locate the input/output panel on the back of the power supply.

3. Install the sensing wires:

A Fabricate sensing 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 installing the wires from the power supply to the plasma interface assembly, install
appropriate size fork or ring terminals on the wire ends.

B Connect one of the sensing wires to the WORK LEAD (+) connection of the input/output panel. Label
this wire positive (+).

C Connect the other sensing wire to the NEGATIVE LEAD (-) connection of the input/output panel.
Label this wire negative (-).

D At the plasma interface assembly, connect the negative (-) wire to the J5-2 terminal labeled
ELECTRODE. Connect the positive (+) wire to the J5-3 terminal labeled WORK.

3c-2 Command THC for X-Y Table Instruction Manual

5
 HT2000LHF SETUP

Plasma Interface
Assembly

-
C D

B J5
5 4 3 2 1

THC.75
Input/Output Panel

Figure 3c-1 HT2000LHF electrode and work lead sensing wires connection

Command THC for X-Y Table Instruction Manual 3c-3

5
HT2000LHF SETUP

Power supply interface cable

See Figure 3c-2.

A Connect the interface cable plug to the 1X6 receptacle on the back of the power supply.

B Connect the other plug of the interface cable to the CNC.

C Install the 3 pairs of wires of the interface cable to the plasma interface assembly as shown
in Figure 3c-2.

See Figure 3c-3 for the interface cable part numbers and signal list.

3c-4 Command THC for X-Y Table Instruction Manual

5
 HT2000LHF SETUP

Plasma Interface
Assembly

B Power Supply

CNC

Plasma Interface
Assembly
J3
Pilot Arc- 4
Pilot Arc+ 3
Transfer IN- 2 Red Wire
Transfer IN+ 1 Black Wire

C
Pierce Complete+ 8
Pierce Complete- 7
Hold Ignition- 6 Black Wire
Hold Ignition+ 5 White Wire
Plasma Start 4 Black Wire
Plasma Start 3 Blue Wire
24V - 2
THC.79 24V + 1
J4
Figure 3c-2 HT2000LHF power supply interface cable connections

Command THC for X-Y Table Instruction Manual 3c-5

5
HT2000LHF SETUP

Part number Description Length

123329 HT2000LHF Power Supply Interface Cable 6 ft./1.8 m

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 used by power unit to synchronize operation of
Drain Drain 10 multiple torch installations. Output signal.

Plasma Start - Black 9 Not J4-4 Plasma Start signal maintained during plasma cut. If signal
Plasma Start + Blue 15 Connected J4-3 is lost, system must be restarted. Output signal.
Drain Drain 14

Arc Transfer - Black 32 Not J3-2 Arc Transfer signal. Contact closes after arc transfer and
Arc Transfer + Red 37 Connected J3-1 pierce delay (set on power supply front panel). Dry contact
Drain Drain 26 closure. Input signal.

Ramp Down Error Black 28 28 Not

Ramp Down Error Yellow 33 33 Connected
Drain Drain 27 27

Not Used Black 7 7 Not These signals connect to the CNC. Refer to HT2000 LHF
Not Used Brown 3 3 Connected 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

Shaded area indicates plasma interface assembly connections.

Plasma Interface Assembly other J3 and J4 connection points:

• J3-5 (+) and J3-6 (-) – Alternate Nozzle Contact. An optically isolated signal that indicates nozzle is in ohmic contact with
work. Ohmic contact is represented by a logic 1.

• J3-7 through J3-12 – Reserved for future use.

• J3-13 and J3-14 – Protective earth ground.

• J4-1 (+) and J4-2 (-) – Available 24 VDC, 500 mA maximum

• J4-7 and J4-8 – Pierce Complete signal used by power supply to time transition from pierce gas flow to cut gas flow. User
enters this time delay into THC. Output signal.

• J4-9 through J4-14 – Reserved for future use.

Figure 3c-3 HT2000LHF interface cable – Part number & signal list

3c-6 Command THC for X-Y Table Instruction Manual

7
 HT2000LHF SETUP

Ohmic contact wire A Install the ohmic contact wire through the strain relief of the
plasma interface assembly.
See Figure 3c-4.
B Install appropriate size fork terminal on the wire end and
attach the wire to the J5-5 terminal labeled SHIELD.

C Install the other end of the ohmic contact wire to the IHS tab
on the torch retaining cap.

Plasma Interface
Ohmic Contact Wire Assembly

1
2

C
3

B
4

SHIELD
5

J5

THC.71
Torch Retaining Cap with IHS Tab
P/N 120837

Figure 3c-4 HT2000LHF ohmic contact wire connection

Command THC for X-Y Table Instruction Manual 3c-7

5
HT2000LHF SETUP

Blank

3c-8 Command THC for X-Y Table Instruction Manual

5
 HT4001 SETUP

Section 3d

HT4001 SYSTEM INTERCONNECTIONS

Command THC for X-Y Table Instruction Manual 3d-1

5
HT4001 SETUP

Electrode and work lead sensing wires

WARNING
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. In other countries, follow appropriate local or national safety
procedures.

See Figure 3d-1.

1. Remove access covers from the power supply, as required.

2. Locate the input/output bus bars inside the power supply.

3. Install the sensing wires:

A Fabricate sensing 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 installing the wires from the power supply to the plasma interface assembly, install
appropriate size fork or ring terminals on the wire ends.

B Connect one of the sensing wires to the top bus bar (+) where wire No. 42 is connected. Label this
wire positive (+).

C Connect the other sensing wire to the bottom bus bar (-) where wire No. 45 is connected. Label this
wire negative (-).

D At the plasma interface assembly, connect the negative (-) wire to the J5-2 terminal labeled
ELECTRODE. Connect the positive (+) wire to the J5-3 terminal labeled WORK.

3d-2 Command THC for X-Y Table Instruction Manual

5
 HT4001 SETUP

Plasma Interface
Assembly

42 +
B

C 45 -
+

J5
5 4 3 2 1
THC.74

Figure 3d-1 HT4001 electrode and work lead sensing wires connection

Command THC for X-Y Table Instruction Manual 3d-3

5
HT4001 SETUP

Power supply interface cable

See Figure 3d-2.

A Connect the interface cable plug to the 1X6 receptacle on the back of the power supply.

B Connect the other plug of the interface cable to the CNC.

C Install the 3 pairs of wires of the interface cable to the plasma interface assembly as shown
in Figure 3d-2.

See Figure 3d-3 for the interface cable part numbers and signal list.

3d-4 Command THC for X-Y Table Instruction Manual

5
 HT4001 SETUP

Plasma Interface
Assembly

B Power Supply

CNC

Plasma Interface Assembly J3

Pilot Arc- 4
Pilot Arc+ 3
Transfer IN- 2 Red Wire
Transfer IN+ 1 Black Wire

C
Pierce Complete+ 8
Pierce Complete- 7
Hold Ignition- 6 Black Wire
Hold Ignition+ 5 White Wire
Plasma Start 4 Black Wire
Plasma Start 3 Blue Wire
24V - 2
THC.79 24V + 1
J4

Figure 3d-2 HT4001 power supply interface cable connections

Command THC for X-Y Table Instruction Manual 3d-5

5
HT4001 SETUP

Part number Description Length

123330 HT4001 Power Supply Interface Cable 6 ft./1.8 m

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 used by power unit to synchronize operation of
Drain Drain 10 multiple torch installations. Output signal

Plasma Start - Black 9 Not J4-4 Plasma Start signal maintained during plasma cut. If signal
Plasma Start + Blue 15 Connected J4-3 is lost, system must be restarted. Output signal.
Drain Drain 14

Arc Transfer - Black 31 Not J3-2 Arc Transfer signal. Contact closes after arc transfer and
Arc Transfer + Red 36 Connected J3-1 pierce delay (set on power supply front panel). Dry contact
Drain Drain 25 closure. Input signal.

Emergency Stop Black 28 28 Not

Emergency Stop Green 33 33 Connected
Drain Drain 27 27

Arc Voltage Black 32 32 Not These signals 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

Shaded area indicates plasma interface assembly connections.

Plasma Interface Assembly other J3 and J4 connection points:

• J3-5 (+) and J3-6 (-) – Alternate Nozzle Contact. An optically isolated signal that indicates nozzle is in ohmic contact with
work. Ohmic contact is represented by a logic 1.

• J3-7 through J3-12 – Reserved for future use.

• J3-13 and J3-14 – Protective earth ground.

• J4-1 (+) and J4-2 (-) – Available 24 VDC, 500 mA maximum

• J4-7 and J4-8 – Pierce Complete signal used by power unit to time transition from pierce gas flow to cut gas flow. User
enters this time delay into THC. Output signal.

• J4-9 through J4-14 – Reserved for future use.

Figure 3d-3 HT4001 interface cable – Part number & signal list

3d-6 Command THC for X-Y Table Instruction Manual

7
 MAX100 SETUP

Section 3e

MAX100 SYSTEM INTERCONNECTIONS

Command THC for X-Y Table Instruction Manual 3e-1

5
MAX100 SETUP

Electrode and work lead sensing wires

WARNING
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. In other countries, follow appropriate local or national safety
procedures.

See Figure 3e-1.

1. Remove access covers from the power supply, as required.

2. Locate the 1XPCB1 PC board inside the power supply.

3. Install the sensing wires:

A Fabricate sensing 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 installing the wires from the power supply to the plasma interface assembly, install
appropriate size fork or ring terminals on the wire ends.

B Connect one of the sensing wires to the 1XPCB1 PC board where wire No. 42 is connected. Label
this wire positive (+).

C Connect the other sensing wire to the 1XPCB1 PC board where wire No. 39 is connected. Label this
wire negative (-).

D At the plasma interface assembly, connect the negative (-) wire to the J5-2 terminal labeled
ELECTRODE. Connect the positive (+) wire to the J5-3 terminal labeled WORK.

3e-2 Command THC for X-Y Table Instruction Manual

5
 MAX100 SETUP

Plasma Interface
Assembly

-
39

+
42

B
+

C D

J5
5 4 3 2 1

THC.73

1XPCB1 PC Board

Figure 3e-1 MAX100 electrode and work lead sensing wires connection

Command THC for X-Y Table Instruction Manual 3e-3

5
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:

A Fabricate sensing wires as follows:

• Use 18AWG (≈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 appropriate size fork terminals on the 4 wire
ends.

B Connect the 4 wires to TB1 where wire No. 33, 34, 35, and 36 are connected. Label these wires No.
33, 34, 35, and 36.

C Connect the other end of the 4 wires to the J3 and J4 terminal of the plasma interface assembly as
shown in Figure 3e-2.

3e-4 Command THC for X-Y Table Instruction Manual

5
 MAX100 SETUP

Plasma Interface A
Assembly
C

34 33 36 35

TB1

THC.77
J3
Pilot Arc- 4
Pilot Arc+ 3 C
Transfer IN- 2 36
Transfer IN+ 1 35

5 C
Plasma Start 4 34
Plasma Start 3 33
24V - 2
24V + 1
J4
Figure 3e-2 MAX100 power supply interface cable connections

Command THC for X-Y Table Instruction Manual 3e-5

5
MAX100 SETUP

Blank

3e-6 Command THC for X-Y Table Instruction Manual

5
 MAX200 SETUP

Section 3f

MAX200 SYSTEM INTERCONNECTIONS

Command THC for X-Y Table Instruction Manual 3f-1

6
MAX200 SETUP

Electrode and work lead sensing wires

WARNING
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. In other countries, follow appropriate local or national safety
procedures.

See Figure 3f-1.

1. Remove access covers from the power supply, as required.

2. Locate the input/output panel on the back of the power supply.

3. Install the sensing wires:

A Fabricate sensing 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 installing the wires from the power supply to the plasma interface assembly, install
appropriate size fork or ring terminals on the wire ends.

B Connect one of the sensing wires to the WORK LEAD (+) connection of the input/output panel. Label
this wire positive (+).

C Connect the other sensing wire to the NEGATIVE LEAD (-) connection of the input/output panel.
Label this wire negative (-).

D At the plasma interface assembly, connect the negative (-) wire to the J5-2 terminal labeled
ELECTRODE. Connect the positive (+) wire to the J5-3 terminal labeled WORK.

3f-2 Command THC for X-Y Table Instruction Manual

6
 MAX200 SETUP

Plasma Interface
Assembly

-
C D

B J5
5 4 3 2 1

THC.75
Input/Output Panel

Figure 3f-1 MAX200 electrode and work lead sensing wire connections

Command THC for X-Y Table Instruction Manual 3f-3

6
MAX200 SETUP

Power supply interface cable

See Figure 3f-2.

A Connect the interface cable plug to the receptacle on the back of the power supply.

B 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.

3f-4 Command THC for X-Y Table Instruction Manual

6
 MAX200 SETUP

B
A
Plasma Interface
Assembly
Power Supply

J3
Pilot Arc- 4
Pilot Arc+ 3
Transfer IN- 2 Red Wire
Transfer IN+ 1 Black Wire

THC.78
B
Pierce Complete- 8
Pierce Complete+ 7
Hold Ignition- 6 Black Wire
Hold Ignition+ 5 White Wire
Plasma Start 4 Black Wire
Plasma Start 3 Green Wire
24V - 2
24V + 1
J4
Figure 3f-2 MAX200 power supply interface cable connections

Command THC for X-Y Table Instruction Manual 3f-5

6
MAX200 SETUP

Part number Description Length

123358 MAX200 Power Supply Interface Cable 6 ft./1.8 m
1X6

Power Plasma
Supply Interface
Signal Name Color End (1X6) End Function

Hold I/O - Black 5 J4-6 (Optional) Hold Ignition (I/O) signal used for preflow during
Hold I/O + White 1 J4-5 IHS. Also used by power unit to synchronize operation of
Drain Drain 10 multiple torch installations. Output signal.

Plasma Start - Black 9 Relay Plasma Start signal maintained during plasma cut. If signal
Plasma Start + Green 15 Relay 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 J3-1 pierce delay (set on power supply front panel). Dry contact
Drain 25 closure. Input signal.

Plasma Interface Assembly other J3 and J4 connection points:

• J3-5 (+) and J3-6 (-) – Alternate Nozzle Contact. An optically isolated signal that indicates nozzle is in ohmic contact with
work. Ohmic contact is represented by a logic 1.

• J3-7 through J3-12 – Reserved for future use.

• J3-13 and J3-14 – Protective earth ground.

• J4-7 and J4-8 – Pierce Complete signal used by power unit to time transition from pierce gas flow to cut gas flow. User
enters this time delay into THC. Output signal.

• J4-9 through J4-14 – Reserved for future use.

Figure 3f-3 MAX200 interface cable – Part number & signal list

3f-6 Command THC for X-Y Table Instruction Manual

7
 MAX200 SETUP

Ohmic Contact Wire A Install the ohmic contact wire through the strain relief of the
plasma interface assembly.
See Figure 3f-4.
B Install appropriate size fork terminal on the wire end and
attach the wire to the J5-5 terminal labeled SHIELD.

C Install the other end of the ohmic contact wire to the IHS tab
on the torch retaining cap.

Plasma Interface
Ohmic Contact Wire Assembly

1
2

C
3

B
4

SHIELD
5

J5

THC.71
Torch Retaining Cap with IHS Tab
P/N 120837

Figure 3f-4 MAX200 ohmic contact wire connection

Command THC for X-Y Table Instruction Manual 3f-7

6
MAX200 SETUP

Blank

3f-8 Command THC for X-Y Table Instruction Manual

6
 POWERMAX SETUP

Section 3g

POWERMAX SYSTEM INTERCONNECTIONS

For Powermax800, Powermax900 and Powermax 1100

Verify power supply machine interface

Look at the back of the power supply and check

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 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

Command THC for X-Y Table Instruction Manual 3g-1

7
POWERMAX SETUP

Electrode and work lead sensing wires

WARNING
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. In other countries, follow appropriate local or national safety
procedures.

See Figure 3g-1.

1. Remove access cover from the power supply.

2. Locate the machine interface board inside the power supply.

3. Install the sensing wires:

A Fabricate sensing 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 installing the wires from the power supply to the plasma interface assembly, install
appropriate size fork or ring terminals on the wire ends.

B Connect one of the sensing wires to the J1-6 terminal of the machine interface board. Label this wire
positive (+).

C Connect the other sensing wire to the J1-8 terminal of the machine interface board. Label this wire
negative (-).

D At the plasma interface assembly, connect the negative (-) wire to the J5-2 terminal labeled
ELECTRODE. Connect the positive (+) wire to the J5-3 terminal labeled WORK.

3g-2 Command THC for X-Y Table Instruction Manual

5
 POWERMAX SETUP

Plasma Interface
Assembly

J1
1

B
6 +
ARC
VOLTAGE
8 -
C
+

THC.72
Machine Interface Board D

J5
5 4 3 2 1

Figure 3g-1 Powermax electrode and work lead sensing wire connections

Command THC for X-Y Table Instruction Manual 3g-3

5
POWERMAX SETUP

Power supply interface cable

See Figure 3g-2.

A Connect the interface cable to the receptacle on the back of the power supply.

B Install the 2 pairs of wires of the interface cable to the plasma interface assembly as shown in
Figure 3g-2.

See applicable Powermax service manual for the interface cable part numbers and signal list.

3g-4 Command THC for X-Y Table Instruction Manual

6/9/00
5
 POWERMAX SETUP

B
A
Plasma Interface
Assembly
Power Supply

J3
Pilot Arc- 4
Pilot Arc+ 3
Transfer IN- 2 Red Wire
Transfer IN+ 1 Black Wire

THC.78
B
Pierce Complete- 8
Pierce Complete+ 7
Hold Ignition- 6
Hold Ignition+ 5
Plasma Start 4 Green Wire
Plasma Start 3 Black Wire
24V - 2
24V + 1
J4
Figure 3g-2 Powermax power supply interface cable connections

Command THC for X-Y Table Instruction Manual 3g-5

5
POWERMAX SETUP

Blank

3g-6 Command THC for X-Y Table Instruction Manual

5
 HT4400 SETUP

Section 3h

HT4400 SYSTEM INTERCONNECTIONS

Command THC for X-Y Table Instruction Manual 3h-1

5
HT4400 SETUP

Plasma interface PC board preparation

See Figure 3h-1.

A Remove and discard the access cover from the plasma interface assembly.

B Remove and discard the 2 connectors from the plasma interface PC board.

C Remove the plasma interface PC board from the interface enclosure. Save the PC board, the
4 standoffs and the 4 mounting screws.

D Discard the interface enclosure.

3h-2 Command THC for X-Y Table Instruction Manual

5
 HT4400 SETUP

THC.102

Figure 3h-1 Plasma interface PC board preparation

Command THC for X-Y Table Instruction Manual 3h-3

5
HT4400 SETUP

Install the plasma interface PC board into the HT4400 power supply

WARNING
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. In other countries, follow appropriate local or national safety
procedures.

See Figure 3h-2.

A Remove access covers from the power supply, as required.

B Install the 4 standoffs on the plasma interface PC board.

C Install the plasma interface PC board into the power supply as show in figure 3h-2. Use the 4 screws
that were removed from the plasma interface assembly.

3h-4 Command THC for X-Y Table Instruction Manual

5
 HT4400 SETUP

mid plane
B

THC.104

Figure 3h-2 Install the plasma interface PC board

Command THC for X-Y Table Instruction Manual 3h-5

5
HT4400 SETUP

Plasma interface PC board connection

See Figure 3h-3.

A Install the 37-pin connector to the plasma interface PC board.

B 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.

C Connect wire No. 42 to the plasma interface board J5-2 terminal labeled ELECTRODE.
Connect wire No. 45 to the plasma interface board J5-3 terminal labeled WORK.

D Connect the other end of wire No. 42 to the top bus bar.
Connect the other end of wire No. 45 to the bottom bus bar.

Secure all wires and cables as required.

3h-6 Command THC for X-Y Table Instruction Manual

5
 HT4400 SETUP

mid plane

J4

B
J3 D

1 2 3 4 5

J5
+

C
45 42

42

45 -

THC.105

Figure 3h-3 Plasma interface PC board connection

Command THC for X-Y Table Instruction Manual 3h-7

5
HT4400 SETUP

Ohmic contact wire

See Figure 3h-4.

A Install the ohmic contact wire through the strain relief of the power supply.

B 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.

C Install the other end of the ohmic contact wire to the IHS tab on the torch retaining cap.

3h-8 Command THC for X-Y Table Instruction Manual

5
 HT4400 SETUP

Ohmic Contact Wire

1 2 3 4 5

J5
C
B

THC.106

Torch Retaining Cap with

IHS Tab P/N 120907

Figure 3h-4 HT4400 ohmic contact wire connection

Command THC for X-Y Table Instruction Manual 3h-9

5
HT4400 SETUP

Blank

3h-10 Command THC for X-Y Table Instruction Manual

5
 HPR130 SETUP

Section 3i

HPR SYSTEM INTERCONNECTIONS

Command THC for X-Y Table Instruction Manual 3i-1

9
HPR130 SETUP

Install the plasma interface PC board into the HPR130 power supply

WARNING
ELECTRIC SHOCK CAN KILL

Turn off all electrical power before removing the power supply cover. Press the
power supply OFF (0) 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 national safety procedures.

See Figures 3i-1, 3i-2 and 3i-3

A Remove left and right side panels from the power supply.

B Install the plasma interface PC board (041842) on the 4 standoffs in the power supply.

C Install the machine interface cable (123760) from the control board to the plasma interface board.

Figure 3i-1 left side panel removal

3i-2 Command THC for X-Y Table Instruction Manual

9
 HPR130 SETUP

Figure 3i-2 Install the plasma interface PC board

Male

Female

Figure 3i-3 Plasma interface and control PC board connections

Command THC for X-Y Table Instruction Manual 3i-3

9
HPR130 SETUP

Plasma interface and I/O board connections

See Figures 3i-4, .3i-5, 3i-6, and 3i-7

A Cut tywrap on wires (numbered 25 and 26) bundled below the THC board.

B Attach wire number 25 to stud marked WORK and wire number 26 to stud marked ELECTRODE.

C Cut tywrap on wires (numbered 25 and 26) bundled near the I/O board.

Connect wire Number 25 to the bus bar marked WORK (+).

D Connect wire No. 26 to the bus bar marked TORCH (-).

Secure all wires and cables as required.

A Bundled wires
tywrapped in place

Figure 3i-4 Plasma interface wire location

Figure 3i-5 Plasma interface PC board connection

3i-4 Command THC for X-Y Table Instruction Manual

9
 HPR130 SETUP

Figure 3i-6 I/O wire location

25

D
WORK (+)

TORCH (-)

PILOT ARC (++)

26

Figure 3i-7 I/O PC board connections

Command THC for X-Y Table Instruction Manual 3i-5

9
HPR130 SETUP

Ohmic contact wire

See Figure 3i-8.

A Install the ohmic contact wire through the strain relief of the power supply.

B Install appropriate size fork terminal on the wire end and attach the wire to the terminal labeled
SHIELD on the plasma interface PC board.

C Install the other end of the ohmic contact wire to the IHS tab on the torch retaining cap.

Ohmic Contact Wire

B C

Shield Cap with IHS Tab

P/N 220173

Figure 3i-8 Ohmic contact wire connection

3i-6 Command THC for X-Y Table Instruction Manual

9
 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
Problems and solutions ........................................................................................................................4-16
Manual mode time-line .........................................................................................................................4-18
THC selectable responses (DIP switch)...............................................................................See section 3 Setup

Command THC for X-Y Table Instruction Manual 4-1

5
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

4-2 Command THC for X-Y Table Instruction Manual

5
 OPERATION

KEY 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; Torch moves to plate and then retracts to cutting height.
Press again to return to RUN mode.

Selects data field for changing operating parameters.

Changes the value of selected field. Changes torch height while in manual mode.

small increase large increase

small decrease large decrease

Returns to main operating screen (automatic or manual).

Selects operator pendant (local) or CNC (remote) as control.

Press SHIFT key to enable this key.

Enables LCL/RMT key.

Enables B key when viewing the Diagnostic Screen.

Selects Setup Screen A.

Selects Diagnostic Screen B. Press SHIFT B to begin diagnostic.

Command THC for X-Y Table Instruction Manual 4-3

5
OPERATION

Pendant display screens

Pendant display screens are shown in Figure 4-3.

TO GET TO
SCREEN THIS SCREEN FUNCTION

AUTOMATIC Press Can view and adjust basic operating parameters.

OPERATION Can perform initial height sensing (IHS).
Automatic voltage control (AVC) is active. Torch height is
automatically adjusted during a cut to maintain the displayed
Set Arc Volts.

MANUAL Press Torch height can be changed (stationary or during a cut)

OPERATION by pressing the yellow increment (arrow up) or decrement
(arrow down) keys.
No IHS, AVC, or Rapid Pull-back.

SETUP A Press Can view and adjust detailed operating parameters.

Press to return to main operation screen.

Press
DIAGNOSTIC B Can perform limited on-site testing of the THC controls, cabling and
lifter. Proper testing requires that the lifter have an unobstructed
path through full length of stroke.
Also displays Firmware revision and type of lifter installed.

Press to return to main operation screen.

REMOTE Press Turns system control over to the CNC.

MODE No parameters can be changed from the pendant.
and Press same keys to return to main operation screen.

or from CNC

MAINTENANCE Press Informs operator that the system is in the maintenance mode. The
MODE lifter brake is locked and the system will not respond to the Cycle
Start signal.

Press to return to main operation screen.

4-4 Command THC for X-Y Table Instruction Manual

5
 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

Command THC for X-Y Table Instruction Manual 4-5

5
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). The THC adjusts 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

Set Cut Height Sets the initial cutting height before AVC is activated. Also sets the pierce
height. See Determining Pierce Height Factor later in this section.

During a normal cut cycle, the torch will move down and sense the workpiece,
and then retract to the Pierce Height. At this point the THC will issue a "Start"
signal to the plasma system and wait for a "Transfer" signal. The torch will
move to the Set Cut Height after the Pierce Delay time has elapsed.

Small change: +/- 0.010 inch/0.2 mm

Large change: +/- 0.100 inch/2 mm

Setpoint range: 0.010–1 inch (0.25–25.4 mm)

4-6 Command THC for X-Y Table Instruction Manual

5
 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" output will become active and the cutting machine
will begin to move. At the same time, the torch height will rapidly adjust to the
Set Cut Height setting and the Machine Accel Delay will begin.

Note: For best performance, use the THC pierce delay, not the CNC pierce delay.
The Pierce Complete signal only applies to HyDefinition plasma systems.

Small change: +/- 0.010 second

Large change: +/- 0.100 second

Setpoint range: 0–9 seconds

Retract Selects Retract to FULL or to a programmed value set by the operator. In the
FULL mode, the torch will retract to the home position (full up).

A retract distance that is too low will increase the risk of a torch collision when
moving to a new cutting position.

Small change: +/- 0.050 inch/1.27 mm

Large change: +/- 0.50 inch/12.7 mm

Setpoint range: 0–8 inches (0.0–203 mm)

IHS Selects IHS TEST (no plasma arc) or RUN mode. This control is used to 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. Then when IHS RUN is selected, the torch
will retract to the set retract height. After testing, return to the RUN mode for
proper cutting operation.

Command THC for X-Y Table Instruction Manual 4-7

5
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.

4-8 Command THC for X-Y Table Instruction Manual

5
 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). At
this point the THC will issue a "Start" signal to the plasma system and wait for
a "Transfer" signal.

See Determining Pierce Height Factor later in this section.

Stall Force Sets the lifter downward force during the IHS cycle. This value is a
compromise between IHS speed, accuracy and lifter load capacity. Normally
this value is set to the lowest force that will reliably move the lifter at the set
IHS Speed. This setting will result 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 if the Nozzle Ohmic
Contact is set to OFF.

The use of Stall Force sensing is not as accurate as ohmic contact sensing. To
compensate for plate deflection, the user may need to increase the values for
Set Cut Height and/or Pierce Height Factor.

Setpoint range: Relative value between

1 (minimum) and 10 (maximum)

IHS Speed Sets the lifter downward speed during the IHS cycle. This value is a
compromise between lifter speed and IHS accuracy.

Note: At lower speeds the IHS accuracy will be improved. At excessive

speeds the torch tip may be damaged and decrease IHS accuracy.

Setpoint range: Relative value between

1 (minimum) and 10 (maximum)

Command THC for X-Y Table Instruction Manual 4-9

5
OPERATION

Nozzle Contact Active HD3070, MAX200, HT2000 and HT2000LHF only. Sets ohmic contact
sensing to ON or OFF. When sensing is ON, the torch will advance to the
workpiece during IHS. The nozzle completes an electrical circuit when it
contacts the plate, providing ohmic sensing by the THC.

This parameter should remain ON for most applications. May be disabled

(OFF) to get a more reliable IHS when cutting underwater or when cutting
extremely dirty or rusty metal. Limited-stall-force sensing is always active
and provides secondary sensing to the nozzle ohmic contact sensing.

Preflow During IHS Sets Preflow During IHS to ON or OFF. When this parameter is ON, the
"Plasma Start" and "Hold Ignition" signals will be activated at the start of
an IHS cycle.

The "Hold Ignition" signal makes it possible to increase the overall

machine throughput. This is done by allowing the two normally sequential
processes of IHS and preflow to occur simultaneously. When the IHS
cycle is complete and the torch is positioned at the piercing height, the
"Hold Ignition" signal is deactivated, allowing the power supply to ignite the
torch.

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.

Machine Accel Delay Sets a delay to allow the cutting machine to reach a steady cutting speed
before activating the automatic voltage control (AVC). If AVC is active
before the cutting machine reaches a steady cutting speed, the torch may
dive toward the plate. During the Machine Accel Delay time, the torch will
maintain the Set Cut Height.

This delay is based on the cutting machine acceleration time to reach

steady state speed. Set this delay as low as possible without allowing
the torch to dive excessively at the beginning of the cut.

Auto Kerf Detect Sets Auto Kerf Detect to ON or OFF. Reduces the probability of the torch
diving toward the plate when the arc is crossing a kerf. When this
parameter is ON, the THC will constantly monitor the arc voltage for
sudden changes. If a sudden change is detected, the THC will assume the
torch is crossing a kerf and will maintain the torch height until the arc
voltage becomes steady, when AVC is resumed.

If the part being cut does not require crossing a kerf, this parameter
should be set to OFF (inactive).

4-10 Command THC for X-Y Table Instruction Manual

5
 OPERATION

Homing Speed Sets the lifter retract (homing) speed. This value is a compromise between
machine speed and the amount of weight on the lifter. At lower speeds,
the lifter is capable of lifting heavier loads.

Setpoint range: Relative value between

1 (minimum) and 10 (maximum)

Inch or Metric Units Units can be set for inches or millimeters.

Retract Delay Sets a retract delay to allow time for the arc to ramp down and extinguish.
This time delay will start when the CNC removes the "Cycle Start" signal
and the plasma system is commanded to shutdown. After this
programmed delay, the torch will retract. 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.

The Pierce Height Factor is a percentage of the cut height. The factor is entered into the THC pendant and the
system calculates the required pierce height. The Cut Height will be maintained until the Machine Acceleration
Delay time has elapsed, then Automatic Voltage Control will control torch height.

The default pierce height factor is 150%. Typically, this value is left at 150%.

EXAMPLE: Cut Height = 0.100 inch

Pierce Height Factor = 150%

0.100 inch X 150% = 0.150 inch*

Pierce Height = 0.150 inch

*THC system performs this calculation.

Command THC for X-Y Table Instruction Manual 4-11

5
OPERATION

EVENT
1 Pierce Height

Plate

2 Pierce Delay

4
Machine Automatic
3 Acceleration 5 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. See Figure 4-5. To avoid this, the cut height
and pierce height factor can be set so that the torch will jump over the molten metal after
piercing is completed.

When to Apply: If the torch dives into the molten metal accumulated on top of the plate during piercing.
Do not apply if this problem is not encountered during 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
pierce delay, the torch will retract to the cut height for Machine Acceleration Delay (clearing
the molten metal) and then Automatic Voltage Control (AVC) will take over. See Figure 4-6 for
sequence of events.

EXAMPLE: Desired Pierce Height = 0.25 inch

Cut Height = 0.500 inch

Pierce Height Factor = 50%

0.500 inch X 50% = 0.250 inch*

Pierce Height = 0.250 inch

*THC system performs this calculation.

4-12 Command THC for X-Y Table Instruction Manual

5
 OPERATION

Molten metal accumulated

on top of plate during
piercing.

Figure 4-5 Arc piercing thicker materials

EVENT
1 Pierce Height

Plate

2 Pierce Delay

4 Machine
Acceleration Automatic
3 Cut Height Delay 5 Voltage
Control

Plate

Plate

Figure 4-6 Pierce height factor for thicker materials – Sequence of events

Command THC for X-Y Table Instruction Manual 4-13

5
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. The numbers shown in an operating cycle correspond to the
numbers in the list of problems and solutions.

WARNING
THE THC LIFTER CAN INJURE YOUR HAND

The down force pressure of the X-Y THC Lifter has potential to cause injury. Be sure that
the system is in a safe condition before accessing the lifter area.

4-14 Command THC for X-Y Table Instruction Manual

5
 OPERATION

Automatic mode time-line

Start

1. CNC traverses to next piercing position.

2. 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.

3. CNC issues a CYCLE-START-IN to THC.

4. If Preflow During IHS is enabled, THC issues a PLASMA-START-OUT and a HOLD-IGNITION-OUT signal to
plasma power supply.

5a. If Nozzle Contact (ohmic contact) is enabled, torch approaches plate at programmed speed and stall force until
nozzle makes ohmic contact with plate; then retracts slowly until nozzle ohmic contact is lost and then retracts to
pierce height.
or
5b. If Nozzle Contact (ohmic contact) is disabled, torch dives at programmed speed and stall force, until a motor stall
is detected and then retracts to pierce height

6. For multiple torch /THC installations only: THC issues IHS-COMPLETE-OUT signal to CNC. When all IHS-
COMPLETE-OUT signals have been satisfied, CNC releases IHS-SYNC-IN signal.

7. If Preflow During IHS is not enabled, THC issues a PLASMA-START-OUT signal 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 workpiece. Plasma power supply issues ARC-TRANSFER-IN to THC.

12. Programmed pierce delay signal elapses.

13. Torch quickly dives from pierce height to programmed cut height; programmed MACHINE ACCEL DELAY begins;
THC issues PIERCE-COMPLETE-OUT signal to plasma power supply; and THC issues MACHINE-MOTION-
OUT signal to CNC to begin profiling part.

14. After MACHINE ACCEL DELAY elapses, arc voltage control (AVC) begins. During AVC, an AUTO-HEIGHT-
ON/OFF from CNC freezes torch position (traditional CORNER HOLD). During AVC, CNC should issue an AUTO-
HEIGHT-OFF when CNC not moving at programmed velocity. During AVC, if AUTO KERF DETECT is enabled,
torch position is frozen when crossing kerfs.

15. At end of cut, CNC releases CYCLE-START-IN signal to THC. Programmed retract delay begins.

16. Programmed retract delay time elapses and the THC raises torch until home limit switch is reached or partial
retract height is checked.

17. THC issues RETRACT-COMPLETE-OUT signal to CNC allowing traverse to next cut position.

Cycle completed, return to Start for next cycle.

Command THC for X-Y Table Instruction Manual 4-15

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OPERATION

Table 4-1 THC operating cycle (automatic mode) process problems and solutions

Problem Solution
(Refer to operating cycle time-line on previous page)

1. No response to • Check power to THC. On THC control PCB, D41 – D44 should be illuminated.
CYCLE-START-IN at THC. Check line input fuses in THC power module.
• Check for bad Cycle Start connection. Check on THC control PCB, Machine
Interface Inputs, that D9 is illuminated.
• Check on control PCB, Machine Interface Inputs, that D15 is illuminated.
• Check on control PCB, External Interlock OK, that D16 is illuminated.
• Check that Maintenance Mode is not selected on pendant or do query on
RS-422.

2. Arc ignites before IHS is complete. • Check that Preflow During IHS is OFF (disabled) on Setup Screen A.
• If plasma power supply has a Hold signal, check that it is wired properly.

3. Torch does not approach workpiece • Check that THC is in Automatic Mode. If not, press <AUTO/MAN> key on
at programmed IHS speed and stall keypad.
force. • Check that Stall Force is not set too low on Setup Screen A.
• Check that IHS Speed is not set too high on Setup Screen A.
• Check for cable and hose obstructions that may stop movement.

4. 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 Setup Screen A.
• Check that nozzle ohmic contact wire is not disconnected. Ensure wire is
connected at both ends.
• Check Pierce Height Factor on Setup Screen A.
• Check that torch retaining cap is tight.
• Check for water on the workpiece. If present, use Stall Force sensing. Refer to 5b
on previous page.
• Check for coating (oil, plastic, etc.) on the workpiece. If present, use Stall Force
sensing. Refer to 5b on previous page.
• Check nozzle/shield, clean or replace.
• Check work lead connection.

5. Inaccurate IHS with Stall Force sensing • Check that Nozzle Ohmic Contact is OFF (disabled) on Setup Screen A.
• Check Pierce Height Factor on Setup Screen A.
• Check that Stall Force is not set too high on Setup Screen A.
• Check that workpiece is not deflecting excessively. Check the work table supports
under the workpiece.
• Offset workpiece deflection by adjusting Set Cut Height on Automatic Operating
Screen and Pierce Height Factor on Setup Screen A to achieve desired results.

6. Torch fails to ignite. • Ensure plasma system is operational.

• Check for proper IHS piercing height. Check torch.
• Check that IHS SYNC is off. Check on THC control PCB, Plasma Interface Inputs,
that D13 is extinguished.
• Check torch consumables.

7. Torch arc fails to transfer to workpiece. • 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.
• Check work lead connection.
• Check torch consumables.
• Check for Transfer signal on control PCB, Machine Interface Inputs, that D17 is
illuminated.

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 OPERATION

Table 4-1 THC operating cycle (automatic mode) process problems and solutions
(continued)

Problem Solution
8. Arc extinguishes immediately after • Check Pierce Delay on Automatic Operating Screen; the delay is set too long.
transfer/excessively large pierce hole. (The torch dwells in the piercing position too long before machine motion.)
• Check that Machine Motion Out is active after Pierce Delay ends.
Check on control PCB, Machine Interface Outputs, that D25 is illuminated.

9. Torch moves before workpiece is pierced all • Check Pierce Delay on Automatic Operating Screen, the delay is set too short.
the way through.

10. Torch dives below cutting height immediately • Increase Set Cut Height on Automatic Operating Screen and decrease Pierce
after pierce delay and before AVC begins. Height Factor on Setup Screen A.
• Increase Machine Accel Delay on Setup Screen A.

11A. Torch dives toward workpiece immediately • Increase Set Arc Volts on Automatic Operating Screen.
after AVC begins. • Increase Machine Accel Delay on Setup Screen A.
• Decrease Set Cut Height on Automatic Operating Screen.

11b. Torch retracts from workpiece immediately • Decrease Set Arc Volts on Automatic Operating Screen.
after AVC begins. • Increase Set Cut Height on Automatic Operating Screen.
• Check plasma interface arc voltage wiring.

11c. Erratic voltage control • Check for faulty grounds (work lead connection).
• Check for water leaks.

12. Retract begins before arc has extinguished. • Increase Retract Delay on Setup Screen A.

13. Failure to retract • Decrease Homing Speed on Setup Screen A.

• Check for obstructions in the torch path and torch lead set.

Command THC for X-Y Table Instruction Manual 4-17

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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.

7. Programmed pierce delay 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-START-IN signal to THC. Torch position freezes until arc has
extinguished (until plasma power supply transfer signal is released to THC).

Cycle completed, return to Start for next cycle.

Note: At any time, the operator can manually jog the torch position up or down using the increment/arrow up or
decrement/arrow down keys.

4-18 Command THC for X-Y Table Instruction Manual

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 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

Command THC for X-Y Table Instruction Manual 5-1

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MAINTENANCE

Routine maintenance

Every 3 months complete the following:

WARNING
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. In other countries, follow appropriate local or national safety
procedures.

1. Check the THC control module, plasma interface assembly, lifter assembly and associated cables for wear and
damage.

2. Check the inside of the THC control module and plasma interface assembly for dirt. Use compressed air to
clean the units. If the work environment is extremely dirty, clean the units more often.

3. Check the lifter assembly sealing band for tears and fraying

4. Replace or repair damaged parts.

NOTE: Do not grease or lubricate any part of the X-Y lifter assembly.

X-Y lifter sealing band removal and replacement

The sealing band keeps foreign matter out of the lifter assembly. Replace the band if it is torn or worn by installing a
Band Seal Kit. The kit contains a new band, screws and retainers.

CAUTION: Turn off all power to the plasma system and THC before working on the THC lifter.
The THC system can be damaged if disconnected with power applied.

Sealing band—Remove (Figure 5-1)

1. Turn off all power to the plasma system and THC.

2. Remove the lifter from the cutting machine.

3. Remove the torch mounting block or breakaway mounting bracket from the lifter retaining block (View 1).

4. Remove the left side cover (View 1).

5. Remove the 2 retainers that secure the band to the retaining block (View 2).

6. Remove the band from the rear of the lifter (View 3).

5-2 Command THC for X-Y Table Instruction Manual

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 MAINTENANCE

VIEW 1 Retaining Block

Left Side Cover

Screws (5)

Left Side Cover

VIEW 2 Retainer
Retaining Block

VIEW 3
Sealing Band

Figure 5-1 Sealing band – Remove

Command THC for X-Y Table Instruction Manual 5-3

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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. 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 side cover. Make sure the band is in the groove (View 3).

5. Install the torch mounting block or breakaway bracket as described in Section 3, Setup.

VIEW 1

Back of Lifter

Channel

Figure 5-2 Sealing Band – Install (1 of 2)

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 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)

Command THC for X-Y Table Instruction Manual 5-5

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MAINTENANCE

Troubleshooting

WARNING
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. In other countries, follow appropriate local or national safety
procedures.

NOTE: See Section 4, Operation, for THC Operating Cycle Process Problems and Solutions.

Diagnostic Screen B

Diagnostic Screen B, Figure 5-3, is used to allow

limited on-site testing of the THC controls, cables and
lifter. The lifter must have an unobstructed path
through its full length of travel to complete testing.
Press <SHIFT-B> to begin the test.

Figure 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 interface are the same as for the Pendant except they are preceded
by ERR -.

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5
Table 5-1 X-Y THC error messages

Error Message* Clear Error Description of Error Corrective Action

Torch is in LOWER LIMIT Press OPR During IHS the torch did • Reposition lifter, torch or workpiece.
SCRN Key not reach the workpiece. • Select Diagnostic Screen B by pressing <B> on keypad. Then press
<SHIFT-B> to start tests. Check for the following:
During cutting the torch hits - "Lower Limit Switch" indicates "Ok"
MAINTENANCE

the Lower Limit. - "Lifter Type" indicates 2 (X-Y lifter)

• On THC control PCB, Motor Drive Interface, D54 should be illuminated.
D53 and D55 should be extinguished.
• Place THC in Manual Position Mode.
- Jog torch to Lower Limit position to activate switch. On THC control
PCB, Motor Drive Interface, D50 should illuminate.
- Jog torch up to deactivate switch, D50 should extinguish.
• Check Lower Limit switch and cable, replace if required.

Torch is in HOME LIMIT Press OPR During IHS the torch retracted • Reposition lifter, torch or workpiece.
SCRN Key to the Home Limit. • Stall Force and IHS speed in combination or separately are improperly set.
- Try a lower speed or a higher stall force.
• Select Diagnostic Screen B by pressing <B> on keypad. Then press

Command THC for X-Y Table Instruction Manual

<SHIFT-B> to start tests. Check for the following:
- "Upper Limit Switch" indicates "Ok"
- "Lifter Type" indicates 2 (X-Y lifter)
• Place THC in Manual Position Mode.
- Jog torch to Home position to activate switch. On THC control PCB,
Motor Drive Interface, D49 should illuminate.
- Jog torch down to deactivate switch, D49 should extinguish.
• Check Home Limit switch and cable, replace if required.

EEPROM Checksum Error Press OPR Changed the processors. This error will • Clear error by pressing <OPR SCRN> key and then reenter parameters.
SCRN Key occur one time after upgrading software.

Lifter NOT Installed Repower Power up with no lifter cable installed. • Check that lifter I/O cable is connected at both ends.

Motion FAIL Press OPR Torch did not reach Home position • Verify torch is not blocked from moving.
SCRN Key during full retract. • Check for an encoder problem.
• Place THC in Manual Position Mode.
- Jog torch to Home position to activate switch. On THC control PCB,
Motor Drive Interface, D49 should illuminate.
- Jog torch down to deactivate switch, D49 should extinguish.
• Check Home Limit switch and cable, replace if required.

* Error Messages for the RS-422 serial interface are the same as for the Pendant except they are preceded by ERR -.

5-7
Error Messages for the RS-422 serial interface are cleared by using the CL command.
5
Table 5-1 X-Y THC error messages (continued)

5-8
Error Message* Clear Error Description of Error Corrective Action

Motion FAIL Press OPR Encoder failed during a cut. • Verify torch is not blocked from moving.
SCRN Key • Check for an encoder problem.
• Place THC in Manual Position Mode.
- Jog torch up. On THC control PCB, Motor Drive Interface, D58 and D59
MAINTENANCE

should blink alternately.

• Check Lower Limit switch and cable, replace if required.
• Check Home Limit switch and cable, replace if required.

Watch Dog Timeout FAIL Repower A processor on THC control PCB has • Call Hypertherm Technical Service.
failed.

InterProcessor Comm Fail Repower Changed real-time processor to a • Check firmware revisions in both processors for compatibility.
higher revision level. • Call Hypertherm Technical Service.

Nozzle Contact at Home Press OPR Nozzle contact is being sensed with • Check ohmic contact wire connections at shield and inside plasma interface
SCRN Key lifter at Home position. assembly.
• Check ohmic contact wire for a short to ground.

Cycle Start ON at INIT Press OPR Cycle start is active during THC power • Verify CNC start up signal is inactive.
SCRN Key up or while exiting Maintenance Mode.

Motor Current Fault Press OPR Cable not installed or external • Install cable. On THC control PCB, Motor Drive Interface, D51 should
SCRN Key interlock not satisfied. illuminate.
• On THC control PCB, Ext Interlock Ok, D16 should be illuminated. If not,
jumper machine interface cable at CNC at pins 16 and 35 on plug J6.
See Section 3, External Emergency Interlock for details.

Machine Cable Missing Repower Cable not installed or external • Install cable. On THC control PCB, Machine Interface Inputs, D15 should
interlock not satisfied. illuminate.
• On THC control PCB, Ext Interlock Ok, D16 should be illuminated. If not,
jumper machine interface cable at CNC at pins 3 and 22 on plug J6.

Plasma Cable Missing Repower Cable not installed • Check cable connections at both ends. On THC control PCB, Plasma
Interface Inputs, D23 should illuminate.

Command THC for X-Y Table Instruction Manual

* Error Messages for the RS-422 serial interface are the same as for the Pendant except they are preceded by ERR -.
Error Messages for the RS-422 serial interface are cleared by using the CL command.
5
Table 5-1 X-Y THC error messages

Error Message* Clear Error Description of Error Corrective Action

Diag FAIL Repower Torch inhibited from reaching Home • Place THC in Manual Position Mode and jog torch to Home position to
Limit position during diagnostic test. activate switch.
• On THC control PCB, Motor Drive Interface, D49 should illuminate.
MAINTENANCE

Diag FAIL Repower Torch inhibited from reaching Lower • Place THC in Manual Position Mode and jog torch to Lower limit to activate
Limit position during diagnostic test. switch. On THC control PCB, Motor Drive Interface, D50 should illuminate.

Diag FAIL Repower Encoder failed during diagostic test. • Repower THC.
• Check encoder.
• Verify torch is not blocked from moving.

IOP CHECKSUM FAIL Press <SHIFT-H> Changed firmware. This error will occur • Clear error by pressing <SHIFT-H> on pendant.
one time after upgrading firmware.

Command THC for X-Y Table Instruction Manual

RTP CHECKSUM FAIL Press <SHIFT-H> Changed firmware. This error will occur • Clear error by pressing <SHIFT-H> on pendant.
one time after upgrading firmware.

* Error Messages for the RS-422 serial interface are the same as for the Pendant except they are preceded by ERR -.

5-9
Error Messages for the RS-422 serial interface are cleared by using the CL command.
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

AC Input Filter Power Supply

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

5-10 Command THC for X-Y Table Instruction Manual

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 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.

LED Signal Function Status

D1 Drive Active On
D15 Brake Released On*
D16 Up Off
D17 Down Off

* On = brake is unlocked
Off = brake is on

Figure 5-5 Motor drive board

Command THC for X-Y Table Instruction Manual 5-11

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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

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 MAINTENANCE

Table 5-3 DC power, LEDs and test points

Wire Connection Points/LEDs and Test Points

DC 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 & TP6

Common White TB2-3 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 TB2-8 J1-6/TP5 Ground

Ground White TB2-11 J8-2 Ground

+ 5 VDC Blue TB2-15 J8-1/D44 & TP7

Ground White TB2-12 J1-2 Ground

+ 5 VDC Blue TB2-16 J1-1/TP1

+ 5 VDC Blue TB2-13 Resistor 1 mounted

Ground White TB2-10 on heatsink

Command THC for X-Y Table Instruction Manual 5-13

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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.

LED Signal function Status LED Signal function Status

D9 – cycle start input Off D41 – +24v On

D10 – auto height on/off Off D42 – -12v On
D11 – spare input Off D43 – +12v On
D12 – spare input Off D44 – +5v On
D13 – IHS sync input Off
D14 – spare input Off D45 – response switch 1 Off
D15 – machine cable On (user-definable response)
D46 – response switch 2 Off
D17 – transfer input Off (user-definable response)
D18 – pilot arc input Off D47 – response switch 3 Off
D19 – nozzle contact Off (user-definable response)
D20 – spare input Off D48 – crash detect (Future use) Off
D21 – torch 1 select Off D49 – home position On momentarily,
D22 – torch 2 select Off then Off
D23 – plasma cable On D50 – lower limit switch Off
D51 – motor current check On
D25 – machine motion output Off D52 – response sw4 Off
D26 – THC error out Off D53 – drive ID 1 Off
(On if there is error) D54 – drive ID 2 On
D27 – pilot arc output Off D55 – drive ID 4 Off
D28 – retract complete On D56 – spare input Off
D29 – spare out Off D57 – motor drive installed On
D30 – IHS complete Off D58 – encoder A On or Off
D31 – error #1 (Not functional) On D59 – encoder B On or Off

D32 – plasma start output Off

D33 – hold ignition output Off
D34 – pierce complete out Off
D35 – spare out Off
D36 – spare out Off
D37 – high voltage relay active Off
D38 – error #2 (Not functional) On

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 MAINTENANCE

Figure 5-7 Control board

Command THC for X-Y Table Instruction Manual 5-15

6
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.

LED Signal function Status

D1 Power On
D2 Shield Relay Normally On – Off when arc initiates.
D5 Plasma Start On when plasma start signal to the power supply is active.
D6 Ohmic Contact Normally Off – On when torch is in contact with the plate.

Test Points TP1 (ground) and TP2 (+) allow the measurement of the isolated electrode-to-work voltage
divided by 82.

HT4400 AND HPR130 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 HPR130 power supply are included in
section 3i.
The plasma interface enclosure is not used for the
HT4400.

Figure 5-8 Interface board

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 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
Ohmic contact wire..........................................................................................................................................6-9
Power cords ....................................................................................................................................................6-9
Recommended spare parts...........................................................................................................................6-10
Interface cables ..........................................................................................................See Section 3a through 3i

Command THC for X-Y Table Instruction Manual 6-1

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PARTS LIST

THC control module

Index No. Part No. Description Quantity
– 053018 THC control module 1
1 002261 Enclosure, THC control module 1
129067 Heatsink SA, THC control module 1
2 004705 Heatsink, 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 PCB assembly, control (see Fig. 6-2) 1
081061 Firmware, real-time microprocessor 1
081062 Firmware, interface microprocessor 1
8 123254 Cable, THC 50/C ribbon (not shown) 1
9 129066 Harness wiring THC (not shown) 1

Figure 6-1 THC control module exterior

6-2 Command THC for X-Y Table Instruction Manual

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 PARTS LIST

Figure 6-2 THC control module interior

Command THC for X-Y Table Instruction Manual 6-3

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PARTS LIST

Plasma interface assembly

Index No. Part No. Description Quantity

128494 Plasma interface assembly 1

1 Enclosure, plasma interface 1
2 128408 PC Board Assembly, plasma interface 1
3 041842 HPR PC Board Assembly, plasma interface 1

HT4400 AND HPR130 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 HPR130 power supply are included in
section 3i.
The plasma interface enclosure is not used for the HT4400.

3
THC.94 for HPR

Figure 6-3 Plasma interface assembly

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 PARTS LIST

2 rail X-Y lifter assembly

Index No. Part No. Description Quantity

128606 X-Y lifter assembly 1

1 128726 Encoder replacement kit 1
2 128727 Motor/Encoder replacement kit 1
3 027550 Brake, power off 1
4 129699 Assembly, leadscrew standard 1
5 128607 Band seal kit 1
6 027903 Block, driving 1
7 128190 Band roller kit 4 per lifter
8 027904 Rail and block, bearing 4
9 005195 Limit switch 2

Torch mounting block kit,

mounting location (Fig. 6-5)
1 2 3 (Inside) 4 5

Figure 6-4 X-Y lifter assembly

Command THC for X-Y Table Instruction Manual 6-5

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PARTS LIST

X-Y lifter torch mounting block kits

Index No. Part No. Description Quantity

128277 Kit, torch mounting block, 1-3/8 inch diameter torch 1

128278 Kit, torch 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
3 075583 Socket cap, 1/4-20 X 1-3/4 inch hex SST 2
4 120595 Block, 1-3/8 inch torch mounting (kit 128277) 1
4 120596 Block, 1-3/4 inch torch mounting (kit 128278) 1
4 120597 Block, 2 inch torch mounting (kit 128279) 1
5 002303 Shield 1
6 075071 Screw, 8-32 X 1/4 inch 4

Figure 6-5 X-Y lifter torch mounting block kit

6-6 Command THC for X-Y Table Instruction Manual

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 PARTS LIST

X-Y lifter breakaway kit – optional

Index No. Part No. Description Quantity

128281 Kit, X-Y lifter torch breakaway 1

1 004774 Bracket, breakaway X-Y fiberglass 1
Screw 6
2 075509 Socket cap, 1/4-20 X 1/2 inch hex BTN S/Z 4
3 027574 Breakaway, Command THC 1
3a 123596 Cable: CMD THC lifetr torch breakaway 1
Screw 2
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 Regulator/Filter assembly 1
6 011039 Filter/Regulator 1
7 011038 Gauge, pressure 150 PSI (10.2 Bar) maximum 1
8 015285 Adapter, 1/8 inch NTP X 1/4 inch push-in tube 1

Spacer and hex screws are not

1 used if breakaway is installed.

4 3a 3

Torch Mounting
3 Block Kit
(See Figure 6-5)

5
3a
3
8

Customer Supplied Hex screws (2)

8-32 X 1-1/2 inch (4 mm x 40 mm)

Figure 6-6 X-Y lifter breakaway kit

Command THC for X-Y Table Instruction Manual 6-7

6.1
PARTS LIST

Operator pendant
Index No. Part No. Description Quantity

1 053019 Operator pendant, with 25 ft. cable 1

Figure 6-7 Operator pendant

6-8 Command THC for X-Y Table Instruction Manual

6.1
 PARTS LIST

Ohmic contact wire

Index No. Part No. Description Length Quantity

1 123464 Ohmic contact wire 10 ft./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

Figure 6-8 Ohmic contact wire

Power cords
Index No. Part No. Description Quantity

1 008960 Domestic power cord, 115 VAC 1

2 008961 International power cord, 230 VAC (not shown) 1

Figure 6-9 Power cord

Command THC for X-Y Table Instruction Manual 6-9

9
PARTS LIST

Recommended spare parts

X-Y lifter assembly - 2 rail (128606)
Part No. Description Quantity
128607 Kit: torch lifter band seal replacement 1
128190 Kit: lifter band replacement 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 1

X-Y lifter breakaway kit

Part No. Description Quantity
027574 Breakaway 1
123596 Cable 1
015317 Connector: male 10-32 1

Operator pendant
Part No. Description Quantity
053019 Pendant 1

6-10 Command THC for X-Y Table Instruction Manual

9
APPENDIX A 1 rail Lifter parts list

X-Y lifter assembly - 1 rail

Index No. Part No. Description Quantity

128050 X-Y lifter assembly 1

1 128726 Encoder replacement 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 kit 1
8 128190 Band roller kit 4 per lifter
9 005195 Limit switch 2

5
7 (Located under
seal band) 6
3
(inside)
1
2

8 9 Second limit switch is

located under driving
4 block

Torch mounting block

kit mounting location (Fig. 6-5)

1 rail X-Y lifter assembly

Command THC for X-Y Table Instruction Manual a-1

9