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ArcGlide THC ®

Torch Height Control

Instruction Manual
806450 | Revision 5 | English
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ArcGlide, EDGE, HPR, HSD, Hypernet, MAXPRO200, Phoenix, Powermax, Sensor, and Hypertherm are trademarks of
Hypertherm Inc. and may be registered in the United States and other countries. All other trademarks are the property of their
respective holders.

© 2015 Hypertherm Inc.

ArcGlide

Instruction Manual

806450
Revision 5

English

March 2015

Hypertherm Inc.
Hanover, NH 03755 USA
Hypertherm Inc. Hypertherm Europe B.V.
Etna Road, P.O. Box 5010 Vaartveld 9
Hanover, NH 03755 USA 4704 SE
603-643-3441 Tel (Main Office) Roosendaal, Nederland
603-643-5352 Fax (All Departments) 31 165 596907 Tel
[email protected] (Main Office Email) 31 165 596901 Fax
800-643-9878 Tel (Technical Service) 31 165 596908 Tel (Marketing)
[email protected] (Technical Service Email) 31 165 596900 Tel (Technical Service)
800-737-2978 Tel (Customer Service) 00 800 4973 7843 Tel (Technical Service)
[email protected] (Customer Service Email)
866-643-7711 Tel (Return Materials Authorization) Hypertherm Japan Ltd.
877-371-2876 Fax (Return Materials Authorization) Level 9, Edobori Center Building
[email protected] (RMA email) 2-1-1 Edobori, Nishi-ku
Osaka 550-0002 Japan
Hypertherm Plasmatechnik GmbH 81 6 6225 1183 Tel
Technologiepark Hanau 81 6 6225 1184 Fax
Rodenbacher Chaussee 6
D-63457 Hanau-Wolfgang, Deutschland Hypertherm Brasil Ltda.
49 6181 58 2100 Tel Rua Bras Cubas, 231 – Jardim Maia
49 6181 58 2134 Fax Guarulhos, SP - Brasil
49 6181 58 2123 (Technical Service) CEP 07115-030
55 11 2409 2636 Tel
Hypertherm (S) Pte Ltd. 55 11 2408 0462 Fax
82 Genting Lane
Media Centre Hypertherm México, S.A. de C.V.
Annexe Block #A01-01 Avenida Toluca No. 444, Anexo 1,
Singapore 349567, Republic of Singapore Colonia Olivar de los Padres
65 6841 2489 Tel Delegación Álvaro Obregón
65 6841 2490 Fax México, D.F. C.P. 01780
65 6841 2489 (Technical Service) 52 55 5681 8109 Tel
52 55 5683 2127 Fax
Hypertherm (Shanghai) Trading Co., Ltd.
Unit 301, South Building Hypertherm Korea Branch
495 ShangZhong Road #3904 Centum Leaders Mark B/D,
Shanghai, 200231 1514 Woo-dong, Haeundae-gu, Busan
PR China Korea, 612-889
86-21-60740003 Tel 82 51 747 0358 Tel
86-21-60740393 Fax 82 51 701 0358 Fax
Contents

Safety ....................................................................................................................................... SC-13

Recognize safety information ...............................................................................................................................................SC-13
Follow safety instructions ......................................................................................................................................................SC-13
Electrical hazards ....................................................................................................................................................................SC-13
Electric shock can kill ............................................................................................................................................................SC-14
Cutting can cause fire or explosion ....................................................................................................................................SC-15
Fire prevention .................................................................................................................................................................SC-15
Explosion prevention ......................................................................................................................................................SC-15
Toxic fumes can cause injury or death ...............................................................................................................................SC-16
Grounding safety ....................................................................................................................................................................SC-17
Static electricity can damage circuit boards ....................................................................................................................SC-17
A plasma arc can cause injury and burns .........................................................................................................................SC-18
Compressed gas equipment safety ...................................................................................................................................SC-18
Gas cylinders can explode if damaged .............................................................................................................................SC-18
Arc rays can burn eyes and skin .........................................................................................................................................SC-19
Pacemaker and hearing aid operation ...............................................................................................................................SC-20
Noise can damage hearing ...................................................................................................................................................SC-20
A plasma arc can damage frozen pipes ............................................................................................................................SC-20
Dry dust collection information ............................................................................................................................................SC-21
Laser radiation .........................................................................................................................................................................SC-22
Additional safety information ................................................................................................................................................SC-22
Warning labels ........................................................................................................................................................................SC-23
Symbols and marks ................................................................................................................................................................SC-25

Product Stewardship ........................................................................................................... SC-27

ArcGlide THC Instruction Manual 806450 5

Contents

Differences in national standards .......................................................................................................................................SC-27

Safe installation and use of shape cutting equipment ...................................................................................................SC-27
Procedures for periodic inspection and testing ..............................................................................................................SC-27
Qualification of test personnel .............................................................................................................................................SC-28
Residual current devices (RCDs) .......................................................................................................................................SC-28
Higher-level systems ..............................................................................................................................................................SC-28

Environmental Stewardship .............................................................................................. SC-29

Electromagnetic Compatibility (EMC) ............................................................................ SC-31

Warranty .................................................................................................................................. SC-33

Attention ...................................................................................................................................................................................SC-33
General .....................................................................................................................................................................................SC-33
Patent indemnity .....................................................................................................................................................................SC-33
Limitation of liability ................................................................................................................................................................SC-33
National and local codes ......................................................................................................................................................SC-33
Liability cap ..............................................................................................................................................................................SC-33
Insurance ..................................................................................................................................................................................SC-34
Transfer of rights .....................................................................................................................................................................SC-34

1 Specifications .............................................................................................................................. 35
Introduction .................................................................................................................................................................................... 35

6 ArcGlide THC Instruction Manual 806450

Contents

ArcGlide control module ..................................................................................................................................................... 36

Lifter assembly ....................................................................................................................................................................... 36
Human machine interface (HMI) ........................................................................................................................................ 37
Plasma interface board ........................................................................................................................................................ 37
Industrial Ethernet switch .................................................................................................................................................... 37
Specifications ................................................................................................................................................................................ 38
ArcGlide system .................................................................................................................................................................... 38
ArcGlide control module (090054) .................................................................................................................................. 39
Lifter assembly (090053) ................................................................................................................................................... 40
Optional HMI (090055) ...................................................................................................................................................... 43
Discrete plasma interface board (141094) .................................................................................................................... 44
Hypernet plasma interface board (141162) ................................................................................................................... 45
Ethernet switch ...................................................................................................................................................................... 46
ArcGlide communication ............................................................................................................................................................ 48
Hypernet communication .................................................................................................................................................... 48
Discrete communication ...................................................................................................................................................... 50
Mixed communication .......................................................................................................................................................... 51
Serial communication ........................................................................................................................................................... 51

2 Installation .................................................................................................................................... 53
Hardware setup ............................................................................................................................................................................. 53
Claims ...................................................................................................................................................................................... 53
Installation requirements ..................................................................................................................................................... 54
Placement of system components .................................................................................................................................... 54
Recommended grounding and shielding practices .............................................................................................................. 55
Introduction ............................................................................................................................................................................ 55
Types of grounding ............................................................................................................................................................... 55
Grounding practices ............................................................................................................................................................ 55
System description for a Hypernet configuration .................................................................................................................. 59
System description for a discrete configuration .................................................................................................................... 60
ArcGlide communication configuration examples ................................................................................................................. 61
Install the lifter ................................................................................................................................................................................ 77
Connect the ohmic wire from HPRXD plasma systems .............................................................................................. 79
Connect the ohmic wire to other plasma systems ........................................................................................................ 80
Ground the lifter .................................................................................................................................................................... 80
Extended torch sleeve option ............................................................................................................................................. 81
Install the optional pneumatic breakaway ....................................................................................................................... 82
Install the control module ............................................................................................................................................................ 84
Modify Retract Delay Time for an HT2000 plasma system ........................................................................................ 85
Ground the control module ................................................................................................................................................ 86
Install the optional HMI ................................................................................................................................................................ 87

ArcGlide THC Instruction Manual 806450 7

Contents

Ground the HMI ............................................................................................................................................................................ 89

Install the plasma interface board in a plasma system ......................................................................................................... 90
Discrete plasma interface board (141094) .................................................................................................................... 90
Hypernet plasma interface board (141162) .................................................................................................................. 91
Connect Hypernet cables ........................................................................................................................................................... 92
Connect discrete cables ............................................................................................................................................................. 95
Ground all cables with circular connectors .................................................................................................................... 95
Control module cable connections .................................................................................................................................. 95
Cables ............................................................................................................................................................................................. 97
Power cable ........................................................................................................................................................................... 97
Lifter interface cable ............................................................................................................................................................. 98
Hypernet and HMI interface cable .................................................................................................................................. 100
Optional operator console I/O cable ............................................................................................................................. 101
Optional operator console I/O signals ................................................................................................................... 103
ArcGlide control module CNC interlock kit (228594) ............................................................................................... 104
CNC I/O cable .................................................................................................................................................................... 105
CNC discrete I/O ............................................................................................................................................................... 108
Plasma interface I/O cable ............................................................................................................................................... 110
Plasma discrete I/O ............................................................................................................................................................ 113
Non-serial plasma interface cable .................................................................................................................................. 115
Serial plasma interface cable ........................................................................................................................................... 116
ArcGlide discrete interface signal examples ........................................................................................................................ 117
Inputs ..................................................................................................................................................................................... 117
Relay outputs ....................................................................................................................................................................... 118
ArcGlide setup in Phoenix™ software .................................................................................................................................... 119
Set up ArcGlide and Hypernet ........................................................................................................................................ 119
ArcGlide axis setup ............................................................................................................................................................ 120
ArcGlide axis setup parameters ...................................................................................................................................... 121
Gains ............................................................................................................................................................................. 121
Speeds .......................................................................................................................................................................... 122
Mechanical ................................................................................................................................................................... 123
Miscellaneous .............................................................................................................................................................. 124
Assign an ArcGlide THC to a station ............................................................................................................................ 125

3 Operation .................................................................................................................................... 127

Operator controls ....................................................................................................................................................................... 127
Control module .................................................................................................................................................................... 127
Lifter ....................................................................................................................................................................................... 128
HMI ......................................................................................................................................................................................... 129
Daily operations .......................................................................................................................................................................... 130
Startup procedure .............................................................................................................................................................. 130

8 ArcGlide THC Instruction Manual 806450

Contents

Automatic diagnostic tests ............................................................................................................................................... 130

Verify workpiece sensing .................................................................................................................................................. 130
Shutdown procedure ......................................................................................................................................................... 130
ArcGlide THC operating modes ............................................................................................................................................. 131
Manual mode ....................................................................................................................................................................... 131
Automatic modes ................................................................................................................................................................ 131
Voltage Control Off mode ......................................................................................................................................... 132
Set Arc Voltage mode ................................................................................................................................................ 132
Sample Voltage mode ................................................................................................................................................ 132
Initial height sense ...................................................................................................................................................................... 133
Performing a first IHS on the ArcGlide .......................................................................................................................... 133
Operating the control module .................................................................................................................................................. 135
Screen 0 – Idle Park .......................................................................................................................................................... 136
Screen 1 – ArcGlide control state ................................................................................................................................. 136
Screen 2 – Options ........................................................................................................................................................... 137
Screen 3 – Inputs from the CNC .................................................................................................................................... 138
Screen 4 – Outputs to the CNC .................................................................................................................................... 138
Screen 5 – Inputs from the lifter control board ........................................................................................................... 139
Screen 6 – Outputs from the lifter control board ........................................................................................................ 139
Screen 7 – Inputs from the operator console .............................................................................................................. 140
Screen 8 – Outputs to the operator console ............................................................................................................... 140
Screen 9 – Inputs from the plasma system .................................................................................................................. 141
Screen 10 – Outputs to the plasma system ................................................................................................................ 141
Screen 11 – Last errors .................................................................................................................................................... 142
Screen 12 – Total lifter operating time .......................................................................................................................... 142
Operating the HMI ...................................................................................................................................................................... 143
HMI screen hierarchy ......................................................................................................................................................... 144
Main screen .......................................................................................................................................................................... 146
Setup screen ........................................................................................................................................................................ 147
Diagnostics screen ............................................................................................................................................................. 148
Installation Data screen ..................................................................................................................................................... 153
Manual mode ....................................................................................................................................................................... 155
Lifter Disabled mode .......................................................................................................................................................... 155
ArcGlide operating parameters ............................................................................................................................................... 156
THC mode ............................................................................................................................................................................ 157
Cut chart values .................................................................................................................................................................. 157
Options .................................................................................................................................................................................. 158
Automatically-set parameters ........................................................................................................................................... 158
Plasma cutting tips ..................................................................................................................................................................... 161
Cut quality issues ................................................................................................................................................................ 161
Basic steps to improve cut quality .................................................................................................................................. 164

ArcGlide THC Instruction Manual 806450 9

Contents

4 Maintenance .............................................................................................................................. 169

Introduction .................................................................................................................................................................................. 169
Lifter routine maintenance ........................................................................................................................................................ 169
Carriage ................................................................................................................................................................................ 169
Sealing strip ......................................................................................................................................................................... 171
Cable connections ............................................................................................................................................................. 171
System grounding .............................................................................................................................................................. 171
Calibrate arc voltage .................................................................................................................................................................. 172
Flow of ArcGlide operations .................................................................................................................................................... 174
Basic flow for all ArcGlide operating states ................................................................................................................. 177
Common machine-cutting faults ............................................................................................................................................. 178
Update ArcGlide firmware ........................................................................................................................................................ 180
Download through Phoenix software ............................................................................................................................. 180
Download from a laptop .................................................................................................................................................... 180
Operator tests ............................................................................................................................................................................. 181
Problems and solutions ............................................................................................................................................................. 182
Troubleshooting routines .......................................................................................................................................................... 185
Hypertherm CNC will not communicate with HPR plasma system ........................................................................ 185
Error 19 – Excess plate contact ..................................................................................................................................... 186
Error 21 – Ohmic tip sense .............................................................................................................................................. 188
Error message troubleshooting .............................................................................................................................................. 191
Error message displays ..................................................................................................................................................... 191
ArcGlide errors .................................................................................................................................................................... 191
Printed circuit board (PCB) block diagram for a Hypernet configuration ..................................................................... 209
Printed circuit board (PCB) block diagram for a discrete configuration ....................................................................... 210
ArcGlide PCBs ........................................................................................................................................................................... 211
HMI processor board (228581) ...................................................................................................................................... 211
HMI 7-segment display interface board (228582) ..................................................................................................... 214
THC control interface board (228577) ......................................................................................................................... 215
THC processor board (228578) .................................................................................................................................... 220
Discrete plasma interface board (141094) .................................................................................................................. 224
Hypernet plasma interface board (141162) ................................................................................................................ 228
Lifter interface board (228580) ....................................................................................................................................... 231

5 Parts List ..................................................................................................................................... 235

Lifter parts .................................................................................................................................................................................... 235
Lifter motor and slide parts ...................................................................................................................................................... 237
Control module parts ................................................................................................................................................................. 238
HMI parts ...................................................................................................................................................................................... 239
Plasma interface boards ........................................................................................................................................................... 240

10 ArcGlide THC Instruction Manual 806450

Contents

6 Wiring Diagrams ....................................................................................................................... 241

Wiring diagram symbols ........................................................................................................................................................... 242
1 – Lifter interface board (141097) ....................................................................................................................................... 245
2 – THC control interface board (141088) ......................................................................................................................... 246
3 – THC Processor board (141091) ..................................................................................................................................... 247
4 – HMI processor board (141082) ...................................................................................................................................... 248

A ArcGlide THC Serial Communication Protocol ................................................................ 249

Overview ....................................................................................................................................................................................... 249
ArcGlide THC Operation .......................................................................................................................................................... 249
Serial Protocol ............................................................................................................................................................................. 249
ArcGlide THC Responses ................................................................................................................................................ 250
Calculating the Checksum ............................................................................................................................................... 250
ArcGlide Commands and Examples ...................................................................................................................................... 251
Setup Commands ...................................................................................................................................................................... 252
Operating Commands ............................................................................................................................................................... 255
ArcGlide THC Extended Commands .................................................................................................................................... 260
ArcGlide THC to Command THC error conversions ......................................................................................................... 266

B ArcGlide THC Serial Communication Installation ........................................................... 269

ArcGlide THC Instruction Manual 806450 11

Contents

12 ArcGlide THC Instruction Manual 806450

Safety

RECOGNIZE SAFETY DANGER WARNING CAUTION

INFORMATION Hypertherm uses American National Standards Institute
guidelines for safety signal words and symbols. A signal
The symbols shown in this section are used to identify word DANGER or WARNING is used with a safety
potential hazards. When you see a safety symbol in this symbol. DANGER identifies the most serious hazards.
manual or on your machine, understand the potential
for personal injury, and follow the related instructions to • DANGER and WARNING safety labels are located on
avoid the hazard. your machine near specific hazards.
• DANGER safety messages precede related
instructions in the manual that will result in serious
FOLLOW SAFETY injury or death if not followed correctly.
INSTRUCTIONS • WARNING safety messages precede related
instructions in this manual that may result in injury or
Read carefully all safety messages in this manual and death if not followed correctly.
safety labels on your machine. • CAUTION safety messages precede related
instructions in this manual that may result in minor
• Keep the safety labels on your machine in good injury or damage to equipment if not followed correctly.
condition. Replace missing or damaged labels
immediately.
• Learn how to operate the machine and how to use
the controls properly. Do not let anyone operate it
without instruction.
• Keep your machine in proper working condition.
Unauthorized modifications to the machine may
affect safety and machine service life.

ELECTRICAL HAZARDS
• Only trained and authorized personnel may open this • If the equipment must have power when the enclosure
equipment. is open for servicing, arc flash explosion hazards may
• If the equipment is permanently connected, turn it off, exist. Follow ALL local requirements (NFPA 70E in the
and lock out/tag out power before the enclosure is USA) for safe work practices and for Personal
opened. Protective Equipment when servicing energized
equipment.
• If power is supplied to the equipment with a cord,
unplug the unit before the enclosure is opened. • The enclosure shall be closed and the proper earth
ground continuity to the enclosure verified prior to
• Lockable disconnects or lockable plug covers must be
operating the equipment after moving, opening, or
provided by others.
servicing.
• Wait 5 minutes after removal of power before entering
• Always follow these instructions for disconnecting
the enclosure to allow stored energy to discharge.
power before inspecting or changing torch
consumable parts.

Safety and Compliance SC-13

Safety

ELECTRIC SHOCK CAN KILL

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

SC-14 Safety and Compliance

Safety

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
present an explosion hazard. Keep flames away from
• Quench hot metal or allow it to cool before handling cylinders and hoses that contain methane or hydrogen
or before letting it touch combustible materials. mixtures. Keep flames and sparks away from the torch
• Never cut containers with potentially flammable when using methane or argon-hydrogen plasma.
materials inside – they must be emptied and properly
cleaned first. WARNING
• Ventilate potentially flammable atmospheres before Hydrogen Detonation with
cutting. Aluminum Cutting
• When cutting with oxygen as the plasma gas, an
• Do not cut aluminum underwater or with water
exhaust ventilation system is required.
touching the underside of the aluminum.
Explosion prevention • Cutting aluminum underwater or with the water
touching the underside of the aluminum can result in
• Do not use the plasma system if explosive dust or an explosive condition that can detonate during
vapors may be present. plasma cutting operations.
• Do not cut pressurized cylinders, pipes, or any
closed container.
WARNING
• Do not cut containers that have held combustible Explosion Hazard
materials. Underwater Cutting with Fuel Gases

• Do not cut under water with fuel gases containing

hydrogen.
• Cutting under water with fuel gases containing
hydrogen can result in an explosive condition that
can detonate during plasma cutting operations.

Safety and Compliance SC-15

Safety

TOXIC FUMES CAN CAUSE INJURY OR DEATH

The plasma arc by itself is the heat source used for The air quality level in any relevant workplace depends
cutting. Accordingly, although the plasma arc has not on site-specific variables such as:
been identified as a source of toxic fumes, the material • Table design (wet, dry, underwater).
being cut can be a source of toxic fumes or gases that
• Material composition, surface finish, and composition
deplete oxygen.
of coatings.
Fumes produced vary depending on the metal that is • Volume of material removed.
cut. Metals that may release toxic fumes include, but are • Duration of cutting or gouging.
not limited to, stainless steel, carbon steel, zinc • Size, air volume, ventilation and filtration of the work
(galvanized), and copper. area.
• Personal protective equipment.
In some cases, the metal may be coated with a
substance that could release toxic fumes. Toxic coatings • Number of welding and cutting systems in operation.
include, but are not limited to, lead (in some paints), • Other site processes that may produce fumes.
cadmium (in some paints and fillers), and beryllium.
If the workplace must conform to national or local
regulations, only monitoring or testing done at the site
Gases produced by plasma cutting vary based on the
can determine whether the site is above or below
material to be cut and the method of cutting, but may
allowable levels.
include ozone, oxides of nitrogen, hexavalent chromium,
hydrogen, and other substances if such are contained in
To reduce the risk of exposure to fumes:
or released by the material being cut.
• Remove all coatings and solvents from the metal
Caution should be taken to minimize exposure to fumes before cutting.
produced by any industrial process. Depending upon • Use local exhaust ventilation to remove fumes from
the chemical composition and concentration of the the air.
fumes (as well as other factors, such as ventilation), • Do not inhale fumes. Wear an air-supplied respirator
there may be a risk of physical illness, such as birth when cutting any metal coated with, containing, or
defects or cancer. suspected to contain toxic elements.
• Assure that those using welding or cutting
It is the responsibility of the equipment and site owner
equipment, as well as air-supplied respiration
to test the air quality in the area where the equipment is
devices, are qualified and trained in the proper use of
used and to ensure that the air quality in the workplace
such equipment.
meets all local and national standards and regulations.
• Never cut containers with potentially toxic materials
inside. Empty and properly clean the container first.
• Monitor or test the air quality at the site as needed.
• Consult with a local expert to implement a site plan
to ensure safe air quality.

SC-16 Safety and Compliance

Safety

GROUNDING SAFETY

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

STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS

Use proper precautions when handling printed circuit boards:

• Store PC boards in anti-static containers.

• Wear a grounded wrist strap when handling PC boards.

Safety and Compliance SC-17

Safety

COMPRESSED GAS EQUIPMENT GAS CYLINDERS CAN

SAFETY EXPLODE IF DAMAGED

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

A PLASMA ARC CAN CAUSE INJURY AND BURNS

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

SC-18 Safety and Compliance

Safety

ARC RAYS CAN BURN EYES AND SKIN

Eye protection Plasma arc rays produce intense • Flame-retardant clothing to cover all exposed areas.
visible and invisible (ultraviolet and infrared) rays that • Cuffless trousers to prevent entry of sparks and slag.
can burn eyes and skin.
• Remove any combustibles, such as a butane lighter
or matches, from your pockets before cutting.
• Use eye protection in accordance with applicable
national and local codes. Cutting area Prepare the cutting area to reduce
• Wear eye protection (safety glasses or goggles with reflection and transmission of ultraviolet light:
side shields, and a welding helmet) with appropriate
lens shading to protect your eyes from the arc’s • Paint walls and other surfaces with dark colors to
ultraviolet and infrared rays. reduce reflection.
• Use protective screens or barriers to protect others
Skin protection Wear protective clothing to protect
from flash and glare.
against burns caused by ultraviolet light, sparks, and hot
metal. • Warn others not to watch the arc. Use placards or
signs.
• Gauntlet gloves, safety shoes and hat.

Minimum Suggested shade

Arc current protective shade number for OSHA 29CFR Europe
(amps) number comfort 1910.133(a)(5) EN168:2002
(ANSI Z49.1:2005) (ANSI Z49.1:2005)
Less than 40 A 5 5 8 9
41 to 60 A 6 6 8 9
61 to 80 A 8 8 8 9
81 to 125 A 8 9 8 9
126 to 150 A 8 9 8 10
151 to 175 A 8 9 8 11
176 to 250 A 8 9 8 12
251 to 300 A 8 9 8 13
301 to 400 A 9 12 9 13
401 to 800 A 10 14 10 N/A

Safety and Compliance SC-19

Safety

PACEMAKER AND HEARING AID OPERATION

Pacemaker and hearing aid operation can be affected To reduce magnetic field hazards:
by magnetic fields from high currents. • Keep both the work cable and the torch lead to one
side, away from your body.
Pacemaker and hearing aid wearers should consult a
• Route the torch leads as close as possible to the
doctor before going near any plasma arc cutting and
work cable.
gouging operations.
• Do not wrap or drape the torch lead or work cable
around your body.
• Keep as far away from the power supply as possible.

NOISE CAN DAMAGE HEARING

Cutting with a plasma arc can exceed acceptable noise Use ear protectors if the noise is disruptive or if there is
levels as defined by local codes in many applications. a risk of hearing damage after all other engineering and
Prolonged exposure to excessive noise can damage administrative controls have been implemented. If
hearing. Always wear proper ear protection when hearing protection is required, wear only approved
cutting or gouging, unless sound pressure level personal protective devices such as ear muffs or ear
measurements taken at the installed site have verified plugs with a noise reduction rating appropriate for the
personal hearing protection is not necessary per situation. Warn others in the area of possible noise
relevant international, regional, and local codes. hazards. In addition, ear protection can prevent hot
splatter from entering the ear.
Significant noise reduction can be obtained by adding
simple engineering controls to cutting tables such as
barriers or curtains positioned between the plasma arc
and the workstation; and/or locating the workstation
away from the plasma arc. Implement administrative
controls in the workplace to restrict access, limit
operator exposure time, screen off noisy working areas
and/or take measures to reduce reverberation in
working areas by putting up noise absorbers.

A PLASMA ARC CAN DAMAGE FROZEN PIPES

Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch.

SC-20 Safety and Compliance

Safety

DRY DUST COLLECTION INFORMATION

At some sites, dry dust can represent a potential Note 1 – Hypertherm’s interpretation of these new
explosion hazard. requirements is that unless a site-specific evaluation
has been completed to determine that all dust
The U.S. National Fire Protection Association’s 2007 generated is not combustible, the 2007 edition of
edition of NFPA standard 68, “Explosion Protection by NFPA 68 requires the use of explosion vents designed
Deflagration Venting,” provides requirements for the to the worst-case Kst value (see annex F) that could be
design, location, installation, maintenance, and use of generated from dust so that the explosion vent size and
devices and systems to vent combustion gases and type can be designed. NFPA 68 does not specifically
pressures after any deflagration event. Consult with the identify plasma cutting or other thermal cutting
manufacturer or installer of any dry dust collection processes as requiring deflagration venting systems,
system for applicable requirements before you install a but it does apply these new requirements to all dry dust
new dry dust collection system or make significant collection systems.
changes in the process or materials used with an
existing dry dust collection system. Note 2 – Users of Hypertherm manuals should consult
and comply with all applicable federal, state, and local
Consult your local “Authority Having Jurisdiction” (AHJ) laws and regulations. Hypertherm does not, by the
to determine whether any edition of NFPA 68 has been publication of any Hypertherm manual, intend to urge
“adopted by reference” in your local building codes. action that is not in compliance with all applicable
regulations and standards, and this manual may never
Refer to NFPA68 for definitions and explanations of be construed as doing so.
regulatory terms such as deflagration, AHJ, adopted by
reference, the Kst value, deflagration index, and other
terms.

Safety and Compliance SC-21

Safety

LASER RADIATION
Exposure to the laser output can result in serious eye injury. Avoid direct eye exposure.

For your convenience and safety, on Hypertherm products that use a laser, one of the following laser radiation labels
has been applied on the product near where the laser beam exits the enclosure. The maximum output (mV),
wavelength emitted (nM) and, if appropriate, the pulse duration is also provided.

Additional laser safety instructions: • Modifying the laser or product in any way can
increase the risk of laser radiation.
• Consult with an expert on local laser regulations. • Use of adjustments or performance of procedures
Laser safety training may be required. other than those specified in this manual may result
• Do not allow untrained persons to operate the laser. in hazardous laser radiation exposure.
Lasers can be dangerous in the hands of untrained • Do not operate in explosive atmospheres, such as in
users. the presence of flammable liquids, gases, or dust.
• Do not look into the laser aperture or beam at any • Use only laser parts and accessories that are
time. recommended or provided by the manufacturer for
• Position the laser as instructed to avoid unintentional your model.
eye contact. • Repairs and servicing MUST be performed by
• Do not use the laser on reflective workpieces. qualified personnel.
• Do not use optical tools to view or reflect the laser • Do not remove or deface the laser safety label.
beam.
• Do not disassemble or remove the laser or aperture
cover.

ADDITIONAL SAFETY INFORMATION

1. ANSI Standard Z49.1, Safety in Welding and Cutting, 6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in
American Welding Society, 550 LeJeune Road P.O. Box Cylinders, Compressed Gas Association 1235 Jefferson Davis
351020, Miami, FL 33135 Highway, Arlington, VA 22202
2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting 7. CSA Standard W117.2, Code for Safety in Welding and
and Welding Processes, American National Standards Institute Cutting, Canadian Standards Association Standard Sales
1430 Broadway, New York, NY 10018 178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada
3. ANSI Standard Z87.1, Safe Practices for Occupation and 8. NFPA Standard 51B, Cutting and Welding Processes,
Educational Eye and Face Protection, American National National Fire Protection Association 470 Atlantic Avenue,
Standards Institute, 1430 Broadway, New York, NY 10018 Boston, MA 02210
4. AWS F4.1, Recommended Safe Practices for the Preparation 9. NFPA Standard 70–1978, National Electrical Code, National
for Welding and Cutting of Containers and Piping That Have Fire Protection Association, 470 Atlantic Avenue, Boston, MA
Held Hazardous Substances, American Welding Society 550 02210
LeJeune Road, P.O. Box 351040, Miami, FL 33135 10. OSHA, Safety and Health Standards, 29FR 1910 U.S.
5. AWS F5.2, Recommended Safe Practices for Plasma Arc Government Printing Office, Washington, D.C. 20402
Cutting, American Welding Society 550 LeJeune Road, P.O. 11. AWS Safety and Health Fact Sheets, American Welding
Box 351040, Miami, FL 33135 Society 550 LeJeune Road, P.O. Box 351040, Miami, FL
33135 www.aws.org/technical/facts/

SC-22 Safety and Compliance

Safety

WARNING LABELS
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.

Read and follow these instructions, employer safety

practices, and material safety data sheets. Refer to WARNING AVERTISSEMENT
ANS Z49.1, “Safety in Welding, Cutting and Allied
Processes” from American Welding Society Plasma cutting can be injurious to operator and persons Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se
(http://www.aws.org) and OSHA Safety and Health in the work area. Consult manual before operating. Failure trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le
Standards, 29 CFR 1910 (http://www.osha.gov). to follow all these safety instructions can result in death. non respect des ces instructions de sécurité peut entraîner la mort.

1. Cutting sparks can cause explosion or fire. 1. Les étincelles de coupage peuvent provoquer une explosion
1.1 Do not cut near flammables. ou un incendie.
1.2 Have a fire extinguisher nearby and ready to use. 1.1 Ne pas couper près des matières inflammables.
1.3 Do not use a drum or other closed container as a cutting table. 1.2 Un extincteur doit être à proximité et prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.
2. Plasma arc can injure and burn; point the nozzle away 2. L’arc plasma peut blesser et brûler; éloigner la buse de soi.
from yourself. Arc starts instantly when triggered. Il s’allume instantanément quand on l’amorce;
2.1 Turn off power before disassembling torch. 2.1 Couper l’alimentation avant de démonter la torche.
2.2 Do not grip the workpiece near the cutting path. 2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.
2.3 Wear complete body protection. 2.3 Se protéger entièrement le corps.

3. Hazardous voltage. Risk of electric shock or burn. 3. Tension dangereuse. Risque de choc électrique ou de brûlure.
3.1 Wear insulating gloves. Replace gloves when wet or damaged. 3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou
3.2 Protect from shock by insulating yourself from work and ground. endommagés.
3.3 Disconnect power before servicing. Do not touch live parts. 3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.
3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.

4. Plasma fumes can be hazardous. 4. Les fumées plasma peuvent être dangereuses.
4.1 Do not inhale fumes. 4.1 Ne pas inhaler les fumées
4.2 Use forced ventilation or local exhaust to remove the fumes. 4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.
4.3 Do not operate in closed spaces. Remove fumes with ventilation. 4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.

5. Arc rays can burn eyes and injure skin. 5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.
5.1 Wear correct and appropriate protective equipment to protect 5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les
head, eyes, ears, hands, and body. Button shirt collar. Protect ears oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles
from noise. Use welding helmet with the correct shade of ﬁlter. contre le bruit. Utiliser un masque de soudeur avec un ﬁltre de nuance appropriée.

6. Become trained. Only qualified personnel should operate this 6. Suivre une formation. Seul le personnel qualifié a le droit de faire
equipment. Use torches specified in the manual. Keep non-qualified fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le
personnel and children away. manual. Le personnel non qualifié et les enfants doivent se tenir à l’écart.
7. Do not remove, destroy, or cover this label. 7. Ne pas enlever, détruire ni couvrir cette étiquette.
Replace if it is missing, damaged, or worn (PN 110584 Rev C). La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C).

Safety and Compliance SC-23

Safety

Warning labels 1. Cutting sparks can cause explosion

or fire.
This warning label is affixed to some power supplies. It is important that the
1.1 Do not cut near flammables.
operator and maintenance technician understand the intent of these
warning symbols as described. The numbered text corresponds to the 1.2 Have a fire extinguisher nearby and
numbered boxes on the label. ready to use.
1.3 Do not use a drum or other closed
container as a cutting table.
2. Plasma arc can injure and burn; point
the nozzle away from yourself. Arc
starts instantly when triggered.
2.1 Turn off power before disassembling
torch.
2.2 Do not grip the workpiece near the
cutting path.
2.3 Wear complete body protection.
3. Hazardous voltage. Risk of electric
shock or burn.
3.1 Wear insulating gloves. Replace
gloves when wet or damaged.
3.2 Protect from shock by insulating
yourself from work and ground.
3.3 Disconnect power before servicing.
Do not touch live parts.
4. Plasma fumes can be hazardous.
4.1 Do not inhale fumes.
4.2 Use forced ventilation or local exhaust
to remove the fumes.
4.3 Do not operate in closed spaces.
Remove fumes with ventilation.
5. Arc rays can burn eyes and injure
skin.
5.1 Wear correct and appropriate
protective equipment to protect head,
eyes, ears, hands, and body. Button
shirt collar. Protect ears from noise.
Use welding helmet with the correct
shade of filter.
6. Become trained. Only qualified
personnel should operate this
equipment. Use torches specified in
the manual. Keep non-qualified
personnel and children away.
7. Do not remove, destroy, or cover this
label. Replace if it is missing,
damaged, or worn.

SC-24 Safety and Compliance

Safety

Symbols and marks

Your product may have one or more of the following markings on or near the data plate. Due to differences and conflicts
in national regulations, not all marks are applied to every version of a product.

S mark
The S mark indicates that the power supply and torch are suitable for operations carried out in environments
with increased hazard of electrical shock according to IEC 60974-1.

CSA mark
Products with a CSA mark meet the United States and Canadian regulations for product safety. The products
were evaluated, tested, and certified by CSA-International. Alternatively, the product may have a mark by one
of the other Nationally Recognized Testing Laboratories (NRTL) accredited in both the United States and
Canada, such as UL or TÜV.

CE mark
The CE marking signifies the manufacturer’s declaration of conformity to applicable European directives and
standards. Only those versions of products with a CE marking located on or near the data plate have been
tested for compliance with the European Low Voltage Directive and the European Electromagnetic
Compatibility (EMC) Directive. EMC filters needed to comply with the European EMC Directive are
incorporated within versions of the product with a CE marking.

Eurasian Customs Union (CU) mark

CE versions of products that include an EAC mark of conformity meet the product safety and EMC
requirements for export to Russia, Belarus, and Kazakhstan.

GOST-TR mark
CE versions of products that include a GOST-TR mark of conformity meet the product safety and EMC
requirements for export to the Russian Federation.

C-Tick mark
CE versions of products with a C-Tick mark comply with the EMC regulations required for sale in Australia
and New Zealand.

CCC mark
s
The China Compulsory Certification (CCC) mark indicates that the product has been tested and found
compliant with product safety regulations required for sale in China.

UkrSEPRO mark
The CE versions of products that include a UkrSEPRO mark of conformity meet the product safety and EMC
requirements for export to the Ukraine.

Serbian AAA mark

CE versions of products that include a AAA Serbian mark meet the product safety and EMC requirements for
export to Serbia.

Safety and Compliance SC-25

Safety

SC-26 Safety and Compliance

Product Stewardship

Introduction Differences in national standards

Hypertherm maintains a global Regulatory Management System to Nations may apply different performance, safety or other standards.
ensure that products comply with regulatory and environmental National differences in standards include, but are not limited to:
requirements. • Voltages
• Plug and cord ratings
National and local safety regulations • Language requirements

National and Local safety regulations shall take precedence over any • Electromagnetic compatibility requirements
instructions provided with the product. The product shall be imported, These differences in national or other standards may make it impossible
installed, operated and disposed of in accordance with national and local
or impractical for all certification test marks to be placed on the same
regulations applicable to the installed site.
version of a product. For example, the CSA versions of Hypertherm’s
products do not comply with European EMC requirements, and therefore
Certification test marks do not have a CE marking on the data plate.

Countries that require CE marking or have compulsory EMC regulations

Certified products are identified by one or more certification test marks
must use CE versions of Hypertherm products with the CE marking on
from accredited testing laboratories. The certification test marks are
located on or near the data plate. the data plate. These include, but are not limited to:
• Australia
Each certification test mark means that the product and its safety-critical
• New Zealand
components conform to the relevant national safety standards as
reviewed and determined by that testing laboratory. Hypertherm places • Countries in the European Union
a certification test mark on its products only after that product is • Russia
manufactured with safety-critical components that have been authorized
by the accredited testing laboratory. It is important that the product and its certification test mark be suitable
for the end-use installation site. When Hypertherm products are shipped
Once the product has left the Hypertherm factory, the certification test to one country for export to another country; the product must be
marks are invalidated if any of the following occurs: configured and certified properly for the end-use site.
• The product is modified in a manner that creates a hazard or
non-conformance with the applicable standards.
Safe installation and use of shape cutting
• Safety-critical components are replaced with unauthorized spare
parts.
equipment
• Any unauthorized assembly, or accessory that uses or generates a IEC 60974-9, titled Arc Welding Equipment – Installation and use,
hazardous voltage is added. provides guidance in the safe installation and use of shape cutting
• There is any tampering with a safety circuit or other feature that is equipment and the safe performance of cutting operations. The
designed into the product as part of the certification, or otherwise. requirements of national and local regulations shall be taken into
consideration during installation, including, but not limited to, grounding
CE marking constitutes a manufacturer’s declaration of conformity to or protective earth connections, fuses, supply disconnecting device, and
applicable European directives and standards. Only those versions of type of supply circuit. Read these instructions before installing the
Hypertherm products with a CE Marking located on or near the data equipment. The first and most important step is the safety assessment of
plate have been tested for compliance with the European Low Voltage the installation.
Directive and the European EMC Directive. EMC filters needed to
comply with the European EMC Directive are incorporated within The safety assessment must be performed by an expert, and determines
versions of the power supply with a CE Marking. what steps are necessary to create a safe environment, and what
precautions should be adopted during the actual installation and
Certificates of compliance for Hypertherm products are available from operation.
the Downloads Library on the Hypertherm web site at
https://www.hypertherm.com.
Procedures for periodic inspection and
testing
Where required by local national regulations, IEC 60974-4 specifies test
procedures for periodic inspection and after repair or maintenance, to
ensure electrical safety for plasma cutting power sources built in
conformity with IEC 60974-1. Hypertherm performs the continuity of the
protective circuit and insulation resistance tests in the factory as
non-operating tests. The tests are performed with the power and ground
connections removed.

Safety and Compliance SC-27

English
Product Stewardship

Hypertherm also removes some protective devices that would cause Higher-level systems
false test results. Where required by local national regulations, a label
shall be attached to the equipment to indicate that it has passed the When a system integrator adds additional equipment; such as cutting
tests prescribed by IEC 60974-4. The repair report shall indicate the tables, motor drives, motion controllers or robots; to a Hypertherm
results of all tests unless an indication is made that a particular test has plasma cutting system, the combined system may be considered a
not been performed. higher-level system. A higher-level system with hazardous moving parts
may constitute industrial machinery or robotic equipment, in which case
the OEM or end-use customer may be subject to additional regulations
Qualification of test personnel and standards than those relevant to the plasma cutting system as
manufactured by Hypertherm.
Electrical safety tests for shape cutting equipment can be hazardous and
shall be carried out by an expert in the field of electrical repair, preferably It is the responsibility of the end-use customer and the OEM to perform a
someone also familiar with welding, cutting, and allied processes. The risk assessment for the higher-level system, and to provide protection
safety risks to personnel and equipment, when unqualified personnel are against hazardous moving parts. Unless the higher-level system is
performing these tests, may be much greater than the benefit of periodic certified when the OEM incorporates Hypertherm products into it, the
inspection and testing. installation also may be subject to approval by local authorities. Seek
advice from legal counsel and local regulatory experts if you are uncertain
Hypertherm recommends that only visual inspection be performed unless
the electrical safety tests are specifically required by local national about compliance.
regulations in the country where the equipment is installed. External interconnecting cables between component parts of the higher
level system must be suitable for contaminants and movement as
Residual current devices (RCDs) required by the final end use installation site. When the external
interconnecting cables are subject to oil, dust, water, or other
In Australia and some other countries, local codes may require the use of contaminants, hard usage ratings may be required.
a Residual Current Devices (RCD) when portable electrical equipment is
When external interconnecting cables are subject to continuous
used in the workplace or at construction sites to protect operators from
movement, constant flexing ratings may be required. It is the
electrical faults in the equipment. RCDs are designed to safely
responsibility of the end-use customer or the OEM to ensure the cables
disconnect the mains electrical supply when an imbalance is detected
are suitable for the application. Since there are differences in the ratings
between the supply and return current (there is a leakage current to
and costs that can be required by local regulations for higher level
earth). RCDs are available with both fixed and adjustable trip currents
systems, it is necessary to verify that any external interconnecting cables
between 6 to 40 milliamperes and a range of trip times up to
are suitable for the end-use installation site.
300 milliseconds selected for the equipment installation, application and
intended use. Where RCDs are used, the trip current and trip time on
RCDs should be selected or adjusted high enough to avoid nuisance
tripping during normal operation of the plasma cutting equipment and
low enough in the extremely unlikely event of an electrical fault in the
equipment to disconnect the supply before the leakage current under a
fault condition can pose a life threatening electrical hazard to operators.

To verify that the RCDs continue to function properly over time, both the
trip current and the trip time should be tested periodically. Portable
electrical equipment and RCDs used in commercial and industrial areas
in Australia and New Zealand are tested to the Australian standard
AS/NZS 3760. When you test the insulation of plasma cutting
equipment to AS/NZS 3760, measure the insulation resistance
according to Appendix B of the standard, at 250 VDC with the power
switch in the ON position to verify proper testing and to avoid the false
failure of the leakage current test. False failures are possible because the
metal oxide varistors (MOVs) and electromagnetic compatibility (EMC)
filters, used to reduce emissions and protect the equipment from power
surges, may conduct up to 10 milliamperes leakage current to earth
under normal conditions.

If you have any questions regarding the application or interpretation of

any IEC standards described here, you are required to consult with an
appropriate legal or other advisor familiar with the International
Electrotechnical standards, and shall not rely on Hypertherm in any
respect regarding the interpretation or application of such standards.

SC-28 Safety and Compliance

English
Environmental Stewardship

Introduction • In the United States, check all federal, state, and local laws.
• In the European Union, check the EU directives, national, and local
The Hypertherm Environmental Specification requires RoHS, WEEE and laws. For more information, visit www.hypertherm.com/weee.
REACH substance information to be provided by Hypertherm’s • In other countries, check national and local laws.
suppliers.
• Consult with legal or other compliance experts when appropriate.
Product environmental compliance does not address the indoor air
quality or environmental release of fumes by the end user. Any materials
that are cut by the end user are not provided by Hypertherm with the
The WEEE Directive
product. The end user is responsible for the materials being cut as well On January 27, 2003, the European Parliament and the Council of the
as for safety and air quality in the workplace. The end user must be aware European Union authorized Directive 2002/96/EC or WEEE (Waste
of the potential health risks of the fumes released from the materials Electrical and Electronic Equipment).
being cut and comply with all local regulations.
As required by the legislation, any Hypertherm product covered by the
directive and sold in the EU after August 13, 2005 is marked with the
National and local environmental WEEE symbol. This directive encourages and sets specific criteria for
regulations the collection, handling, and recycling of EEE waste. Consumer and
business-to-business wastes are treated differently (all Hypertherm
National and local environmental regulations shall take precedence over products are considered business-to-business). Disposal instructions for
any instructions contained in this manual. the CE versions of Powermax plasma systems can be found at
www.hypertherm.com/weee.
The product shall be imported, installed, operated and disposed of in
accordance with all national and local environmental regulations The URL is printed on the symbol-only warning label for each of these
applicable to the installed site. CE version Powermax series units shipped since 2006. The CSA
versions of Powermax and other products manufactured by Hypertherm
The European Environmental regulations are discussed later in are either out of scope or exempt from WEEE.
The WEEE Directive.

The REACH regulation

The RoHS directive
The REACH regulation (1907/2006), in force since June 1, 2007, has an
Hypertherm is committed to complying with all applicable laws and
impact on chemicals available to the European market. The REACH
regulations, including the European Union Restriction of Hazardous
regulation requirements for component manufacturers states that the
Substances (RoHS) Directive that restricts the use of hazardous component shall not contain more than 0.1% by weight of the
materials in electronics products. Hypertherm exceeds RoHS Directive
Substances of Very High Concern (SVHC).
compliance obligations on a global basis.
Component manufacturers and other downstream users, such as
Hypertherm continues to work toward the reduction of RoHS materials in
Hypertherm, are obligated to obtain assurances from its suppliers that all
our products, which are subject to the RoHS Directive, except where it is
chemicals used in or on Hypertherm products will have a European
widely recognized that there is no feasible alternative. Chemical Agency (ECHA) registration number. To provide chemical
Declarations of RoHS Conformity have been prepared for the current information as required by the REACH regulation, Hypertherm requires
CE versions of Powermax plasma cutting systems manufactured by suppliers to provide REACH declarations and identify any known use of
Hypertherm. There is also a “RoHS mark” on the Powermax CE versions REACH SVHC. Any use of SVHC in amounts exceeding 0.1% w/w of
below the “CE Marking” on the data plate of CE versions of Powermax the parts has been eliminated. The MSDS contains a full disclosure of all
series units shipped since 2006. Parts used in CSA versions of substances in the chemical and can be used to verify REACH SVHC
Powermax and other products manufactured by Hypertherm that are compliance.
either out of scope or exempt from RoHS are continuously being
The lubricants, sealants, coolants, adhesives, solvents, coatings and
converted to RoHS compliance in anticipation of future requirements. other preparations or mixtures used by Hypertherm in, on, for, or with its
shape cutting equipment are used in very small quantities (except the
Proper disposal of Hypertherm products coolant) and are commercially available with multiple sources that can
and will be replaced in the event of a supplier problem associated with
Hypertherm plasma cutting systems, like all electronic products, may REACH Registration or REACH Authorization (SVHCs).
contain materials or components, such as printed circuit boards, that
cannot be discarded with ordinary waste. It is your responsibility to
dispose of any Hypertherm product or component part in an
environmentally acceptable manner according to national and local
codes.

Safety and Compliance SC-29

English
Environmental Stewardship

Proper handling and safe use of chemicals

Chemical Regulations in the USA, Europe, and other locations require
that Material Safety Data Sheets (MSDS) be made available for all
chemicals. The list of chemicals is provided by Hypertherm. The MSDS
are for chemicals provided with the product and other chemicals used in
or on the product. MSDS can be downloaded from the Downloads
Library on the Hypertherm web site at https://www.hypertherm.com.
On the Search screen, insert MSDS in the document title and click on
Search.

In the USA, OSHA does not require Material Safety Data Sheets for
articles such as electrodes, swirl rings, retaining caps, nozzles, shields,
deflectors and other solid parts of the torch.

Hypertherm does not manufacture or provide the materials that are cut
and has no knowledge whether the fumes released from materials that
are cut will pose a physical hazard or health risk. Please consult with your
supplier or other technical advisor if you need guidance concerning the
properties of the material you will cut using a Hypertherm product.

Fumes emission and air quality

Note: The following information on air quality is intended for general
information only and should not be used as a substitute for reviewing and
implementing applicable government regulations or legal standards in
the country where the cutting equipment will be installed and operated.

In the USA, the National Institute for Occupational Safety and Health
(NIOSH) Manual of Analytical Methods (NMAM) is a collection of
methods for sampling and analyzing contaminants in workplace air.
Methods published by others, such as OSHA, MSHA, EPA, ASTM, ISO
or commercial suppliers of sampling and analytical equipment, may have
advantages over NIOSH methods.

For example, ASTM Practice D 4185 is a standard practice for the

collection, dissolution, and determination of trace metals in workplace
atmospheres. The sensitivity, detection limit, and optimum working
concentrations for 23 metals are listed in ASTM D 4185. An industrial
hygienist should be used to determine the optimum sampling protocol,
considering analytical accuracy, cost, and optimum sample number.
Hypertherm uses a third party industrial hygienist to perform and interpret
air quality testing results taken by air sampling equipment positioned at
operator stations in Hypertherm buildings where plasma cutting tables
are installed and operated.

Where applicable, Hypertherm also uses a third party industrial hygienist

to obtain air and water permits.

If you are not fully aware and up to date on all applicable government
regulations and legal standards for the installation site, you should
consult a local expert prior to purchasing, installing, and operating the
equipment.

SC-30 Safety and Compliance

English
Electromagnetic Compatibility (EMC)

Introduction Methods of reducing emissions

Hypertherm’s CE-marked equipment is built in compliance with standard
Mains supply
EN60974-10. The equipment should be installed and used in
accordance with the information below to achieve electromagnetic Cutting equipment must be connected to the mains supply according to
compatibility. the manufacturer’s recommendations. If interference occurs, it may be
necessary to take additional precautions such as filtering of the mains
The limits required by EN60974-10 may not be adequate to completely
supply.
eliminate interference when the affected equipment is in close proximity
or has a high degree of sensitivity. In such cases it may be necessary to Consideration should be given to shielding the supply cable of
use other measures to further reduce interference. permanently installed cutting equipment, in metallic conduit or
equivalent. Shielding should be electrically continuous throughout its
This cutting equipment is designed for use only in an industrial
length. The shielding should be connected to the cutting mains supply so
environment.
that good electrical contact is maintained between the conduit and the
cutting power source enclosure.
Installation and use
The user is responsible for installing and using the plasma equipment Maintenance of cutting equipment
according to the manufacturer’s instructions.
The cutting equipment must be routinely maintained according to the
If electromagnetic disturbances are detected then it shall be the manufacturer’s recommendations. All access and service doors and
responsibility of the user to resolve the situation with the technical covers should be closed and properly fastened when the cutting
assistance of the manufacturer. In some cases this remedial action may equipment is in operation. The cutting equipment should not be modified
be as simple as earthing the cutting circuit, see Earthing of the in any way, except as set forth in and in accordance with the
workpiece. In other cases, it could involve constructing an manufacturer’s written instructions. For example, the spark gaps of arc
electromagnetic screen enclosing the power source and the work striking and stabilizing devices should be adjusted and maintained
complete with associated input filters. In all cases, electromagnetic according to the manufacturer’s recommendations.
disturbances must be reduced to the point where they are no longer
troublesome.
Cutting cables
Assessment of area The cutting cables should be kept as short as possible and should be
positioned close together, running at or close to the floor level.
Before installing the equipment, the user shall make an assessment of
potential electromagnetic problems in the surrounding area. The Equipotential bonding
following shall be taken into account:
Bonding of all metallic components in the cutting installation and
a. Other supply cables, control cables, signaling and telephone adjacent to it should be considered.
cables; above, below and adjacent to the cutting equipment.
b. Radio and television transmitters and receivers. However, metallic components bonded to the workpiece will increase
the risk that the operator could receive a shock by touching these
c. Computer and other control equipment. metallic components and the electrode (nozzle for laser heads) at the
d. Safety critical equipment, for example guarding of industrial same time.
equipment.
The operator should be insulated from all such bonded metallic
e. Health of the people around, for example the use of pacemakers components.
and hearing aids.
f. Equipment used for calibration or measurement. Earthing of the workpiece
g. Immunity of other equipment in the environment. User shall Where the workpiece is not bonded to earth for electrical safety, nor
ensure that other equipment being used in the environment is connected to earth because of its size and position, for example, ship’s
compatible. This may require additional protection measures. hull or building steel work, a connection bonding the workpiece to earth
h. Time of day that cutting or other activities are to be carried out. may reduce emissions in some, but not all instances. Care should be
taken to prevent the earthing of the workpiece increasing the risk of injury
The size of the surrounding area to be considered will depend on the to users, or damage to other electrical equipment. Where necessary, the
structure of the building and other activities that are taking place. The connection of the workpiece to earth should be made by a direct
surrounding area may extend beyond the boundaries of the premises. connection to the workpiece, but in some countries where direct
connection is not permitted, the bonding should be achieved by suitable
capacitances selected according to national regulations.

Safety and Compliance SC-31

Electromagnetic Compatibility (EMC)

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

Screening and shielding

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

SC-32 Safety and Compliance

Warranty

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

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

General
Patent indemnity
Hypertherm Inc. warrants that its Products shall be free from defects in
materials and workmanship for the specific periods of time set forth Except only in cases of products not manufactured by Hypertherm or
herein and as follows: if Hypertherm is notified of a defect (i) with respect manufactured by a person other than Hypertherm not in strict conformity
to the plasma power supply within a period of two (2) years from the date with Hypertherm’s specifications and in cases of designs, processes,
of its delivery to you, with the exception of Powermax brand power formulae, or combinations not developed or purported to be developed
supplies, which shall be within a period of three (3) years from the date of by Hypertherm, Hypertherm will have the right to defend or settle, at its
delivery to you, and (ii) with respect to the torch and leads within a period own expense, any suit or proceeding brought against you alleging that
of one (1) year from its date of delivery to you, with the exception of the the use of the Hypertherm product, alone and not in combination with
HPRXD short torch with integrated lead, which shall be within a period of any other product not supplied by Hypertherm, infringes any patent of
six (6) months from the date of delivery to you, and with respect to torch any third party. You shall notify Hypertherm promptly upon learning of any
lifter assemblies within a period of one (1) year from its date of delivery to action or threatened action in connection with any such alleged
you, and with respect to Automation products one (1) year from its date infringement (and in any event no longer than fourteen (14) days after
of delivery to you, with the exception of the EDGE Pro CNC, learning of any action or threat of action), and Hypertherm’s obligation to
EDGE Pro Ti CNC, MicroEDGE Pro CNC, and ArcGlide THC, which defend shall be conditioned upon Hypertherm’s sole control of, and the
shall be within a period of two (2) years from the date of delivery to you, indemnified party’s cooperation and assistance in, the defense of the
and (iii) with respect to HyIntensity fiber laser components within a claim.
period of two (2) years from the date of its delivery to you, with the
exception of laser heads and beam delivery cables, which shall be within
a period of one (1) year from its date of delivery to you.
Limitation of liability
This warranty shall not apply to any Powermax brand power supplies that In no event shall Hypertherm be liable to any person or entity for
have been used with phase converters. In addition, Hypertherm does not any incidental, consequential direct, indirect, punitive or
warranty systems that have been damaged as a result of poor power exemplary damages (including but not limited to lost profits)
quality, whether from phase converters or incoming line power. This regardless of whether such liability is based on breach of
warranty shall not apply to any product which has been incorrectly contract, tort, strict liability, breach of warranty, failure of
installed, modified, or otherwise damaged. essential purpose, or otherwise, and even if advised of the
possibility of such damages.
Hypertherm provides repair, replacement or adjustment of the Product as
the sole and exclusive remedy, if and only if the warranty set forth herein
properly is invoked and applies. Hypertherm, at its sole option, shall National and local codes
repair, replace, or adjust, free of charge, any defective Products covered
National and local codes governing plumbing and electrical installation
by this warranty which shall be returned with Hypertherm’s prior
shall take precedence over any instructions contained in this manual.
authorization (which shall not be unreasonably withheld), properly
In no event shall Hypertherm be liable for injury to persons or property
packed, to Hypertherm’s place of business in Hanover, New Hampshire,
damage by reason of any code violation or poor work practices.
or to an authorized Hypertherm repair facility, all costs, insurance and
freight pre paid by the customer. Hypertherm shall not be liable for any
repairs, replacement, or adjustments of Products covered by this Liability cap
warranty, except those made pursuant to this paragraph and with
Hypertherm’s prior written consent. In no event shall Hypertherm’s liability, if any, whether such
liability is based on breach of contract, tort, strict liability,
breach of warranties, failure of essential purpose or otherwise,
for any claim, action, suit or proceeding (whether in court,
arbitration, regulatory proceeding or otherwise) arising out of or
relating to the use of the Products exceed in the aggregate the
amount paid for the Products that gave rise to such claim.

Safety and Compliance SC-33

Warranty

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

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

SC-34 Safety and Compliance

Section 1
Specifications

Introduction
The Hypertherm ArcGlide THC is a voltage sensing, torch height control (THC) system that is designed for plasma
cutting applications on an X-Y cutting machine. The system uses the plasma arc voltage to control the physical distance
between the torch and the workpiece during cutting. Up to 4 ArcGlide systems can be installed on a cutting machine.
The system includes the components shown in Figure 1.

Figure 1
10 9 8
1
7

5
2
3 4

1 Plasma system 6 ArcGlide control module

2 ArcGlide HMI (optional) 7 Gantry
3 CNC 8 ArcGlide lifter
4 Rails 9 Workpiece
5 Star ground 10 Cutting machine

ArcGlide THC Instruction Manual 806450 35

1 – Specifications

 The ArcGlide control module and Ethernet switch should be located in an electrical cabinet that is electrically grounded
and environmentally clean.

ArcGlide control module

The ArcGlide control module houses a micro-controller, I/O board, and a motor drive. This component provides arc
voltage control and interfaces with the torch lifter, the CNC, and the plasma system through standard discrete I/O
interfaces or through the Hypernet® plasma interface board.

Lifter assembly

The torch lifter station, under control of the ArcGlide control module, positions a torch head vertically above the
workpiece.

The lifter has the following features:

 Ability to detect the workpiece using ohmic contact sense circuitry or stall force
 Lifter station ENABLE/DISABLE switch with an indicator lamp
 Manual UP/DOWN switch
 Laser pointer for workpiece alignment
 Signal interface cable
 Optional magnetic or pneumatic torch breakaway with circuitry to indicate a collision
 Optional torch mounting block

36 ArcGlide THC Instruction Manual 806450

1 – Specifications

Human machine interface (HMI)

The HMI includes a liquid crystal display (LCD), operating switches, and a selector knob for THC setup and control. The
HMI is an optional operator interface for adjusting or reading settings.

The main functions of the HMI are:

 THC system and operation setup
 Entry for operating parameters
 Manual and automatic operation
 Initial height sense (IHS) test
 THC status and arc voltage display
 THC error display
 Multiple language support (English, German, Portuguese, and Spanish)
 English or metric unit support
 Station ENABLE/DISABLE switch

Plasma interface board

The plasma interface board has 2 main functions:

1. Precise, scaled feedback of the plasma arc voltage to the ArcGlide THC control module.

2. A convenient, control signal interface to the ArcGlide THC.

Hypertherm offers 2 types of plasma interface boards. See Discrete plasma interface board (141094) on page 44 or
Hypernet plasma interface board (141162) on page 45.

Industrial Ethernet switch

An industrial grade Ethernet switch with multiple ports is required in configurations that have more than one cable
connection for Hypernet. See Ethernet switch on page 46 for more information.

ArcGlide THC Instruction Manual 806450 37

1 – Specifications

Specifications

ArcGlide system

Input power 115 VAC, 50/60 Hz, 1-phase

230 VAC, 50/60 Hz, 1-phase*

Operating temperature -10ºC to 40ºC (14ºF to 104ºF)

Operating humidity 95% relative humidity

Warranty 2 years for electronics and lifter

* Factory default setting

38 ArcGlide THC Instruction Manual 806450

1 – Specifications

ArcGlide control module (090054)

Regulatory approvals CE, CSA, C-Tick, GOST-TR, UkrSEPRO

Current rating (selectable)* 2.6 A at 100 VAC – 120 VAC, 50/60 Hz, 1-phase
1.5 A at 200 VAC – 230 VAC, 50/60 Hz, 1-phase**

Slow blow fuse 250 VAC, 5 A, 0.25 inch X 1.25 inch

Parallel digital input range +12 VDC to +24 VDC

Serial digital I/O +5 VDC (Plasma interface serial)

Maximum motor drive output 70 VDC, 6 A

Hypernet communication Shielded RJ-45 Cat5e or Cat6

* To prevent damage to equipment, select the input voltage using the input fuse module on the front of the ArcGlide control module
above the power connector (115 V or 230 V).
** Factory default setting

Figure 2
157.23 mm
(6.19 inch)

206.25 mm
(8.12 inch)

381.00 mm
(15.37 inch)

7.26 kg 358.65 mm
(16.00 lb) (14.12 inch)

ArcGlide THC Instruction Manual 806450 39

1 – Specifications

Lifter assembly (090053)

The following table lists specifications that are common for all lifter assemblies. Table 1 lists specifications that differ from
the model listed below.

Regulatory approvals CE, CSA, C-Tick, GOST-TR, UkrSEPRO

Motor 70 VDC, 3 A continuous, 6 A maximum

Limit switches +24 VDC

Motor Permanent magnet

Motor drive Pulse width modulation (PWM) servo amplifier

Lifter feedback Incremental encoder

Lifter limit switches Home switch and lower limit switch

Lifter control switches Manual UP/DOWN and station ENABLE/DISABLE switches

Maximum Z-axis speed 15,200 mm/min (600 in/min)

Maximum Z-axis stroke 239 mm (9.40 inch)

Breakaway switch +24 VDC

Motor brake +24 VDC

Laser pointer (Class 3B) +5 VDC

Maximum power: 500 mW
Wavelength: 400 – 695 nm

Lifter capacity 11.3 kg (25.0 lb)

40 ArcGlide THC Instruction Manual 806450

1 – Specifications

Table 1

Part No. Torch mounting block Breakaway options

090082 51 mm (2 inch) 11 kg (25 lb) magnetic

090083 51 mm (2 inch) Pneumatic

090084 44 mm (1.75 inch) Pneumatic

090085 35 mm (1.375 inch) Pneumatic

090086 44 mm (1.75 inch) 11 kg (25 lb) magnetic

090087 35 mm (1.375 inch) 11 kg (25 lb) magnetic

090088 51 mm (2.0 inch) 4.5 kg (10 lb) magnetic

090089 44 mm (1.75 inch) 4.5 kg (10 lb) magnetic

090090 35 mm (1.375 inch) 4.5 kg (10 lb) magnetic

090091 Not included Pneumatic

090092 Not included 4.5 kg (10 lb) magnetic

090093 Not included 11 kg (25 lb) magnetic

ArcGlide THC Instruction Manual 806450 41

1 – Specifications

Figure 3
151.10 mm 78.70 mm
(5.95 inch) (3.10 inch)

269.20 mm
(10.60 inch)

744.20 mm
(29.30 inch)

50.80 mm
(2.00 inch)

14.00 kg
186.70 mm (30.90 lb)
149.10 mm
(5.87 inch) (7.35 inch)

42 ArcGlide THC Instruction Manual 806450

1 – Specifications

Optional HMI (090055)

Regulatory approvals CE, CSA, C-Tick, GOST-TR, UkrSEPRO

Input power 100 VAC, 40 mA, 50/60 Hz, 1-phase

240 VAC, 20 mA, 50/60 Hz, 1-phase

Hypernet communication Shielded RJ-45 Cat5e or Cat6

Operating temperature -10ºC to 40ºC (14ºF to 104ºF)

Operating humidity 95% relative humidity

Figure 4

130.50 mm
(5.14 inch)

117.60 mm
(4.63 inch)

1.91 kg 298.00 mm
(4.20 lb) (11.73 inch)

ArcGlide THC Instruction Manual 806450 43

1 – Specifications

Discrete plasma interface board (141094)

This plasma interface board is required for configurations that use discrete communication.

Figure 5

127.00 mm
50.80 mm (5.00 inch)
(2.00 inch)

145.29 mm
(5.72 inch)

0.68 kg
(1.50 lb)

27.69 mm
(1.09 inch)

Input power 24 V (AC or DC)

Parallel digital I/O +12 VDC to +24 VDC

Serial digital I/O 5 VDC

Voltage divider ratio 50:1 Arc voltage

44 ArcGlide THC Instruction Manual 806450

1 – Specifications

Hypernet plasma interface board (141162)

This plasma interface board is required for configurations that use Hypernet communication.

Figure 6

171.45 mm
(6.75 inch)

145.29 mm
(5.72 inch)

0.20 kg
(0.45 lb)

Input power 24 V (AC or DC)

Parallel digital I/O +12 VDC to +24 VDC

Serial digital I/O 5 VDC

Voltage divider ratio 50:1 Arc voltage

ArcGlide THC Instruction Manual 806450 45

1 – Specifications

Ethernet switch

If the ArcGlide THC has more than one connection to Hypernet that communicates with either the CNC or the plasma
system, you must include an industrial grade Ethernet switch with multiple ports for communication between these
components.

 switch
This switch must be an industrial grade switch that supports shielded Cat5e or Cat6 Ethernet cable. The Ethernet
should be located in an electrical cabinet that is electrically grounded and environmentally clean.

A plasma arc cutting machine can be configured with the following units:
 1 CNC with Hypernet support
 Up to 4 plasma systems
 4 ArcGlide THC control modules
 4 ArcGlide THC lifters
 4 ArcGlide TNC HMIs

The total number of Ethernet ports the system requires depends on the number of plasma systems and ArcGlide THCs
installed. Use Table 2 to help determine the number of Ethernet ports the system needs.

Table 2

For each of these components: You need this many Ethernet ports:

CNC 1

Plasma system (1 to 4) + lifter (1 to 4) 2 to 8

Plasma system (1 to 4) + lifter (1 to 4) + HMI (1 to 4) 3 to 12

For example, a cutting machine with 2 plasma systems + 2 THCs + 2 HMIs + 1 CNC = 7 ports.

 Hypernet connections and Ethernet connections to a LAN cannot be made through the same switch. If your cutting
machine is connected to a LAN over Ethernet, you must use a separate Ethernet switch for these connections.

Hypertherm recommends 3 different models of Advantech™ industrial Ethernet switches. These switches are available
from Hypertherm. Table 3 provides details about each model. Choose the switch that fits your needs.

46 ArcGlide THC Instruction Manual 806450

1 – Specifications

Table 3 – Recommended Advantech Ethernet switches

5 Ports 8 Ports 16 Ports

Hypertherm part number 005657 005655 005656

Advantech part number EKI-2525I-AE EKI-7629C-AE EKI-7626C-AE

Width × height × depth 37 mm X 140 mm X 95 mm 79 mm X 152 mm X 79 mm X 152 mm X

(1.46 inch X 5.51 inch X 105 mm 105 mm
3.74 inch) (3.11 inch X 5.98 inch X (3.11 inch X 5.98 inch X
4.13 inch) 4.13 inch)

Maximum power 5W 6.5 W 6.5 W

consumption

Power input (not included) 12 – 48 VDC redundant dual inputs with twisted pair cable.

Table 4 lists the operating specifications for the recommended Ethernet switches. See the respective Advantech user
manuals for information about installing and operating these switches.

If your cutting machine does not include one of these Advantech Ethernet switches, use the specifications in Table 4 to
select an industrial-grade Ethernet switch that will support your plasma cutting machine.

Table 4 – Advantech Ethernet switch specifications

Ethernet connections Shielded RJ-45 ports

Electrical protection 4000 VDC Ethernet ESD protection, 3000 VDC surge (EFT) protection for
the power line

I/O transmission distance Up to 100 m (109 yard) (4-wire Cat5e or Cat6)

I/O transmission speed 10/100 Mbps auto-negotiation

Operating temperature -10ºC to 60ºC (14ºF to 140ºF)

ArcGlide THC Instruction Manual 806450 47

1 – Specifications

ArcGlide communication
Figure 7 through Figure 10 show discrete and Hypernet communication that the ArcGlide THC uses to exchange signals
with the CNC and the plasma system. Use the following table to distinguish between discrete and Hypernet
communication.

Communication style Data architecture Cabling configuration

Discrete Discrete I/O and serial A dedicated cable to each component from the ArcGlide control
data module; within each cable, there is a dedicated wire for each
signal.

Hypernet Ethernet data packets A standard, Cat5e or Cat6, shielded, Ethernet cable from the
Ethernet switch to each component of the cutting machine.

 Both communication styles transmit the same signals. The difference is in the way the signals are “packaged” for
transmission over the two cabling configurations.

 Do not use redundant (both discrete and Hypernet) communication between the same two components in the same
ArcGlide configuration.

Hypernet communication

ArcGlide THCs in Hypernet configurations connect to the CNC and plasma system using the Hypernet protocol over
shielded, Ethernet Cat5e or Cat6 cables. Both the CNC and plasma systems in this configuration must have a dedicated,
Hypernet-configured, Ethernet port for these connections.

In addition, a Hypernet configuration must include an industrial-grade Ethernet switch to route communication from the
CNC to the other components in the system.

 Each ArcGlide THC component (HMI, control module, and plasma interface board) that is connected to the Hypernet
must have the same Hypernet component address. This address must correspond to the station number for the THC
that is selected in Phoenix, on the Station Configuration screen. See Assign an ArcGlide THC to a station on page 125
for more information.

48 ArcGlide THC Instruction Manual 806450

1 – Specifications

Figure 7

Station 1
Lifter
HPR plasma system

Hypernet plasma interface

HMI ArcGlide control module
board
Hypernet address: 1 Hypernet address: 1
Hypernet address: 1

HyPath CNC Ethernet switch

HMI ArcGlide control module

HPR plasma system
Hypernet address: 2 Hypernet address: 2
Hypernet plasma interface
board
Lifter Hypernet address: 2
Station 2

Key:
Hypernet connection

Discrete connection

In a Hypernet configuration, serial communication is carried on the Hypernet cable between the CNC and the ArcGlide
THC and the ArcGlide plasma interface board in the plasma system. Within the plasma system, serial communication is
carried between the ArcGlide plasma interface board and the plasma control board by a serial cable (123760).

ArcGlide
ArcGlide plasma Plasma
CNC
interface control board
board
Hypernet Hypernet RS-422
Cat5e or Cat6 Cat5e or Cat6

ArcGlide THC Instruction Manual 806450 49

1 – Specifications

Discrete communication

In a discrete configuration, signals are routed through the ArcGlide control module. Each component in the configuration,
except the HMI, is connected to the ArcGlide control module with discrete cables. The HMI communicates with the
control module using the Hypernet protocol over a shielded, Ethernet Cat5e or Cat6 cable.

Figure 8

Lifter
Plasma system

Picopath CNC ArcGlide control module Plasma interface board

HMI

Key:
Hypernet connection

Discrete connection

50 ArcGlide THC Instruction Manual 806450

1 – Specifications

Mixed communication

In a mixed configuration, Hypernet communication is used between the ArcGlide control module and CNC or plasma
system and discrete communication is used for the alternate connection from the ArcGlide control module. When the
HMI is included, it must be connected to the ArcGlide control module with a Hypernet connection. See Figure 9 and
Figure 10 for details.

Figure 9

Lifter
Plasma system
Discrete plasma
ArcGlide control module
interface board

Hypernet-capable CNC Ethernet switch

HMI

Figure 10

Lifter

CNC ArcGlide control module

Plasma system
Hypernet plasma
Ethernet switch
interface board

HMI

Key:
Hypernet connection

Discrete connection

Serial communication

The ArcGlide THC supports an optional serial interface to a non-Hypernet CNC. See ArcGlide THC Serial
Communication Installation on page 269 for more information on serial communication.

ArcGlide THC Instruction Manual 806450 51

1 – Specifications

52 ArcGlide THC Instruction Manual 806450

Section 2
Installation

Hardware setup
After you receive your new equipment:
 Make sure that all items on your order have been received in good condition. Contact your table manufacturer if any
parts are damaged or missing.
 Inspect the system components for damage that may have occurred during shipping. See Claims if there is evidence
of damage. All communications regarding this equipment must include the model number and the serial number
located on the back of the unit.
 Before you set up and operate this Hypertherm system, read Safety on page 13 for important safety information.

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 the nearest Hypertherm office listed in the front of this manual.
 Claims for defective or missing merchandise – If any of the components are missing or defective, contact your
table manufacturer. If you need additional assistance, call the nearest Hypertherm office listed in the front of this
manual.

ArcGlide THC Instruction Manual 806450 53

2 – Installation

Installation requirements

All installation and service of the electrical system must conform to national and local electrical codes. This work should
be performed only by qualified, licensed personnel.

Direct any technical questions to the nearest Hypertherm Technical Service office listed in the front of this manual, or to
your table manufacturer.

Placement of system components

Place all system components in position prior to making electrical and interface connections.

Ground all system components to earth. See Recommended grounding and shielding practices on page 55 for more
information.

54 ArcGlide THC Instruction Manual 806450

2 – Installation

Recommended grounding and shielding practices

WARNING!
ELECTRIC SHOCK CAN KILL

Disconnect electrical power before performing any maintenance.

All work requiring the removal of the plasma system cover must be performed
by a qualified technician.
See the Safety section of your manual for more safety precautions.

Introduction

This section describes practices for grounding and shielding to protect a plasma cutting system against radio frequency
interference (RFI) and electromagnetic interference (EMI) (also called noise). It also describes the DC power ground and
the service ground. The diagram at the end of this section shows these types of grounds in a plasma cutting system.

 The grounding practices in this section have been used on many installations with excellent results, and Hypertherm
recommends that these practices be a routine part of the installation process. The actual methods used to implement
these practices may vary from system to system, but should remain as consistent as possible. However, due to the
variation in equipment and installations, these grounding practices may not succeed in every case to eliminate RFI/EMI
noise issues.

Types of grounding

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

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

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

Grounding practices

1. Unless noted, use only 16 mm2 (6 AWG) welding cables (047040) for the EMI ground cables shown on the diagram
at the end of this section.

2. The cutting table is used for the common, or star, EMI ground point and should have threaded studs welded to the
table with a copper bus bar mounted on them. A separate bus bar should be mounted on the gantry as close to

ArcGlide THC Instruction Manual 806450 55

2 – Installation

each motor as possible. If there are motors at each end of the gantry, run a separate EMI ground cable from the
far motor to the gantry bus bar. The gantry bus bar should have a separate, heavy EMI ground cable 21.2 mm2
(4 AWG; 047031) to the table bus bar. The EMI ground cables for the torch lifter and the RHF console must each
run separately to the table ground bus.

3. A ground rod that meets all applicable local and national electrical codes must be installed within 6 m (20 ft) of the
cutting table. This is a PE ground and should be connected to the cutting table ground bus bar using 16 mm2
(6 AWG) green and yellow grounding cable (047121) or equivalent.

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

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

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

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

8. For a system with an RHF console, the ignition console should be mounted as closely as possible to the torch, and
must have a separate ground cable that connects directly to the cutting table ground bus bar.

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

10. The metal braided shield on the torch lead must be connected firmly to the ignition console and to the torch. It must
be electrically insulated from any metal and from any contact with the floor or building. The torch lead can be run in a
plastic cable tray or track, or covered with a plastic or leather sheath.

11. The torch holder and the torch breakaway mechanism – the part mounted to the lifter, not the part mounted to the
torch – must be connected to the stationary part of the lifter with copper braid at least 12.7 mm (0.5 inches) wide. A
separate cable must run from the lifter to the gantry ground bus bar. The valve assembly should also have a separate
ground connection to the gantry ground bus bar.

12. If the gantry runs on rails that are not welded to the table, then each rail must be connected with a ground cable from
the end of the rail to the table. The rail ground cables connect directly to the table and do not need to connect to the
table ground bus bar.

13. If you are installing a voltage divider board, mount it as closely as possible to where the arc voltage is sampled.
One recommended location is inside the plasma system enclosure. If a Hypertherm voltage divider board is used, the
output signal is isolated from all other circuits. The processed signal should be run in twisted shielded cable
(Belden 1800F or equivalent). Use a cable with a braided shield, not a foil shield. Connect the shield to the chassis
of the plasma system and leave it unconnected at the other end.

14. All other signals (analog, digital, serial, and encoder) should run in twisted pairs inside a shielded cable. Connectors
on these cables should have a metal housing. The shield, not the drain, should be connected to the metal housing of
the connector at each end of the cable. Never run the shield or the drain through the connector on any of the pins.

56 ArcGlide THC Instruction Manual 806450

2 – Installation

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

1 2 3 4 5 6 7
1 Gantry ground bus
2 Ground rod
3 Plasma system lead (+)
4 Remote high frequency (RHF) console
5 CNC enclosure
6 Torch holder
7 Plasma system chassis

The following picture shows an example of a gantry ground bus. It is bolted to the gantry, close to the motor. All of the
individual ground cables from the components mounted on the gantry connect to the bus. A single heavy cable then
connects the gantry ground bus to the table ground bus.

1 Cable to the cutting table ground bus

2 Ground cables from components on the gantry

1 2

ArcGlide THC Instruction Manual 806450 57

2 – Installation

The following diagram shows an example of grounding the components in a plasma cutting system.

6 7 8 9 10

5
12

Chassis and RFI ground

3 13
AC earth ground

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

console, gas console, or selection console
2 Gantry
10 CNC chassis
3 Plasma system
11 Torch height control module
4 Table ground bus bar
(ArcGlide, Command THC)
5 Gantry ground bus bar
12 System-specific component such as a cooler or
6 Torch height control lifter (ArcGlide, Sensor THC, chiller
Sensor PHC, or other)
13 DC power ground
7 RHF console (not on all systems). Connect to table
ground bus bar.

58 ArcGlide THC Instruction Manual 806450

2 – Installation

System description for a Hypernet configuration

Figure 11 shows the cable and signal connections in a Hypernet communication configuration.

 Hypernet cables transmit serial communication.

Figure 11
Key:
Hypernet connection ––––––
Discrete connection ——————

ArcGlide control module

HMI (optional)

Industrial Ethernet
switch

ArcGlide lifter

CNC with Hypernet HPR plasma system

with Hypernet

ArcGlide THC Instruction Manual 806450 59

2 – Installation

System description for a discrete configuration

Figure 12 shows the cable and signal connections in a discrete communication configuration.

 For information on multi-drop configurations, refer to the instruction manual for your plasma system.
Figure 12
Key:
Hypernet connection ––––––
Discrete connection ——————
ArcGlide control module

HMI (optional) Customer-supplied operator console

(optional):
Station on/off/program switch
Station active light
Lifter UP/DOWN switch

CNC

ArcGlide lifter
Plasma system

60 ArcGlide THC Instruction Manual 806450

2 – Installation

ArcGlide communication configuration examples

Table 5 lists the ArcGlide configurations on the following pages. If you are viewing this manual online, click the page
number in the left column to view that configuration.

Table 5

Drawing
number and Connection to plasma Connection to CNC
page

1 Hypernet to multiple HPR or HPRXD plasma Hypernet to Hypernet-capable CNCs.

page 63 systems, each with plasma interface board
141162. Requires an Ethernet switch.

2 Discrete to HPR or HPRXD plasma system with Hypernet to Hypernet-capable CNCs.

page 64 plasma interface board 141094.

3 Discrete to HPR or HPRXD plasma system with Discrete to a CNC with a Picopath interface.
page 65 plasma interface board 141094. Serial cable from CNC to plasma system, supplied
by the table manufacturer.

4 Discrete to HPR or HPRXD plasma system with Discrete to third party CNC. Serial cable from
page 66 plasma interface board 141094. CNC to plasma system, supplied by the table
manufacturer.

5 Discrete to HPR400XD or HPR800XD plasma Discrete to third party CNC. Serial cable from
page 67 system with plasma interface board 141094. CNC to plasma system, supplied by the table
manufacturer.

6 Discrete to HPR or HPRXD plasma system with plasma interface board141094, showing circuits,
page 68 signals, and connections to terminal blocks.

7 Discrete to HSD130 plasma system with the Discrete to a CNC with a Picopath interface.
page 69 plasma interface board 141094, machine interface
cable (123209) from the plasma interface board to
the control board in the plasma system.

8 Discrete to MAX 200, HT2000 or HT2000 LHF Discrete to a CNC with a Picopath interface.
page 70 plasma system with plasma interface board
141094. 1 X 6 interface cable between the
plasma interface board and plasma system.

9 Discrete to MAX 200, HT2000 or HT2000 LHF plasma system with plasma interface board 141094,
page 71 showing circuits, signals, and connections to terminal blocks.

10 Discrete to Powermax plasma systems with Discrete to a CNC with a Picopath interface.
page 72 plasma interface board 141094 and Powermax
interface cable 023206 between the plasma
interface board and the Powermax plasma system.

ArcGlide THC Instruction Manual 806450 61

2 – Installation

Drawing
number and Connection to plasma Connection to CNC
page

11 ArcGlide to Picopath CNC. Discrete to a CNC with a Picopath interface.

page 73 Provides suggested cable termination at CNC
port.

12 Discrete communication to any plasma system with plasma interface board 141094, showing circuits,
page 74 signals, and connections to terminal blocks.

13 Hypernet communication to MAXPRO200 plasma Hypernet to Hypernet-capable CNCs.

page 75 system with plasma interface board 141162
installed. Requires an Ethernet switch.

14 Discrete communication to MAXPRO200 plasma Discrete communication to a CNC with a Picopath

page 76 system. interface.

WARNING!
SHOCK HAZARD, ENERGY HAZARD, AND FIRE HAZARD

Connecting directly to the plasma circuit for access to raw arc voltage increases the risk of shock
hazard, energy hazard, and fire hazard in the event of a single fault. The output voltage and the output
current of the circuit are specified on the data plate.

 The output of the internal voltage divider board is designed to prevent shock, energy and fire hazards, and is intended
to satisfy most codes and standards for external wiring outside the electrical enclosure.

All external wiring practices for an unprotected raw arc voltage should be reviewed and approved by the local
inspection authorities at the time of installation prior to operation and use. Raw arc voltage wiring terminals and
connections should not be exposed to accidental contact under normal and single fault conditions. External wiring
from an unprotected (that is, no voltage divider used in the power source) raw arc voltage routed inside conduit
between electrical enclosures will normally satisfy all electrical codes and standards worldwide. Failure to address
the hazards associated with live contact, accessibility and single fault failures to this unprotected output can result in
death or fire.

 Awiring
voltage divider board inside the CNC protects only the CNC and does NOT protect the external interconnecting
between the power source and the CNC. Overcurrent protection may be required to protect the user or machine
in fault conditions.

 External wiring outside the electrical enclosure should be suitable for the installation and meet national and local
regulations (for example, NFPA 70 NEC, NFPA 79, Canadian Electrical Code, CSA/CAN E60974-1, IEC 60204-1,
BS 7671) or other codes or standards applicable to the installed site where the equipment will be operated.

62 ArcGlide THC Instruction Manual 806450

2 – Installation

1 – Multiple ArcGlide THCs with Hypernet connection to a Hypernet-enabled CNC and HPR or HPRXD plasma system
Rotary address switch, set to 1
ArcGlide control module

Rotary address switch, set to 1

Optional ArcGlide HMI

Interlock
Rotary address switch,
set to 2 Lifter I/O cable
Shielded Ethernet cables, up to 61 m
Optional ArcGlide HMI (200 feet) long Rotary address switch,
set to 2
ArcGlide control module

Industrial Ethernet switch

EDGE Pro, EDGE Pro Ti,
with 5, 8, or 16 ports
or MicroEDGE Pro CNC

Interlock
Shielded Ethernet cables, up to 61 m
Lifter I/O cable
(200 feet) long

Rotary address switch,

Rotary address switch,
set to 2
set to 1

Hypernet
Hypernet plasma interface board
Hypernet plasma interface board (141162) installed in the plasma system
(141162) installed in the plasma system (below)
(below)

HPR130/HPR260
HPR130XD/HPR260XD
HPR400XD/HPR800XD
with built-in Hypernet adapter or optional
Hypernet kit ArcGlide lifters
(228611) or (228604)

ArcGlide THC Instruction Manual 806450 63

2 – Installation

2 – ArcGlide THC with Hypernet connection to a Hypernet-enabled CNC and discrete connection to an HPR130/260 or HPR130/260XD plasma system

Rotary address switch, set to 1

EDGE Pro, EDGE Pro Ti,

or MicroEDGE Pro CNC
Shielded Ethernet cable up to 61 m (200 foot) long

Lifter I/O cable

Discrete plasma interface board (141094) Arc voltage sense wires

Hypernet

DB37 to DB37 cable

(123760)

DB50
ArcGlide lifter

HPR130/260 or HPR130/260XD plasma system

64 ArcGlide THC Instruction Manual 806450

2 – Installation

3 – ArcGlide THC with discrete connection to a Picopath interface CNC and HPR130/260 or HPR130/260XD plasma system
Rotary address switch, set to 1

Optional ArcGlide HMI

Rotary address switch,
set to 1
ArcGlide control module
Picopath interface CNC Shielded Ethernet cable, up
to 61 m (200 feet) long

Axes 3, 4

Axes 1, 2

I/O
CNC I/O cable
To CNC RS-422 serial port,
terminate as required
RS-422 serial port Lifter I/O cable

Serial cable supplied by

the table manufacturer

Discrete plasma interface board (141094) Arc voltage sense wires

DB37 (female)

Serial cable supplied by the Plasma I/O cable

table manufacturer

HPR control board

DB37 (male)

To plasma ArcGlide lifter

Cable 223192 without serial interface board
(with red band) Cable 223192
without serial (with DB50
DB37 (female)
red band) (male)

HPR130/260 or HPR130/260XD plasma system

ArcGlide THC Instruction Manual 806450 65

2 – Installation

4 – ArcGlide THC with discrete connection to a generic CNC and HPR130/260 or HPR130/260XD plasma system
Rotary address switch, set to 1 Rotary address switch,
Optional ArcGlide HMI set to 1

ArcGlide control module

Generic CNC with serial Shielded Ethernet cable, up

communication to 61 m (200 feet) long

Axes 3, 4

Axes 1, 2

I/O
CNC I/O cable
To CNC RS-422 serial port,
terminate as required
Lifter I/O cable

RS-422 serial port

Serial cable supplied by the table
manufacturer

Discrete plasma interface board (141094) Arc voltage sense wires

DB37 (female)
Plasma I/O cable

Serial cable supplied by the

table manufacturer

HPR control board

DB37 (male)

Cable 223192 without serial ArcGlide lifter

(with red band) To plasma
interface board
Cable 223192
without serial DB50
DB37 (female) (with red band) (male)

HPR130/260 or HPR130/260XD plasma system

66 ArcGlide THC Instruction Manual 806450

2 – Installation

5 – ArcGlide THC with discrete connection to a generic CNC and HPR400/800XD plasma system

Rotary address switch, set to 1 Rotary address switch,

set to 1
Optional ArcGlide HMI ArcGlide control module

Shielded Ethernet cable, up

Generic CNC with serial to 61 m (200 feet) long
communication

Axes 3, 4

Axes 1, 2

I/O
CNC I/O cable

Lifter I/O cable

RS-422 serial port
Serial cable supplied by the table manufacturer
To CNC RS-422 serial port, terminate as required

DB37 (female)

Plasma I/O cable

Cable 223192 without serial

(with red band)

Arc voltage
sense wires
Discrete plasma interface board
(141094)

ArcGlide lifter

DB50
(male)

HPR400XD plasma system

ArcGlide THC Instruction Manual 806450 67

2 – Installation

6 – Discrete plasma interface board with connection to an HPR or HPRXD plasma system

DB37 to DB37 interface cable J3 Outputs

(123760)
J2 Inputs
24V

J2-16
+24V THC 16 Field +24 V out
J2-16 FOR I/O USE IF NEEDED
16 Not connected J2-15
500MA MAX 15 Field +24 V out
J2-15
FUTURE USE 15 Not connected
J2 Inputs J3 Outputs J2-14
14 Common
J2-14 14 Common J2-13
16 16 13 Common
15 J2-13 FIELD COMMON
15
14 14
13 Common
D1
13 13 J2-12
PLASMA ON 12 Common
12 12
J2-11
11 11 11 Common J3-12
10 10 D2
J2-10
9 9 PLASMA STRT 10 Common REMOTE ON 12 Remote ON B
FIELD COMMON
Electrode - 8 8 RELAY J3-11 11 Remote ON A
7 7
D3
6 6
ARC XFER
5 5
4 4 J2-9
Work + 3 3 D4
9 Spare in J3-10
2 2 THC ON SPARE 10 Spare out B
1 1 RELAY J3-9 9 Spare out A
J2-8
FIELD COMMON 8 Common

24V *
PULL UP J3-8
PLASMA START
8 Plasma Start**
J2-7
7 Not ready RELAY J3-7 7 Plasma Start A**
Discrete plasma interface board (141094)
J2-6
FIELD COMMON 6 Common
J3-6
HOLD
6 Hold B
24V *
PULL UP RELAY J3-5 5 Hold A
Arc voltage sense wires to J2-5
5 Rampdown error
plasma system, use ~0.9 mm2
(18 AWG) twisted pair wire, J3-4
rated 600 V or greater. J2-4 PIERCE 4 Pierce B
FIELD COMMON 4 Common
To terminal block 2, RELAY J3-3 3 Pierce A
pins 1 and 3 24V *
PULL UP

J2-3 J3-2
3 Error
CORNER 2 Corner B
RELAY J3-1 1 Corner A
J2-2
FIELD COMMON 2 Common
24V *
To plasma system Electrode- PULL UP
** Motion and Start are the minimum connections. Use other signals if they are
J2-1
1 Motion** supported by the plasma system.
To plasma system Work+

* 24 V pull-up resistors on inputs are active only if they are set to dry (D) on the ArcGlide control module

68 ArcGlide THC Instruction Manual 806450

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7 – ArcGlide THC with discrete communication to a Picopath interface CNC and HSD130 plasma system

Rotary address switch, set to 1

Optional ArcGlide HMI Rotary address switch, set to 1

CNC with Picopath interface ArcGlide control module

Shielded Ethernet cable, up

to 61 m (200 feet) long

Axes 3, 4

Axes 1, 2
Lifter I/O cable

I/O CNC I/O cable

Plasma I/O cable Electrode -

See the table in the drawing on page 73 for information about HSD130
wiring Picopath I/O. Work +

DB50 (male)

DB37

Discrete plasma interface

board (141094)

Interface cable 123209

1.5 m (5 feet) ArcGlide THC lifter

Arc voltage sense wires to plasma system, use ~0.9 mm2 (18 AWG) twisted pair wire,
Plasma interface board (141094), mounted externally by the customer
rated 600 V or greater.

ArcGlide THC Instruction Manual 806450 69

2 – Installation

8 – ArcGlide THC with discrete connections to a Picopath interface CNC and MAX200, HT2000, or HT2000 LHF plasma system

Rotary address switch, set to 1

Optional ArcGlide HMI
ArcGlide control module

Picopath interface CNC

Lifter I/O cable

Axes 3, 4

Axes 1, 2
MAX200
Shielded Ethernet cable

I/O

CNC I/O cable

See the table in the drawing on page 73 for information

about wiring Picopath I/O. Plasma I/O cable

MACHINE

1 X 6 machine interface cable

1X6

Discrete plasma
interface board
(141094)

ArcGlide lifter

Arc voltage sense wires to plasma system, use ~0.9 mm2 (18 AWG) twisted pair wire,
rated 600 V or greater.

70 ArcGlide THC Instruction Manual 806450

2 – Installation

9 – Discrete plasma interface board with connection to MAX200, HT2000, or HT2000 LHF plasma system

ArcGlide plasma interface terminal blocks Machine interface 1 X 6 CPC connector

Not connected

J3-7 Start A - Blue 9

+24V
PLASMA START
RELAY 15 START
J2 J3 J3-8
Discrete plasma interface board Start B - Black
COMMON
(141094)

J3-5
Hold A - White
1
IHS SYNC +24V
HOLD IGNITION
RELAY 5 HOLD
J3-6
Electrode - 8 Hold B- Black
7 COMMON
6
5

Work + 24V
2 PULL UP
1 Remove J2-1 Motion - Red 36(37)
MACHINE MOTION
J2-2 31(32) DELAYED
FIELD COMMON Common - Blue
Replace with
bushing (008245) ( ) - FOR HT2000, HT2000LHF

Refer to the HT2000 Instruction

Manual (802070) or the
1 x 6 machine interface cable HT2000LHF Instruction Manual
(803020) for information about the
1 X 6 connection

Plasma interface termination

Signal Wire color Pin Cable label
Plasma Start A Blue 9 82
Plasma Start B Black 15 83
Hold A White 1 87 MACHINE

Hold B Black 5 86
1X6
Motion Red 36 (37*) 84
Common Blue 31 (32*) 85
Ring terminal to ground stud Shield wire No connection To plasma system
Electrode -
Set plasma inputs to dry (D) using the input switch on the control module. ( * ) For HT2000, HT2000LHF

To plasma system Plasma interface board (141094), mounted externally

Work + by the customer
Arc voltage sense wires to plasma system, use ~0.9 mm2 (18 AWG) twisted pair wire,
rated 600 V or greater.

ArcGlide THC Instruction Manual 806450 71

2 – Installation

10 – Discrete plasma interface board with connection to Powermax plasma systems

Rotary address switch, set to 1

Set ArcGlide plasma inputs to dry (D) using the plasma input
switch on the THC processor board in the control module.

Optional ArcGlide HMI ArcGlide control module Rotary address switch, set to 1
Shielded Ethernet cable

Lifter I/O cable

CNC with Picopath interface
Axes 3, 4

Axes 1, 2

I/O
Terminal blocks on the CNC I/O cable
discrete plasma interface Powermax machine interface
board connector

Start - Green
J3-7 3
+24V Electrode - J2 J3
Plasma I/O cable
PLASMA START
RELAY 4 START
J3-8
Start - Black COMMON Work +
8
7
24V
PULL UP
Motion - Red Discrete plasma interface
J2-1 12 2 board (141094)
1
MACHINE MOTION
J2-2 14
FIELD COMMON Common - ArcGlide lifter
Black
Powermax machine interface cable
(023206)
Arc voltage sense wires to plasma system.
Use ~0.9 mm2 (18 AWG) twisted pair wire,
rated 600 V or greater.

Plasma Interface Termination

Signal Wire color Powermax pins
Plasma Start A Green 3
J6 J5 J3 J2 J1

Plasma Start B Black 4

B
R

ORG
J17
J11

Motion A Red 12
Common Black 14
RED
J18

Powermax Powermax
Arc voltage
1000/1230/1650 65/85/105/125
J27
J26
J15 1000/1230/1650 Electrode- 0.9 mm (18 AWG)
2 J16
J28
WORK
LEAD

J16
Work+ 0.9 mm2 (18 AWG) J15
65/85 CSA Electrode- 0.9 mm2 (18 AWG) J28
Powermax Powermax Work+ J26
65/85/105/125 1000/1230/1650 65/85 CE Electrode- See Field Service Bulletin J29
Work+ Machine Interface for J27
105/125 CSA or CE Electrode- Raw Arc Voltage J28
For Work and Electrode connections, see the table at right.
Work+ (807060) J27

72 ArcGlide THC Instruction Manual 806450

2 – Installation

11 – ArcGlide with discrete connection to a Picopath interface CNC

Set dry contacts by sliding Picopath CNC end A ArcGlide control module end B
the switch to D.
DS DS 24V
Picopath interface CNC CNC PLASMA
PULL UP
OUTPUT 12 32 CYCLE START 1

24V
PULL UP
OUTPUT 11 31 IHS SYNC 7

24V
PULL UP
Axes 3, 4 OUTPUT 10 30 AVC DISABLE 5

12 MOTION 17
+24V
ArcGlide control module INPUT 12 CUT/MARK
Axes 1, 2 18 SENSE
JUMPER 29
COMMON

Picopath connector kit (228490) B +24V

11 BREAKAWAY 21
TORCH
I/O INPUT 11 BREAKAWAY
22 RELAY
JUMPER 30
COMMON

A INTERLOCK
25
24V
CNC I/O cable INPUT 26

37 31
24V COMMON COMMON

End A of the Hypertherm ArcGlide CNC I/O cable is terminated during installation and will work only if the I/O setup in Phoenix software corresponds to the setup End B of the Hypertherm ArcGlide CNC I/O cable is terminated at the
described in this half of this table. factory as described in this half of the table.
Pin No. Function* Phoenix mapping name Wire color* Pin No. Signal
32 Output 12 Cut Control Red 1 Cycle start input +
31 Output 11 Hold Ignition Blue 7 IHS sync input +
30 Output 10 Torch Height Disable Green 5 AVC disable input +
12 Input 12** Cut/Mark Sense Green 17 Machine motion output A
Red 18 Machine motion output B
Jumper blue and red, pins 18 and 29.
Blue 29 Common
11 Input 11** Torch Collision Yellow 21 Torch breakaway output A
Red 22 Torch breakaway output B
Jumper red and green, pins 22 and 30.
Green 30 Common
Orange 25 Interlock input + **
External switch Satisfy with switch or jumper.
Red 26 Interlock input - **
37 24 V common Yellow 31 Common
Backshell Chassis ground Drain wire Ring terminal Chassis ground
* This example uses CNC outputs 10, 11, 12, and inputs 11 and 12. Assign the I/O points in the Phoenix software. * Multiple wires are the same color. Verify pin-to-pin connections before plugging cables into equipment.
** Set ArcGlide plasma inputs to dry (D) using the plasma input switch on the THC processor board in the control module. ** ArcGlide interlock must be closed to enable ArcGlide motion.

ArcGlide THC Instruction Manual 806450 73

2 – Installation

12 – Discrete plasma interface board with connection to any plasma system

No connection J3 Outputs
24V

J2 Inputs J3 Outputs J2 Inputs J2-16

+24V THC 16 Field +24 V out
FOR I/O USE IF NEEDED J2-15
16 16
J2-16
500MA MAX 15 Field +24 V out
16 Not connected
Discrete plasma interface 15 15
14 14 D1 J2-15
board (141094) FUTURE USE 15 Not connected J2-14
13 13 PLASMA ON
12 12 14 Common
11 11 J2-13 13 Common
J2-14
10 10 D2 14 Common FIELD COMMON
9 9 PLASMA STRT J2-13
Electrode - 13 Common
8 8
7 7 J2-12
D3 12 Common
6 6
ARC XFER J2-11
Work + 5 5 J3-12
4 4
11 Common 12 Remote ON B
J2-10 REMOTE ON
3 3 D4 10 Common
2
FIELD COMMON RELAY J3-11 11 Remote ON A
2 THC ON
1 1
24V *
PULL UP

J2-9 J3-10
9 Spare in 10 Spare out B
SPARE
RELAY J3-9 9 Spare out A
J2-8
FIELD COMMON 8 Common
24V * J3-8
PULL UP 8 Plasma Start**
PLASMA START
J2-7 RELAY J3-7 7 Plasma Start A**
7 Not ready

J2-6 J3-6
FIELD COMMON 6 Common
HOLD
6 Hold B
24V * RELAY J3-5 5 Hold A
PULL UP

J2-5
5 Rampdown error
J3-4
PIERCE 4 Pierce B
To plasma system FIELD COMMON
J2-4 RELAY J3-3 3 Pierce A
4 Common
machine interface
24V *
PULL UP
J3-2
J2-3 2 Corner B
3 Error CORNER
To plasma system Electrode - RELAY J3-1 1 Corner A
Arc voltage sense wires to plasma system.
Use ~0.9 mm2 (18 AWG) twisted pair wire, FIELD COMMON
J2-2
2 Common
rated 600 V or greater.
To plasma system Work + 24V *
PULL UP
** Motion and Start are the minimum connections. Use other signals if they
J2-1 are supported by the plasma system.
1 Motion**

* 24 V pull-up resistors on inputs are active only if they are set to dry (D) on the THC processor board in the control module.

74 ArcGlide THC Instruction Manual 806450

2 – Installation

13 – ArcGlide THC with Hypernet connection to an EDGE Pro CNC and MAXPRO200 plasma system

Rotary address switch, set to 1 ArcGlide control module Rotary address switch, set to 1

Optional ArcGlide HMI

Shielded Ethernet cables, up

to 61 m (200 feet) long

Lifter I/O cable

Interlock

Industrial Ethernet switch

with 5, 8, or 16 ports

Shielded Ethernet cables, up to 61 m

(200 feet) long

EDGE Pro, Micro EGDE Pro,

or EDGE Pro Ti CNC

Rotary address switch, set to 1

Hypernet

Hypernet plasma interface board (141162)

installed in the plasma system

ArcGlide lifter
MAXPRO200 with built-in Hypernet adapter
or optional Hypernet kit (428276)

ArcGlide THC Instruction Manual 806450 75

2 – Installation

14 – ArcGlide THC with discrete connection to a Picopath interface CNC and MAXPRO200 plasma system

Rotary address switch, set to 1

Optional ArcGlide HMI

Rotary address switch, set to 1

ArcGlide control module

Lifter I/O cable

Axes 3, 4
CNC with Picopath
interface
Axes 1, 2

I/O

Shielded Ethernet cable, up to

61 m (200 feet) long

CNC I/O cable

Machine interface cable (223327)

Plasma I/O cable

Yellow 25+ wire

ArcGlide lifter
Discrete plasma interface
module
Arc voltage sense wires to plasma system. Use 25
(228572) or (228576)
~0.9 mm2 (18 AWG) twisted pair wire, rated
26
600 V or greater.

MAXPRO200
Yellow/black 26- wire Terminal strip

76 ArcGlide THC Instruction Manual 806450

2 – Installation

Install the lifter

Figure 13

44.45 mm (1.75 inch)

6.75 mm (0.27 inch) diameter

114.30 mm
(4.5 inch)

ArcGlide THC Instruction Manual 806450 77

2 – Installation

1. Position the lifter on the gantry:

 Low enough that the torch can reach the workpiece.
 High enough that the torch does not touch the table.
 The bottom of the lifter must be within 20 mm (8 inches) of the
thinnest workpiece.
 Mounting holes have the same spacing as the Sensor THC and
Command THC lifters.

2. Mount the lifter on the gantry:

a. Remove the shield panels and side panels to expose the mounting
screw holes. 3 1 b
b. Loosely fasten the screws in a diagonal pattern, top to bottom and
5
right to left (see the numbers in the illustration on the right).
c. Use a minimum of 4 screws to mount the lifter.
d. Place a level vertically along the side of the lifter to verify that it is
mounted vertically. d
e. Tighten the screws using a maximum torque of 9.1 kg∙cm (8.0 in∙lb).
f. When they are tightened, the tops of the screws must be below the
surface of the back panel of the lifter so the side panels can be
replaced.
g. Reinstall the side panels and shield panels.

Level

2 4
Side panel Side panel

3. Connect the lifter interface cable and secure it.

a. The cable connector is not rated for hard use or constant flexing.
Support the cable and add enough slack to prevent strain on the
cable and prevent damage to the cable assembly, lifter connector, or
both. c
a
b. Use the cable clamp that is included with the lifter to secure the
cable to either side of the lifter with a generous service loop.
c. Connect the cable ground to the ground connector on the top of the b
lifter.

78 ArcGlide THC Instruction Manual 806450

2 – Installation

Connect the ohmic wire from HPRXD plasma systems

 Do not splice ohmic wires.

Figure 14

6 Ohmic wire from an HPRXD

plasma system

Lifter motor

Front view of the motor

enclosure

Side view of the lifter

To connect the ohmic wire from an HPRXD torch to the ArcGlide lifter:

1. Remove the top cover of the motor compartment on the lifter.

2. Disconnect the existing ohmic wire from the J5 connector on the underside of the lifter interface board.

3. Remove the ohmic wire from the motor compartment of the lifter.

4. Cut the terminal end off the ohmic wire from the HPRXD torch and strip 5 mm (0.2 inch) of the covering.

5. Insert the end of the ohmic wire from the HPRXD system through the grommet in the bottom of the motor
compartment of the lifter.

6. Insert the stripped HPRXD ohmic wire into the J5 connector on the underside of the lifter interface board.

7. Use cable ties to fasten the wire to the mounts on the inside back wall of the lifter compartment.

8. Replace the top cover of the motor compartment.

ArcGlide THC Instruction Manual 806450 79

2 – Installation

Connect the ohmic wire to other plasma systems

 Do not splice ohmic wires.

If your plasma system is not an HPRXD system, connect the ArcGlide ohmic
wire to the torch:

1. Unfasten the cable tie around the coiled ohmic wire and straighten the
ohmic wire.

2. Install the free end of the ohmic wire on the IHS tab on the torch retaining
cap.

Ohmic wire

2
Ground the lifter

The lifter must be grounded correctly to make sure the lifter performs
accurate initial height sense (IHS).

To ground the lifter:

1. Remove the bottom nut and washer of the grounding assembly on

the lifter.

2. Fit the terminal on the ground wire over the grounding post.

3. Replace the bottom nut and washer on the ground post and
finger-tighten it so the terminal is in contact with the washer and
bottom nut.

4. Connect the other end of the ground wire to a terminal on the table
ground bus bar on the cutting machine.

5. Verify that the wire is not in the path of the lifter mechanics

See Recommended grounding and shielding practices on page 55 for

more information.

80 ArcGlide THC Instruction Manual 806450

2 – Installation

Extended torch sleeve option

An extended torch sleeve (220790) is available for torches used with HPR130XD, HPR260XD, HPR400XD, and
HPR800XD plasma systems. This torch sleeve extends the reach of the torch tip 127.00 mm (5.00 inches) and increases
the mounting flexibility of your cutting machine setup.

 For additional stability, clamp the torch body as close to the torch tip as possible.
 Extended torch sleeve options for the MAXPRO200 plasma system are 220942 and 220943.
Figure 15

ArcGlide and HPRXD torch (228354) ArcGlide and HPRXD torch (228354)
with standard sleeve with extended sleeve (220790)

228.60 mm
(9.00 inch) 355.60 mm
(14.00 inch)

127.00 mm
(5.00 inch)
228.60 mm
(9.00 inch)
111.76 mm 355.60 mm
(4.40 inch) 239 mm (14.00 inch)
(9.40 inch)

ArcGlide THC Instruction Manual 806450 81

2 – Installation

Install the optional pneumatic breakaway

 Installing the torch breakaway kit on the lifter assembly also requires using parts of the torch mounting block kit of the
proper diameter.
 The maximum inlet pressure of the pressure regulator is 10.2 bar (150 psi). Typically, the maximum inlet pressure
should be set at 6.9 bar (100 psi).
 The routing of the leads, stall force, IHS speed, and acceleration or deceleration movements can affect the pressure
setting required to achieve reliable operation.
 If air pressure is removed, the breakaway must be manually repositioned when air is applied. The breakaway will not
rest in its position when air pressure is lost.

Figure 16

Pin 4

Pin 1 Pin 3
Wire to emergency stop
circuit
33.34 mm Tubing
(1.31 inch)
Brown = 4 Blue = 3 (not connected)

Filter/regulator
Black = 1
Inlet port 0.25 inch NPTF*
6.9 bar (100 psi)

Breakaway pressure switch,

Pressure gauge Breakaway normally-open

Moisture drain 2 hexagonal screws, 4 mm X

40 mm (8-32 X 1.50 inch),
supplied by the customer
* National pipe thread female

To install the pneumatic breakaway:

1. Mount the fiberglass bracket to the lifter using the 4 hexagonal screws.

2. Mount the breakaway to the 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 torch collision input of the CNC.

5. Mount the filter/regulator.

6. Connect the tubing between the filter/regulator and the breakaway.

82 ArcGlide THC Instruction Manual 806450

2 – Installation

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

8. Adjust the filter/regulator to indicate 2 bar (30 psi), the recommended starting pressure, on the gauge. Typical
operating pressure is 2.75 bar to 4 bar (40 psi to 60 psi)

9. Simulate a crash by forcing the breakaway to separate by hand.

10. Manually reposition the breakaway in the locked position.

11. Adjust the air pressure until the desired trip force is achieved.

12. Enable the emergency stop circuit at the CNC after the breakaway is installed.

ArcGlide THC Instruction Manual 806450 83

2 – Installation

Install the control module

Install the control module where it will be easy to read the display and to reach the controls during installation and
troubleshooting. A dry, dust-free wiring cabinet is ideal. Leave a clearance space of 200 mm (8 inches) from the front of
the control module and 6.00 mm (0.25 inch) from the heatsink.

Figure 17

381.00 mm 168.91 mm
(15.37 inch) (6.65 inch)

71.63 mm
(2.82 inch)

107.95 mm
(4.25 inch)

25.40 mm 157.23 mm
358.65 mm
(1.00 inch) (6.19 inch)
(14.12 inch)
Front view
166.62 mm
(6.56 inch)
Right side view
371.35 mm
(14.62 inch)

165.00 mm
(6.50 inch)

5.10 mm (0.20 inch) wide 127.00 mm

(5.00 inch)

6.35 mm (0.25 inch) bolt

377.70 mm
(14.87 inch)
Rear view

84 ArcGlide THC Instruction Manual 806450

2 – Installation

1. Mount the control module with 4 screws.

2. Connect the end of the lifter interface cable with the red band to the connector marked Lifter (with the red circle).
See Connect Hypernet cables on page 92 or Connect discrete cables on page 95 for more information.

3. Attach one end of the power cord to the AC power connector on the front of the control module. Prepare the other
end for the 100 VAC – 120 VAC or 200 VAC – 230 VAC power outlet.

Modify Retract Delay Time for an HT2000 plasma system

If you are installing an ArcGlide THC with an HT2000 plasma system, set switch 1 on the auxiliary DIP switch options
( 1 ) to ON on the THC processor board (228578) in the control module. This setting modifies Retract Delay Time for
correct operation.

Figure 18
1 2

1 Switch 1 set to ON 2 THC processor board (228578)

ArcGlide THC Instruction Manual 806450 85

2 – Installation

Ground the control module

To ground the control module:

1. Remove the top nut and washer of the grounding assembly on the front of the control module.

2. Fit the ground wire terminal over the grounding post.

3. Replace the top nut and washer on the ground post and finger-tighten it so the terminal is in contact with the washer
and the bottom nut.

4. Connect the other end of the ground wire to a terminal on the table ground bus bar on the cutting machine.

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

Figure 19

See Operating the control module on page 135 for more information.

86 ArcGlide THC Instruction Manual 806450

2 – Installation

Install the optional HMI

Figure 20
130.58 mm
(5.14 inch)

101.60 mm
298.00 mm (4.00 inch)
(11.73 inch)

65.00 mm
(2.50 inch)

117.60 mm Front view 19.43 mm 10-32 X 9.52 mm

9.55 mm
(4.63 inch) (0.77 inch) (0.375 inch)
(0.38 inch)
Phillips screw

Right side view

203.20 mm
(8.00 inch)

5.00 mm
(0.20 inch)
diameter

63.50 mm Bottom view

(2.50 inch)

ArcGlide THC Instruction Manual 806450 87

2 – Installation

The mounting brackets on the top and bottom of the HMI allow you to install it singly or stacked, under or on another
piece of equipment, and level or tilted. See Figure 21.

Figure 21

HMI mounted on a surface HMI mounted on a surface

and tilted down. and tilted up.

Two HMIs stacked and mounted

level under a surface.

To install the HMI:

1. Remove the mounting bracket from the HMI.

2. Place the mounting bracket on the surface where you will mount the HMI and attach the bracket with screws through
the holes in the bottom of the bracket.

3. Remount the HMI in the mounting bracket by loosely fastening the screws through the sides of the bracket into the
top or bottom holes in the sides of the HMI.

4. Adjust the HMI to the angle you want it and tighten the screws.

5. Attach one end of the power cord to the AC power connector on the back of the HMI. Prepare the other end for the
100 VAC – 120 VAC or 200 – 230 VAC power outlet.

You can also mount the HMI on top of the EDGE Pro CNC. The
EDGE Pro enclosure has 4 mounting holes for the HMI bracket.

Use 4 10-32 x 1/2 inch screws to fasten the HMI to the EDGE Pro
CNC enclosure.

88 ArcGlide THC Instruction Manual 806450

2 – Installation

Ground the HMI

To ground the HMI:

1. Remove the top nut and washer of the grounding assembly on the back of the HMI.

2. Fit the ground wire terminal over the grounding post.

3. Replace the top nut and the washer on the ground post and finger-tighten it so the terminal is in contact with the
washer and bottom nut.

4. Connect the other end of the ground wire to a terminal on the gantry ground bus bar of the cutting machine.

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

Figure 22

See Operating the HMI on page 143 for more information.

ArcGlide THC Instruction Manual 806450 89

2 – Installation

Install the plasma interface board in a plasma system

The plasma interface board includes the voltage divider and allows the ArcGlide THC to communicate with the plasma
system.

If you are replacing a Command THC with an ArcGlide THC, you must replace the Command THC plasma interface
board in your plasma system with an ArcGlide plasma interface board.

Discrete plasma interface board (141094)

The discrete plasma interface board is mounted in an enclosure that is installed in your plasma system, either internally or
externally. For specific instructions and safety-related information about mounting the enclosure, refer to the manual that
came with your plasma system.

Figure 23

114.30 mm
(4.50 inch)

152.40 mm
(6.00 inch)

See Discrete plasma interface board (141094) on page 224 for information about electrical installation.

90 ArcGlide THC Instruction Manual 806450

2 – Installation

Hypernet plasma interface board (141162)

The Hypernet plasma interface board is mounted inside an HPRXD plasma system on standoffs built into the plasma
system, as shown in Figure 24.

Figure 24

Hypernet plasma
interface board

HPR130XD and HPR260XD HPR400XD

See Hypernet plasma interface board (141162) on page 228 for information about electrical installation.

ArcGlide THC Instruction Manual 806450 91

2 – Installation

Connect Hypernet cables

A system configuration in which there is more than one Hypernet connection requires an industrial-grade Ethernet switch.
See Ethernet switch on page 46 for more information.

In this type of configuration, Hypernet connections are made from the ArcGlide control module directly to the Ethernet
switch and from there to the CNC or plasma system. See Figure 11 on page 59 for an example.

 Each unit assigned to a station must have the same Hypernet address. This common address between units allows
the Ethernet switch to direct communications to the appropriate station. See Figure 25 for an example.

Figure 25

Station 1
Lifter
HPR plasma system

Hypernet plasma interface

HMI ArcGlide control module
board
Hypernet address: 1 Hypernet address: 1
Hypernet address: 1

HyPath CNC Ethernet switch

Station 2
HMI ArcGlide control module
HPR plasma system
Hypernet address: 2 Hypernet address: 2
Hypernet plasma interface
board
Lifter Hypernet address: 2

Key:
Hypernet connection

Discrete connection

See the following pages for details:

 See Assign an ArcGlide THC to a station on page 125 for information about linking unit addresses to a station in
Phoenix software on a Hypertherm CNC.
 See the following sections for the location of the unit address switches:
 HMI processor board (228581) on page 211
 THC processor board (228578) on page 220
 Hypernet plasma interface board (141162) on page 228

 Hypernet connections and Ethernet connection to a LAN cannot be made through the same switch. If your cutting
machine is connected to a LAN over Ethernet, you must use a separate Ethernet switch for these connections.

92 ArcGlide THC Instruction Manual 806450

2 – Installation

Figure 26
To Ethernet switch power supply 1

To Ethernet switch power supply 2

+ - + -

6 5 4 3 2 1

+
PWR1 1A @24V PWR2

Power connections to the Ethernet switch Hypernet connections to the Ethernet switch

It is also possible to have a mixed Hypernet and discrete configuration in which the ArcGlide THC communicates with
only the CNC or plasma system over Hypernet and uses discrete communication for the alternate connection. See Mixed
communication on page 51.

Use the portions of the following instructions that apply to your configuration.

1. Use a Hypernet cable to connect the control module to

the Ethernet switch:
a. Insert one end of the Hypernet cable into the
Hypernet port on the front of the control module.
b. Insert the other end of the cable into one of the ports
of the Ethernet switch.
To the Ethernet
switch

2. Use a Hypernet cable to connect the CNC to the Ethernet

switch.
a. Insert one end of the Hypernet cable into the Hypernet
port on the back of a Hypertherm CNC or to a
dedicated, Hypernet port on any other CNC.
b. Insert the other end of the cable into one of the ports
of the Ethernet switch.

To the Ethernet
switch

ArcGlide THC Instruction Manual 806450 93

2 – Installation

3. Use a Hypernet cable to connect the plasma system to the

Ethernet switch:
a. Insert one end of the Hypernet cable into the Hypernet
port on the plasma interface board in the plasma
system.
b. Insert the other end of the cable into one of the ports
of the Ethernet switch. To the Ethernet
switch
Refer to the manual for your plasma system for detailed
instructions about these connections.

4. If your configuration includes the optional HMI, use a

Hypernet cable to connect it to the Ethernet switch:
a. Insert one end of the Hypernet cable into the Hypernet
port on the HMI.
b. Insert the other end of the cable into one of the ports
of the Ethernet switch.

To the Ethernet
switch

94 ArcGlide THC Instruction Manual 806450

2 – Installation

Connect discrete cables

In a discrete configuration, the communication connections are made from the control module to the HMI, CNC, plasma
system, and optional operator console. In this type of configuration, the control module and HMI communicate over a
single Hypernet connection. Therefore, this is the only configuration that does not require an Ethernet switch. See
Figure 12 on page 60.

It is also possible to have a mixed Hypernet and discrete configuration in which the ArcGlide THC communicates with the
CNC or the plasma system over a discrete connection and uses Hypernet communication for the remaining connection.
In configurations where there is more than one connection of Hypernet, an industrial-grade Ethernet switch is required for
the Hypernet connections.

Use the portions of the following instructions that apply to your configuration.

Each port on the front of the control module is color-coded to match the connector on the interface cable that connects
to it, as shown in the illustrations for each cable later in this section.

 the
To extract pins and sockets from the Amp style connectors used to create and troubleshoot discrete I/O cables, use
AMP pin extractor tool (008197).

Ground all cables with circular connectors

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

1. Remove the top nut and washer of the grounding assembly.

2. Fit the ground wire terminal on the cable over the grounding post.

3. Replace the top nut and the washer on the ground post and finger-tighten it so the
terminal is in contact with the washer and bottom nut.

Control module cable connections

1. Connect the HMI to the control module:

a. Insert one end of the HMI cable into the Hypernet connector on Hypernet connection
between the HMI and the
the front of the control module.
control module
b. Insert the other end of the cable into the Hypernet port on the
back of the HMI.

ArcGlide THC Instruction Manual 806450 95

2 – Installation

2. Connect the CNC to the control module:

a. Insert the end of the CNC I/O cable with the yellow band into the
CNC I/O connector on the front of the control module.
b. Connect the wires on the other end of the cable to the I/O signals on
the CNC.

See CNC I/O cable on page 105 for more information.

Discrete connection to the CNC

3. Connect the plasma system to the control module:

a. Insert the end of the plasma interface I/O cable with the blue band
into the Plasma I/O connector on the front of the control module.
b. Connect the other end of the cable into the plasma I/O connector
(J5) on the plasma interface board in the plasma system.

See Plasma interface I/O cable on page 110 for more information.
Discrete connection to the plasma
system

4. If your configuration includes a, optional, customized operator console,

connect it to the control module:
a. Connect the end of the operator console I/O cable with the green
band into the operator console I/O connector on the front of the
control module.
b. Connect the other end of the cable into the appropriate connectors
on the custom operator console.
Connection to the operator
See Optional operator console I/O cable on page 101 for more information. console

5. See Install the lifter on page 77 for more information on connecting the
ArcGlide lifter to the control module.

Connection to the lifter

96 ArcGlide THC Instruction Manual 806450

2 – Installation

Cables

Power cable

An AC power cable is standard equipment for North America, and is shipped with the ArcGlide THC. For other regions,
use a power cable that has an IEC-60320-C13 end which meets the requirements of local code and power connections.

To make a power cable, use the power connector (108842) that ships with the ArcGlide THC and connect a 3-wire
cable for line, neutral, and ground signals according to local electrical codes. Figure 27 shows examples of how power
cables can be made.

Figure 27
Customer-supplied power 220 VAC

Power entry module:

L1 – line 2 Fuses: 250 V, 5 A, slow blow,
L2 – line 0.25 inch x 1.25 inch
PE ground

Customer-supplied power 120 VAC

Power entry module:

L1 – line
2 Fuses: 250 V, 5 A, slow blow,
L2 – neutral 0.25 inch x 1.25 inch
PE ground

ArcGlide THC Instruction Manual 806450 97

2 – Installation

Lifter interface cable

Red band
Diameter = 20.07 mm (0.79 inch)
Bend radius = 150.00 mm (6.00 inch)

Connect one end to the port on the control

module with the red circle. Connect the other
end to the top of the lifter.

Part number Length Part number Length

223219 3.0 m (10 feet) 223115 23.0 m (75 feet)
223220 6.0 m (20 feet) 223116 30.5 m (100 feet)
223120 7.5 m (25 feet) 223117 45.5 m (150 feet)
223221 10.5 m (35 feet) 223118 61.0 m (200 feet)
223007 15.0 m (50 feet)

Pin No.* Color and size Signal name

1 Red 1.31 mm2 (16 AWG) Motor +
2 Black 1.31 mm2 (16 AWG) Motor -
3 Black 0.82 mm2 (18 AWG) Brake -
4 Brown 0.33 mm2 (22 AWG) Common -
5 Brown 0.82 mm2 (18 AWG) Power +24 VDC
6 Gray 0.33 mm2 (22 AWG) Ohmic contact sense common
7 White 0.33 mm2 (22 AWG) Ohmic contact sense
8 Violet 0.33 mm2 (22 AWG) Ohmic contact sense bias +12 VDC
9 Black 0.33 mm2 (22 AWG) Encoder common
10 Red 0.33 mm2 (22 AWG) Lifter station active
11 White/Blue 0.33 mm2 (22 AWG) Encoder input B -
12 Blue 0.33 mm2 (22 AWG) Encoder input B +
13 White/Yellow 0.33 mm2 (22 AWG) Encoder input A -
* Pin numbers are the same on both ends of the cable.

98 ArcGlide THC Instruction Manual 806450

2 – Installation

Pin No.* Color and size Signal name

14 Yellow 0.33 mm2 (22 AWG) Encoder input A +
15 White/Black 0.33 mm2 (22 AWG) Common -
16 White/Red 0.33 mm2 (22 AWG) Change consumables switch +
17 Green 0.33 mm2 (22 AWG) Lifter down switch +
18 Orange 0.33 mm2 (22 AWG) Lifter up switch +
19 White/Violet 0.33 mm2 (22 AWG) Breakaway switch +
20 White/Orange 0.33 mm2 (22 AWG) Upper limit switch +
21 White/Green 0.33 mm2 (22 AWG) Lower limit switch +
22 White/Gray 0.33 mm2 (22 AWG) Not connected
23 White/Brown 0.33 mm2 (22 AWG) Common -
24 Not connected
* Pin numbers are the same on both ends of the cable.

ArcGlide THC Instruction Manual 806450 99

2 – Installation

Hypernet and HMI interface cable

Diameter = 6.35 mm (0.25 inch)

Bend radius = 152.40 mm (6.00 inch)

Connect one end to the control module or Ethernet switch.

Connect the other end to the ArcGlide HMI.

In a Hypernet or mixed configuration where there is more than one Hypernet connection, use these cables to connect the
components of the system to the Ethernet switch.

Part number Length Part number Length

223212 3.0 m (10 feet) 223099 23.0 m (75 feet)
223222 6.0 m (20 feet) 223100 30.5 m (100 feet)
223119 7.5 m (25 feet) 223101 45.5 m (150 feet)
223223 10.5 m (35 feet) 223102 61.0 m (200 feet)
223008 15.0 m (50 feet)

If you use Ethernet cable from another supplier, make sure that the cable is a standard, shielded RJ-45 Cat5e or Cat6
cable.

Pin No.* Signal name

1 Tx + (transmit data +)
2 Tx - (transmit data -)
3 Rx + (receive data +)
4 Not connected
5 Not connected
6 Rx - (receive data -)
7 Not connected
8 Not connected
* Pin numbers are the same on both ends of the cable.

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2 – Installation

Optional operator console I/O cable

Add the appropriate connector
for your console on this end.
Contact your console supplier
for additional information.

Green band
Diameter = 7.36 mm (0.29 inch)
Bend radius = 152.40 mm (6.00 inch)

Connect this end to the port on the

control module with the green circle.

Part number Length Part number Length

223216 3.0 m (10 feet) 223111 23.0 m (75 feet)
223217 6.0 m (20 feet) 223112 30.5 m (100 feet)
223121 7.5 m (25 feet) 223113 45.5 m (150 feet)
223218 10.5 m (35 feet) 223114 61.0 m (200 feet)
223006 15.0 m (50 feet)

 See Optional operator console I/O signals on page 103 for more information about discrete
operator console I/O signals.

ArcGlide THC Instruction Manual 806450 101

2 – Installation

Pin No.*. Color Signal name** Dry contact circuit

1 Black Not connected
2 White Manual disable switch input +
+24 V
3.9 K
3 Red Manual select switch input +
+
4 Green Torch up switch input + 3.9 K

5 Orange Torch down switch input +

Common
6 Blue Spare switch input +

7 White/black Common

8 Red/black Torch Enabled output A A normally open

9 Green/black Torch Enabled output B B

10 Orange/black Error output A A normally open

11 Blue/black Error output B B

12 Black/white Spare output A A normally open

13 Red/white Spare output B B

14 Green/white Power +24 VDC output +24 V

* Pin numbers are the same on both ends of the cable.
** Input signals (pins 2 – 6) use 24 VDC; Output signals (pins 8 – 14) use dry contact closures at 24 VDC.

102 ArcGlide THC Instruction Manual 806450

2 – Installation

Optional operator console I/O signals

The following discrete signals are used between the control module and the optional, customized operator console:

Green ring on port

Manual Disable Switch: When this switch is active, its contact input signal indicates that the cutting station connected
to this THC is disabled and will not operate when an active Cut Control command is issued from the CNC.
If the plasma system is capable of turning OFF remotely, then it will be turned OFF whenever this disable
switch is active. When neither the Manual Disable nor Manual Select inputs are active, the CNC can select
the individual stations under program control.

Manual Select Switch: This switch’s contact input signal indicates that the connected station will be manually forced
into the active state and will operate when an active Cut Control command is issued from the CNC. When
the Manual Disable or Manual Select inputs are inactive, the CNC can select the individual stations under
part program control.

Torch UP Switch: This is a switch contact input signal that raises the torch. This input raises the torch manually if the
torch is not cutting. The manual motion starts as a 0.01-inch jog; after a 1/2 second, the motion remains at
the slow speed. After an additional second, the motion accelerates to the intermediate programmed speed.
If the torch is in the process of cutting, this input increases the voltage setpoint at a rate of 0.2 V every
1/4 second.

Torch DOWN Switch: This is a switch contact input signal that can be used to lower the connected torch. This input will
cause the torch to lower manually. The manual motion starts as a 0.01-inch jog; after 1/2 second, the motion
remains at the slow IHS speed. After an additional second, the motion accelerates to the intermediate
programmed speed. If the torch is in the process of cutting, this input decreases the voltage setpoint at a
rate of 0.2 V every 1/4 second.

ArcGlide THC Instruction Manual 806450 103

2 – Installation

ArcGlide control module CNC interlock kit (228594)

As part of a motion control system, the ArcGlide has an interlock to enable and disable Z-axis motion. This interlock must
be wired correctly and according to the appropriate national and local codes to allow the quick stop of motion.

 A closed circuit between pins 25 and 26 is required to satisfy the interlock circuit and enable
the Z-axis motion of the ArcGlide.

The interlock kit includes the connector, backshell, and pins that are necessary to build the interlock.

104 ArcGlide THC Instruction Manual 806450

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CNC I/O cable

Connect this end to

the CNC by adding the
appropriate connector
for your CNC.

Yellow band
Diameter = 13.72 mm (0.54 inch)
Bend radius = 152.40 mm (6 inch)

Connect this end to the port on the

control module with the yellow ring.

Part number Length Part number Length

223213 3.0 m (10 feet) 223107 23.0 m (75 feet)
223214 6.0 m (20 feet) 223108 30.5 m (100 feet)
223122 7.5 m (25 feet) 223109 45.5 m (150 feet)
223215 10.5 m (35 feet) 223110 61.0 m (200 feet)
223005 15.0 m (50 feet)

 See CNC discrete I/O on page 108 for more information about discrete CNC I/O signals.

ArcGlide THC Instruction Manual 806450 105

2 – Installation

All ArcGlide CNC inputs can be configured for dry contact closures or 12 – 24 V sourced inputs.

Dry contact Sourced circuit

Pin No.* Color Signal name circuit (D) (S)

1 Red Cycle Start input + 3.9 K +24 V

3.9 K 3.9 K
2 Black Cycle Start input -

3 White Low Gain input + 3.9 K +24 V

3.9 K 3.9 K
4 Black Low Gain input -

5 Green AVC** Disable input + 3.9 K +24 V

3.9 K 3.9 K
6 Black AVC** Disable input -

7 Blue IHS Sync input + 3.9 K +24 V

3.9 K 3.9 K
8 Black IHS Sync input -

9 Yellow Spare input 1 + 3.9 K +24 V

3.9 K 3.9 K
10 Black Spare input 1 -

11 Brown Spare input 2 + 3.9 K +24 V

3.9 K 3.9 K
12 Black Spare input 2 -

* Pin numbers are the same on both ends of the cable.

** AVC = Arc voltage control

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All ArcGlide CNC inputs can be configured for dry contact closures or 12 V – 24 V sourced inputs.

Pin No.* Color Signal name Dry contact or sourced circuit

13 Orange IHS Complete output A A normally open
14 Black IHS Complete output B B

15 White Retract Complete output A A normally open

16 Red Retract Complete output B B

17 Green Machine Motion output A A normally open

18 Red Machine Motion output B B

19 Blue THC Error output A A normally open

20 Red THC Error output B B

21 Yellow Torch Breakaway output A A normally open

22 Red Torch Breakaway output B B

23 Brown CNC Spare output A A normally open

24 Red CNC Spare output B B

25 Orange Motion Interlock input +** +24 V

26 Red Motion Interlock input -**

A
27 White Interlock output A
B
28 Green Interlock output B

29 Blue Common

30 Green Common

31 Yellow Common

32 Green Common

33 Brown +24 VDC output +24 V

34 Green +24 VDC output +24 V

35 Orange +24 VDC output +24 V

36 Not connected
37 Not connected
* Pin numbers are the same on both ends of the cable.
** The circuit is closed if a jumper is used.

ArcGlide THC Instruction Manual 806450 107

2 – Installation

CNC discrete I/O

CNC inputs have two different modes that are selected using switches behind the calibration and setup door. The inputs
can be configured for dry contacts (no external voltage), or for positive voltage sourced inputs.

If the THC control module interface is configured with dry contacts, the operation of LEDs on the discrete plasma
interface board is reversed and the LEDs turn OFF when input is active. With sourced inputs, LEDs turn ON when an
input is active.

 Ifsignals
the Hypernet interface to the CNC is used, only the interlock input signal must be wired on this connector. If discrete
are used, the required discrete signals on this connector must be connected.

Figure 28

This connector has a yellow ring. Calibration and setup door Dry or sourced CNC input switch

All the required discrete interface signals are described below. All other signals are optional for multiple torch operation,
improved performance, or reduction in cycle times.

Cut Control: This is a required output from the CNC and an input to the ArcGlide. The CNC should activate this signal
to begin a plasma cut. This signal begins the entire process of IHS, Plasma Start and Motion, and Automatic
Voltage Control (AVC) followed by a retract at the end of the cut when this signal is removed. This signal
must be maintained during the plasma cut.

Low Gain: This input automatically reduces the AVC gain for marking. This improves the stability of the height control
during marking.

Torch Height Disable: This is an optional signal input to the ArcGlide. When it is active, this signal temporarily disables
the automatic height control and forces the torch to hold its height position. It is primarily used to disable the
height control in corners or whenever the machine speed is not at the optimal cutting speed. This signal
improves cutting performance by disabling the height control when the machine slows down for corners.
This improves the corner cut quality and prevents the torch from diving into the workpiece.

Hold Ignition: This is an optional input to the ArcGlide to allow multiple torches to start synchronized. For a single torch
installation, this signal is optional but recommended. The CNC should activate this signal to delay plasma
torch ignition until all active torches in a multiple torch configuration have completed their IHS sequence and
are in position and ready to fire. At this point all active torches will return an active IHS Complete signal to
the CNC and the CNC should remove all Hold Ignition input signals and allow all active plasma torches to
ignite simultaneously.

Spare inputs 1 and 2: These inputs to the ArcGlide are reserved and should not be connected.

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2 – Installation

IHS Complete: This is an optional signal output from the ArcGlide to the CNC that is used only when the CNC has to
synchronize IHS for multiple ArcGlide systems. This signal is used to indicate that the initial height sensing
(IHS) is complete and that the torch is in position and ready to fire. For multiple torch installations, the CNC
should wait for all active torches to return an IHS Complete signal before simultaneously removing the Hold
Ignition signal and allowing all torches to ignite at the same time. For single torch installations this signal is
not used.

Retract Complete: This signal is an output from the ArcGlide that is active when a cut is completed and the torch has
been raised to the selected Retract Height. The CNC uses this signal to delay the move to the next cut and
to clear any tip-ups.

Cut Sense: This is a required output from the ArcGlide to the CNC. This signal is issued after plasma torch ignition and
the Pierce Delay (Pierce Time in Phoenix software) time has expired. This signal indicates that the CNC
should begin the cutting motion.

See Operation on page 127 for more information on Pierce Delay.

THC Error: This is an output from the ArcGlide to the CNC that indicates that the THC has encountered an error
condition. The HMI displays the actual error condition.

See ArcGlide errors on page 191 for more information about ArcGlide error messages.

Breakaway Error: This output from the ArcGlide indicates that the torch breakaway has separated. This output is reset
by replacing the torch breakaway.

Interlock input: This is a normally-closed contact closure that allows ArcGlide motion. If this contact is opened, the
ArcGlide lifter motor drive will lose power. This circuit must be wired according to national and local
regulations.

Interlock output: The Interlock output is an independent contact closure that is also normally-closed. The Interlock
output must have the same state as the Interlock input.

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2 – Installation

Plasma interface I/O cable

Connect this end to the
discrete plasma
interface board in the
plasma system.
Blue band Pins 36 – 50 are not
Diameter = 13.72 mm (0.54 inch) used.
Bend radius = 152.40 mm (6.00 inch)

Connect this end to the port on the

control module with the blue circle.

Part number Length Part number Length

223227 3.0 m (10 feet) 223103 23.0 m (75 feet)
223228 6.0 m (20 feet) 223104 30.5 m (100 feet)
223123 7.5 m (25 feet) 223105 45.5 m (150 feet)
223229 10.5 m (35 feet) 223106 61.0 m (200 feet)
223004 15.0 m (50 feet)

 See Plasma discrete I/O on page 113 for more information about discrete plasma I/O signals.

110 ArcGlide THC Instruction Manual 806450

2 – Installation

Dry contact Sourced

Pin No* Color Signal name
circuit (D) circuit (S)

1 Red RS-422 Rx +
2 Black RS-422 Rx -
3 White RS-422 Tx +
4 Black RS-422 Tx -
5 Green RS-422 common
6 Black Motion input + 3.9 K +24 V
3.9 K 3.9 K
7 Blue Motion input -

8 Black Error input + 3.9 K +24 V

3.9 K 3.9 K
9 Yellow Error input -

10 Black Rampdown Error input + 3.9 K +24 V

3.9 K 3.9 K
11 Brown Rampdown Error input -

12 Black Not ready input + 3.9 K +24 V

3.9 K 3.9 K
13 Orange Not ready input -

14 Black Spare input + 3.9 K +24 V

3.9 K 3.9 K
15 White Spare input -

* Pin numbers are the same on both ends of the cable.

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2 – Installation

Pin No.* Color Signal name Dry contact or sourced circuit

16 Red Corner output A A normally open
17 Green Corner output B B

18 Red Pierce output A A normally open

19 Blue Pierce output B B

20 Red Hold output A A normally open

21 Yellow Hold output B B

22 Red Start output A A normally open

23 Brown Start output B B

24 Red Spare output A A normally open

25 Orange Spare output B B

26 Red Remote ON output A A normally open

27 White Remote ON output B B

28 Green Common

29 Blue Common

30 Green Common

31 Yellow +24 VDC output +24 V

32 Green +24 VDC output +24 V

33 Brown +24 VDC output +24 V

34 Green 1/50 Arc voltage +

35 Orange 1/50 Arc voltage -
36 to 50 Not connected
* Pin numbers are the same on both ends of the cable.

112 ArcGlide THC Instruction Manual 806450

2 – Installation

Plasma discrete I/O

Plasma inputs have two different modes that are selected using switches behind the calibration and setup door. The
inputs can be configured for dry contacts (no external voltage), or for positive-voltage sourced inputs.

 Ifinstalled
the THC control board is configured with dry contacts, LED operation on the discrete plasma interface board,
in the plasma system, is reversed and the LEDs will turn OFF when the input is active.

 Ifsignals
the plasma system uses Hypernet communication with the ArcGlide, these discrete signals are not used. If discrete
are used, the required signals of this connector must be connected to the discrete plasma interface board.

Figure 29

This connector has a blue ring. Calibration and setup door Dry or sourced plasma input switch

The following discrete signals are used to connect the ArcGlide THC to the plasma system. All the required discrete
interface signals between the control module and the plasma system are described below. All other signals are optional
for multiple torch operation, improved performance, or reduction in cycle times.

Arc Transfer: This is a required input to the ArcGlide. This signal is input to the ArcGlide from the plasma system to
indicate that arc transfer has occurred.

Plasma Error: This is an optional signal that is output from the plasma system to indicate that an error has occurred.

Rampdown Error: This is an optional output from the plasma system that indicates the plasma torch lost arc transfer
before the controlled arc turns off. This condition indicates that the consumable life may be reduced. You
should make changes to the part programming to reduce or eliminate these types of errors to achieve
optimal consumable life.

Not Ready: This is an optional output from the plasma system that indicates that the plasma system is not ready to
receive a Plasma Start. The plasma system may be busy changing or purging gas flows or be involved in
some other time-consuming operation. To verify proper operation, the CNC should check this signal before
issuing a Plasma Start.

Corner: This is an optional output from the THC to the plasma system. This signal indicates that the plasma system
should reduce its output current to a pre-programmed level to improve the cutting performance in corners.
The default value is 50% of the normal cutting current. This signal is not available with Hypernet.

Serial Enable: This is an optional input that enables serial communication between the ArcGlide and the plasma
system.

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2 – Installation

Pierce: This is an optional output from the THC and input to HPR supplies. This signal informs the plasma system that
the unit is piercing and the plasma system should maintain the high shield gas preflow during the pierce. This
signal is used to improve the piercing capability of HPR plasma systems only.

Hold: This is an optional output from the THC and input to the plasma system. For a single torch installation, this signal is
optional but recommended. The CNC should activate this signal to delay plasma torch ignition until all active
torches in a multiple torch configuration have completed their IHS sequence and are in position and ready to
fire. At this point, all active torches will return an active IHS Complete signal to the CNC and the CNC
should remove all Hold Ignition input signals and allow all active plasma torches to ignite simultaneously. This
signal can also be used to save cycle time by performing gas preflow during the IHS sequence.

Start: This output from the THC is used to start the plasma system. This signal is a maintained signal. The plasma system
will continue to power the plasma cutting torch until this signal is removed. When the Start signal is removed
the plasma system begins to ramp down and turn off the torch power.

Spare output: This is an extra output for future use.

Remote On: This is an optional output signal from the ArcGlide THC that can be used to turn ON or OFF capable
plasma systems. On capable systems, such as the HPR plasma systems, deactivating this signal will remove
the high power input to the plasma system and will turn off the gas and torch cooling pump. See Hypernet
plasma interface board (141162) on page 228 for more information.

1/50th Arc Voltage: This analog input to the THC provides the arc voltage feedback used for automatic height control.
The signal is scaled so that 5 VDC equals an arc voltage of 250 VDC. The positive side of this voltage
should be connected to chassis ground. To provide high accuracy, this voltage should have an effective
output resistance of 2 KΩ or less.

114 ArcGlide THC Instruction Manual 806450

2 – Installation

Non-serial plasma interface cable

This cable connects the ArcGlide plasma interface board and control board inside the plasma system. Use this cable only
when the CNC provides serial communication directly to the control board.

Red band
Diameter = 13.72 mm (0.54 inch)
Bend radius = 152.40 mm (6.00 inch)

Part number Length Used in

223192 0.61 m (2 feet) HPR130XD, HPR260XD
223193 2.3 m (7.5 feet) HPR400XD

Pin No. Color Signal Pin No. Color Signal

1 Not connected 20 Not connected
2 Not connected 21 Not connected
3 Black RS-422 communication 22 Blue HPR turned ON
4 Black Motion - 23 Yellow Motion +
5 Black Error - 24 Brown Error +
6 Black Rampdown error - 25 Orange Rampdown error +
7 Red HPR not ready - 26 White HPR not ready +
8 Red Not connected 27 Green Not connected
9 Red Not connected 28 Blue Not connected
10 Red Not connected 29 Yellow Not connected
11 Red Not connected 30 Brown Not connected
12 Red Corner A 31 Orange Corner B
13 Green Pierce A 32 White Pierce B
14 Green Hold A 33 Blue Hold B
15 Green Plasma Start relay A 34 Yellow Plasma Start relay B
16 Green Remote ON A 35 Brown Remote ON B
17 Green Not connected 36 Orange Ground
18 White Ground 37 Black +24 VDC HPR plasma
19 Blue Not connected 38 Ground

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2 – Installation

Serial plasma interface cable

This cable connects the ArcGlide plasma interface board and control board inside the plasma system. Use this cable
when the ArcGlide THC supplies serial communication to the plasma system.

Diameter = 9.65 mm (0.38 inch)

Bend radius = 152.40 mm (6.00 inch)

Part number Length

123760 0.61 m (2 feet)
123209 1.5 m (5 feet)

Pin No. Color Signal Pin No. Color Signal

1 Black HPR Rx - 20 Red HPR Rx +
2 Black HPR Tx - 21 Green HPR Tx +
3 Black RS-422 communication 22 Blue HPR turned ON
4 Black Motion - 23 Yellow Motion +
5 Black Error - 24 Brown Error +
6 Black Rampdown error - 25 Orange Rampdown error +
7 Red HPR not ready - 26 White HPR not ready +
8 Red Not connected 27 Green Not connected
9 Red Not connected 28 Blue Not connected
10 Red Not connected 29 Yellow Not connected
11 Red Not connected 30 Brown Not connected
12 Red Corner A 31 Orange Corner B
13 Green Pierce A 32 White Pierce B
14 Green Hold A 33 Blue Hold B
15 Green Plasma Start relay A 34 Yellow Plasma Start relay B
16 Green Not used 35 Brown Not used
17 Green Not connected 36 Orange Ground
18 White Ground 37 Black +24 VDC HPR plasma
19 Not connected 38 Ground

116 ArcGlide THC Instruction Manual 806450

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ArcGlide discrete interface signal examples

Inputs

Figure 30 shows a simplified schematic of the ArcGlide THC inputs.

The inputs for both CNC and plasma can be configured for dry
contacts (no external voltage) or for positive voltage sourced inputs.
The default is dry contacts. The inputs have two different modes that
are selected using switches behind the calibration and setup door on
the top right front of the control module.

The mode that is selected automatically compensates for the polarity

reversal so that in both cases, a closed switch input will activate the signal.

All inputs to the lifter interface and operator console interface are fixed in the dry contact mode.

Figure 30

Dry contact inputs

+24 V Field
3.9 K
Switch 3.9 K

+24 V Field
3.9 K
Optoisolator 3.9 K

+24 V Field
3.9 K
3.9 K
Relay

Voltage sourced inputs

Switch

12 VDC to 24 VDC 3.9 K

12 VDC to 24 VDC
(external supply) 3.9 K

ArcGlide THC Instruction Manual 806450 117

2 – Installation

Relay outputs

Most of the ArcGlide THC outputs are relay contacts and can be used for either AC or DC loads. All relay outputs are
protected with thermal fuses that automatically reset and protect against currents above 100 mA. The 24 V supply is
limited to a total of 2 A for all outputs. Figure 31 shows a simplified schematic of the ArcGlide THC outputs.

Figure 31

+24 VDC Field Use internal field +24 VDC

A
LEDs
Relay PTC* 100 mA
B

Optoisolator
A
Relay PTC* 100 mA
B

A
Relay PTC* 100 mA Relay
B

Voltage 12 VAC to 24 VAC or 24 VDC

*Positive temperature coefficient

118 ArcGlide THC Instruction Manual 806450

2 – Installation

ArcGlide setup in Phoenix™ software

If you are installing the ArcGlide THC hardware with a Hypertherm CNC and Phoenix software (version 9.5 or later) and
the Hypernet interface, refer to the Phoenix Software V9 Series Installation and Setup Manual (806410) for complete
information.

Set up ArcGlide and Hypernet

To set up the ArcGlide THC and Hypernet:

1. Choose Setups > Password and enter the Machine password.

2. On the Machine setup screen, shown in Figure 32, use the scroll box next to ArcGlide THCs Installed to specify the
number of ArcGlide THCs installed.

3. Choose Yes next to Use Hypernet to enable Hypernet communication. Choose No to configure the system for
discrete communication.

4. Choose Yes next to Message Plasma PS via Hypernet to enable command-based messaging with the plasma
system.

Figure 32

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2 – Installation

ArcGlide axis setup

Use the setup parameters on the ArcGlide axes screens to verify that the THC operates successfully for your application.

1. Choose Setups > Password > Machine Setups > ArcGlide Axis. If you have installed more than one ArcGlide axis,
the screen displays a numbered soft key for each axis.

2. On the ArcGlide Axis screen, shown in Figure 33, choose the soft key for the ArcGlide axis you want to set up. Set
values for the parameters on the ArcGlide axes screens.

3. Choose OK when you have finished setting up each axis.

The default values for each parameter on the ArcGlide axes screens are optimized for the majority of applications.
However, you may need to adjust the following parameter values:
 Stall Force
 Pointer Offset Side
 Pointer Offset Front
 Voltage Calibration

Figure 33

120 ArcGlide THC Instruction Manual 806450

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ArcGlide axis setup parameters

Gains

Gains enable controlled speed and motion from a closed-loop servo system and reduce the effect of position errors in
these systems. Gains can correct following error that occurs as a result of mechanical delays, friction and load, or
uncontrolled speed.

Each gain value is a multiplier that modifies the output from the encoder and brings this output closer to the set point.
Motion tuning involves adjusting gains to reduce error as much as possible and to make sure cutting performance is
reliable.

Gains are often interrelated and the value for one gain parameter can have an influence on the performance of other
gains. Therefore, motion tuning is experimental and requires multiple tests to reach a set of appropriate values for your
system and application.

Most gains affect the raising and lowering of the torch, and improve the accuracy of the initial height sense motion.
Voltage gain is the only gain that affects cutting.

The following definitions provide the default or recommended value for each parameter. These values are appropriate for
the majority of applications.

Speed: This gain value regulates the speed of the lifter. Set Speed Gain after you enter the value for Maximum Speed.

Set the Maximum Speed before optimizing Speed Gain.

Optimize the Speed Gain value before attempting to change either the Position or Voltage gains. Manual
motion and approaching the workpiece during automatic IHS require regulated speeds. If this value is too
high, the lifter speed regulation will become unstable and prone to oscillation. If this value is too low, the
speed regulation can become slow and inaccurate. Test this value by repeatedly raising and lowering the
lifter in Manual mode. To optimize this gain, raise this value until there is a very slight oscillation during manual
operation and then reduce the setting by 1.

Range: 1 to 10; Setting: 5

Position: This gain is a multiplier for closed-loop positioning. Adjust Position Gain after you find the appropriate value for
Speed Gain.

The THC uses position-based moves to move the torch to the IHS height and to the retract height at the end
of a cut.

If this value is too high, the lifter positioning will become unstable and prone to oscillation. If this value is too
low, the positioning can become slow and inaccurate.

Test this gain by repeatedly executing IHS TEST and checking that the lifter quickly and accurately reaches
the IHS and Retract Heights.

To optimize this gain, raise the value until there is a very slight oscillation when the torch settles into the IHS
or Retract positions and then reduce the setting by 1.

Range: 1 to 10; Setting: 5

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2 – Installation

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

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

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

Range: 1 to 10; Setting: 5

Speeds

Maximum: Sets the maximum linear speed that the THC can achieve. This value depends on the lifter motor speed at
45 VDC, the screw pitch, the weight of the lifter load, and the desired speed of operation.

This value is used as the 100% speed value when scaling the control equations. It is important that this value
is set correctly because it affects the scaling of all the other control loops.

Set this parameter during installation, before optimizing Speed Gain.

Set this value to a speed that can be achieved easily. Use a conservative setting and assume a low, incoming
AC line voltage. If this speed is set too high, the maximum available motor drive voltage will be insufficient to
drive the motor to the desired maximum speed. This will make the top of the linear control range unavailable
and result in sub-optimal operation.

If the Maximum Speed is set too high, it may be difficult for the THC to operate precisely at slow speeds
when trying to control the arc voltage or to move to an accurate IHS distance. If this speed is set too low, the
linear control range will only cover the low portion of the available mechanics range and the result may not be
optimal.

For the Hypertherm 239 mm (9.40 inch) lifter, this value is 15240 mm/min (600 in/min). At the low input line
voltage limit, the motor drive is capable of supplying about 45 VDC. The motor used in the Hypertherm
239 mm (9.40 inch) lifter will produce full-rated torque at about 3,300 r/min at this voltage. The Hypertherm
239 mm (9.40 inch) lifter has a 5-mm pitch ball-screw which requires 25.4 in/mm / 5 mm = 5.08 revolutions
to travel one linear inch. This results in a value of 3,300 r/min / 5.08 revolutions/inch = 650 linear in/min of
travel speed. This value was rounded down to the nearest even hundreds to guarantee a 100% value under
all conditions.

Setting: 15,240 mm/min (600 in/min)

Fast: This speed governs all automatic rapid moves such as the End-of-Cut-Retract or the Initial Approach to the
workpiece.

Set this parameter to the value of Maximum Speed. However, you can set it lower if there is a heavy load on
the lifter. With the Hypertherm 239 mm (9.40-inch) lifter, this value is set to 15,240 mm/min (600 in/min).

Setting: 15,240 mm/min (600 in/min)

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Slow: This speed is the Homing Speed and is the fastest speed for manual moves. It is also the maximum speed limit
during arc voltage control.

Setting: 3,810 mm/min (150 in/min)

IHS: This parameter sets the slow speed for the final approach to the workpiece during an IHS operation. It is also the
slow speed for manual moves. To avoid poor regulation of speed, do not set this value below 10% of
Maximum Speed.

Setting: 1,524 mm/min (60 in/min)

Mechanical

Encoder Counts: This value scales the position feedback from the encoder.

The value is based on the ball-screw pitch and the encoder resolution. It is equal to the number of encoder
counts per revolution, multiplied by the number of revolutions required to travel one inch. The encoder is
operated in 4X mode, so the number of counts per revolution is equal to the number of pulses per revolution
multiplied by four.

The Hypertherm 239 mm (9.40-inch) lifter has an encoder with 1,000 pulses per revolution which produces
4,000 counts per revolution in 4X mode. The lifter has a 5 mm pitch ball-screw which requires
25.4 (in/mm) / 5 (mm) = 5.08 revolutions to travel one linear inch. This results in a value of 5.08 (revolutions)
x 4,000 (counts/revolution) = 20,320 counts per linear inch of travel.

Setting: 800 counts/mm (20,320 counts/inch)

Slide Length: This value is the length of the lifter's usable travel. The ArcGlide lifter has 239 mm (9.40 inches) of usable
travel.

Current Limit: This is the maximum continuous motor current for which the lifter motor is rated.

This value is the normal, continuous operating current limit but motor current can periodically exceed this
value for a few seconds during extreme acceleration. The ArcGlide lifter uses a motor with a 3 A continuous
current limit.

The motor can be damaged if the value for this parameter is set above the continuous current operating limit
for the installed motor.

Range: 1 A to 6 A; Setting: 3 A

Stall Force: This value determines the amount of force for the Stall Force backup to the ohmic contact sensing. The
values are relative values and start at 1 for the minimum force and 10 for the maximum force. This value
should be set high enough to avoid false stall detection but not so high that the excess force causes a
deflection of the workpiece and inaccurate IHS operation.

With the Hypertherm 239 mm (9.40-inch) lifter, the value of 5 is appropriate. It may be necessary to reduce
this value if the THC is used with a thin workpiece. Use the Test IHS function to optimize this value.

Test this feature by disabling the ohmic contact by using the process menu or by removing the ohmic
contact wire. The Stall Force value is optimum when there are no false workpiece detections and the IHS
operation is accurate.

Range: 1 to 10; Setting: 5

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2 – Installation

Miscellaneous

Pointer Offset Side: This value is the offset distance between the torch center and the laser pointer when looking from
the side of the cutting machine. Use the precise distance between the laser spot and the center of the torch
to fine-tune this value.

Setting: 66.04 mm (2.60 inches)

Pointer Offset Front: This value is the offset distance between the torch center and the laser pointer when looking from
the front of the cutting machine.

Use the precise distance between the laser spot and the center of the torch to fine-tune this value. To verify
the laser offset, pierce a hole in the workpiece. Perform a manual offset using the laser pointer offset in
Manual Options. If the offset is set correctly, the laser should be inside the pierce hole.

Setting: 107.93 mm (4.25 inches) (this value can vary slightly)

Voltage Calibration: This value is used to finely calibrate the measured arc voltage accuracy.

While this parameter is not normally required, it can be used when fine tuning multiple ArcGlide THCs on a
cutting machine.

The measured input value is multiplied by this constant before being used for either voltage control or
display.

This calibration affects all of the ArcGlide hardware connected to this station including the HMI display and
the HPR Hypernet interface. When an ArcGlide is shipped from the factory, the voltage has been calibrated
in hardware and this value is set to 1.000. This parameter is normally only used to adjust for the same arc
voltage displays on multiple ArcGlide installations.

Range: 0.900 to 1.100; Setting: 1.000

Arc Voltage: This Arc Voltage value is for display only and cannot be edited. It is provided to check the results after
changing the Arc Voltage Calibration above.

Range: 0 to 400

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

Options: Yes, No

124 ArcGlide THC Instruction Manual 806450

2 – Installation

Assign an ArcGlide THC to a station

The station number that you select in the Phoenix Station Configuration screen must match the address set in the
ArcGlide control module, HMI, and the address set on the Hypernet plasma interface board. Assigning the ArcGlide to a
station in Phoenix software also enables the ArcGlide Process screen (see page 156) and the ArcGlide manual on the
Help screen.

1. Verify that the ArcGlide setup fields are correct in the Machine Setup screen. See Set up ArcGlide and Hypernet on
page 119 for more information.

2. Choose Setups > Password > Station Configuration.

3. Choose Reset if ArcGlide THC does not appear in the Lifter dropdown list.

4. On the Station Configuration screen, shown in Figure 34, select ArcGlide THC for each station where an ArcGlide is
installed.

5. Choose OK when you have finished assigning ArcGlide lifters to the stations on the cutting machine.

Figure 34

ArcGlide THC Instruction Manual 806450 125

2 – Installation

126 ArcGlide THC Instruction Manual 806450

Section 3
Operation

Operator controls

Control module

3
1

Control Description
1 LEDs These LEDs show the status of system operations.
2 Display window This window displays status, error, and diagnostic messages.
3 Display select Push the UP or DOWN arrow to scroll up or down through the screens in the display
window.

ArcGlide THC Instruction Manual 806450 127

3 – Operation

Lifter

2
3

Control Description
1 Station status lamp This lamp is illuminated if the lifter is enabled. The lamp flashes slowly when there is an
error. It flashes rapidly in Align mode.
When the lamp is not illuminated, the brake is locked and the lifter is disabled.
2 Station Push this switch up to enable the lifter for operation. Push the switch down to disable
ENABLE/DISABLE the lifter for maintenance, to replace consumables, or to turn OFF the lifter.
switch If the plasma system allows the THC to turn it on and off and is wired appropriately,
this switch can turn ON and OFF the plasma system.
3 Lifter UP/DOWN Push this switch up or down to raise or lower the torch.
switch

128 ArcGlide THC Instruction Manual 806450

3 – Operation

HMI

1 9

3
4 5
6 8
7

Control Description
1 Parameter window Displays setup and operating parameters, error and status messages. If the system
does not have a CNC connected to Hypernet, the operator can also make changes to
parameter values.
2 LEDs These LEDs show the status of system operations.
3 Station Push this switch up to enable the lifter for operation. Push the switch down to disable
ENABLE/DISABLE the lifter for maintenance, to replace consumables, or to turn OFF the lifter. In HPR
switch and HPRXD systems in which Remote On is installed on the plasma interface, this
switch can be used to turn ON or OFF the plasma system.
4 Scroll and selection Allows the user to select, set, and view values for parameters in the parameter
knob window. Turn the knob to scroll; push it to make a selection.
5 Lifter UP/DOWN Push this switch up or down to raise or lower the torch.
switch
6 Auto or Manual mode Push this switch up or down to select Automatic or Manual mode.
selection switch
7 IHS test button Push this button to test the IHS function of the lifter. With each successive push, the
torch alternates between transfer and retract positions.
8 Tip-touch LED This LED illuminates when the torch makes ohmic contact with the workpiece. If this
LED does not illuminate during ohmic contact, see the description and solution for
Error 21 in ArcGlide errors on page 191.
9 Arc voltage window This window displays the actual arc voltage or OFF if the lifter is disabled.

ArcGlide THC Instruction Manual 806450 129

3 – Operation

Daily operations

Startup procedure

Turn ON the ArcGlide by connecting the power cord of the control module to the power source.

To turn ON an entire cutting machine, turn ON power to the units in the following order:

1. CNC

2. Plasma system and ArcGlide THC

Automatic diagnostic tests

When the ArcGlide THC is turned ON, the control module automatically performs 3 tests to make sure that the system is
ready to operate. During these tests, the control module:

1. Verifies that the necessary Hypernet connections are operational. The minimum Hypernet requirement is the
connection between the HMI or CNC and the control module. In a Hypernet configuration, if the Hypernet
connection between the ArcGlide and the plasma system is not active, the plasma system will not turn ON.

2. Returns the lifter to the Home position.

3. Calibrates the baseline stall force and returns the torch to the home position.

If the system does not perform as expected in these tests, an error message displays on the HMI or the CNC. See Error
message troubleshooting on page 191 for more information.

Verify workpiece sensing

Before you begin operations, verify that workpiece sensing is set up correctly for the type of cutting you intend to do.

When the lifter performs an IHS test, it senses the workpiece through one of two functions; ohmic IHS or stall force. The
system uses the ohmic wire to sense the workpiece if nozzle contact is selected for IHS. If the system does not sense the
workpiece through the ohmic wire, the system uses stall force as a backup method and reports Error 21, “OHMIC TIP
SENSE FAIL.” See Error message troubleshooting on page 191 for more information.

If you want to use stall force, verify that the value for stall force is set correctly. If this value is too high, the torch will bend
the workpiece during sensing.

If you are cutting or sensing the workpiece under water, you must use stall force.

Shutdown procedure

Turn OFF the ArcGlide by disconnecting the power cord of the control module from the power source.

If you disable the ArcGlide with the ENABLE/DISABLE switch on the lifter unit, the plasma system will also turn off.

 IfArcGlide
you are using the HPR Remote On or Off feature with the ArcGlide THC, do not disconnect the power cord on the
control module to turn OFF the ArcGlide THC.

130 ArcGlide THC Instruction Manual 806450

3 – Operation

ArcGlide THC operating modes

The ArcGlide operates in Manual or Automatic mode. Select the operating mode on the Plasma Process screen. See
ArcGlide operating parameters on page 156 for more information.

WARNING!
THE THC LIFTER CAN INJURE YOUR HAND

The down-force pressure of the lifter can cause injury. Verify that the system is in a safe condition
before accessing the lifter area.

Manual mode

The ArcGlide THC can be operated in Manual mode for special circumstances. In Manual mode, there is no THC motion
unless it is initiated by the manual UP/DOWN switch on the HMI or CNC. This mode is rarely used because the torch will
fire in the air if it is not close enough to the workpiece to transfer the arc.
 Momentarily hold the switch in one direction for less than 0.5 second to move the torch 0.254 mm (0.01 inch).
 Hold the switch in one direction for more than 0.5 second to move the torch continuously at the programmed IHS
Speed.
 Hold the switch in one direction for more than 1 second to accelerate the torch to the programmed Slow Speed.

Manual mode is used to:

 Mark or cut a flat workpiece when cut quality is not a primary concern. The torch cuts at the same height regardless
of consumable wear.
 Make rip cuts.
 Check arc voltage calibration.
 Accommodate special conditions that do not operate well in automatic modes.

Automatic modes

The ArcGlide THC can operate in one of three automatic modes:

 Voltage Control Off
 Set Arc Voltage
 Sample Voltage

Automatic modes are most commonly used in production cutting applications. These modes use the settings from the cut
chart, software, and part programs in the CNC to govern the height, speed, timing, position, and movement of the torch.

ArcGlide THC Instruction Manual 806450 131

3 – Operation

Voltage Control Off mode

In Voltage Control Off (also called automatic voltage control disabled or AVC disabled mode), the ArcGlide automatically
performs IHS and then moves to the transfer height. When the torch reaches transfer height, it fires but delays X and Y
cutting motion until it has moved to the pierce height and the pierce is complete.

After the pierce is complete, the torch begins cutting and transitions to the cut height above the workpiece. The cutting is
performed at a fixed position with no adjustment for arc voltage feedback. At the end of the cut, the torch automatically
retracts to the programmed Retract Height.

This mode is commonly used for rip cuts, cutting remnants, or for cutting single, simple parts.

Set Arc Voltage mode

In this mode, the THC performs IHS and moves to the transfer height. After the torch fires, it immediately moves to the
pierce height. After the pierce, cutting motion begins and, after a programmed delay (AVC Delay and Torch Height
Disable), AVC begins. During cutting with AVC, the THC moves the torch up or down to maintain the arc voltage at the
programmed value for Set Arc Voltage in the cut chart or Process screen in the Phoenix software.

The Set Arc Voltage mode is used for special cutting or marking conditions in which obtaining an accurate arc voltage
sample is difficult. Some examples include:
 Marking at low standoff torch heights
 Cutting thin material at low torch heights
 Cutting complex shapes where lead-ins are short
 Cutting or marking under conditions where an accurate IHS is not possible. Some of these conditions include:
 A dirty, rusty, oiled, or painted workpiece
 Stall sensing with thin flexible material
 Cutting with a bevel head

Sample Voltage mode

Sample Voltage mode is the most automatic mode of operation. It optimizes consumable life because it compensates for
the change in arc voltage as consumables wear down.

In Sample Voltage mode, the THC performs the same IHS, piercing, cutting, and retract sequences as the Set Arc
Voltage mode. However, after piercing, the THC samples the arc voltage under steady state operating conditions. The
THC uses sample voltage as the set arc voltage for the remainder of the cut.

This mode requires an accurate IHS and voltage sample. In addition, when Sample Voltage mode is on, the CNC does
not use the Set Arc Voltage from the cut chart.

To enable Sample Voltage mode for the ArcGlide, choose Automatic and set Sample Voltage to ON.

132 ArcGlide THC Instruction Manual 806450

3 – Operation

Sample voltage is used for:

 Any cutting or marking conditions in which accurate IHS and arc voltage sample is possible
 Clean, flat, relatively level workpieces
 Parts with medium or long lead-ins

Figure 35 on page 134 shows the sequence of cut control operations that the parameters in the Phoenix software
control. If your CNC does not use Phoenix software, the operations can have different names but the actions of the torch
are likely to be the same.

Initial height sense

The ArcGlide THC uses a sequence called initial height sense, or IHS, to detect the workpiece. You perform a first initial
height sense after powering up the cutting machine and before each cutting job. A first IHS detects the height of the
workpiece so that the CNC can calculate the torch-to-work distance. The CNC uses the torch-to-work distance for all
subsequent IHSs which it can perform using much faster speeds since the height of the workpiece is known.

The IHS begins at the Start IHS Height set in the Process screen in Phoenix, or in the ArcGlide HMI. When the torch
reaches this distance, the CNC monitors the Nozzle Contact Sense input. This input activates when the torch touches
the workpiece, so the CNC knows the height of the workpiece. The CNC also monitors the axis following error which the
CNC compares to the stall force. When the following error exceeds the stall force, the CNC knows the height of
workpiece.

Performing a first IHS on the ArcGlide

Press the IHS test on the ArcGlide HMI to perform a first IHS. To perform a first IHS on a Hypertherm CNC, choose the
Test Lifter soft key.

The ArcGlide moves to the workpiece at the Slow IHS speed. On subsequent IHSs, the ArcGlide uses the Fast Speed
until it reaches the Start IHS height. Then it switches to Slow speed. After the torch contacts the workpiece, the ArcGlide
raises the torch to the Transfer Height.

A THC error, a manual move, an idle timeout of 30 seconds, or a power cycle all result in the next IHS occurring at the
Slow Speed to find the workpiece height again.

ArcGlide THC Instruction Manual 806450 133

Figure 35

134

3 – Operation
23

25
1 27
26

16 19
2 17
18 20 22
3 21
4
5
6
10
11 12 13
8 9 14 15
7
ArcGlide THC Instruction Manual 806450

1 Torch path 8 Tip touch 15 Retract complete 22 Cut Off time

2 IHS start height 9 Plasma start 16 Pierce delay 23 CNC cut control active
3 Puddle jump height 10 Arc transfer 17 Cut height delay 24 Plasma torch active
4 Pierce height 11 Creep time 18 AVC delay 25 Cutting X/Y motion
5 Transfer height 12 Cut height 19 AVC sampling 26 AVC active
6 Workpiece 13 AVC begins 20 Auto kerf detect 27 Retract height
7 CNC cycle start (Cut Control) 14 Stop time 21 Torch height disable
3 – Operation

Operating the control module

The ArcGlide control module houses a micro-controller, I/O interface, and a motor drive. This component provides arc
voltage control and interfaces with the torch lifter, the CNC, and the plasma system through standard discrete I/O
interfaces or through the Hypernet interface. The main function of the control module for the operator of the ArcGlide
THC is for viewing system status and reading error messages and other system feedback that can help with system
troubleshooting.

You cannot set parameters through the control module using Hypernet or discrete communication. However, if your
system includes a CNC that is not a Hypertherm CNC, you can set parameters on the control module with RS-422
communication and commands. See ArcGlide THC Serial Communication Protocol on page 249 for more information.

On the front of the ArcGlide control module, there is a set of LEDs and a display window. See Control module on
page 127 for more information.

The LEDs illuminate to indicate the status of the ArcGlide control module. The meaning of each LED is described in
Table 6.

Table 6

Control module LED Meaning

START An active cycle START signal has been received.

MOTION Transfer and Pierce Delay (Pierce Time in Phoenix software) have completed and motion can
begin for cutting.

AVC Arc Voltage Control is enabled and is within normal operating limits.

TIP-TOUCH The torch is touching the workpiece.

LIMIT The torch has reached its limit switch.

ERROR There is an error.

In addition to the LEDs, there is also a display window where 13 screens display, screens 0 – 12. These displays can be
used to view the parameters that have been set through the HMI or CNC and can be used to check the state of the
control module I/O. Push the UP or DOWN arrow to scroll up or down through the screens in the display window.

In the description of each entry on each screen, the default values are in bold.

ArcGlide THC Instruction Manual 806450 135

3 – Operation

Screen 0 – Idle Park

0 IDLE PARK

Errors No Errors

CNC HypNet 0 Off AC Power 80%

HMI HypNet 0 On PAC HypNet 1 Off

Errors: Displays “No Errors” or the latest currently active error number and message. See Screen 11 – Last errors on
page 142 for more information.

CNC HypNet or CNC RS-422: Indicates whether the Hypernet connection to the CNC is active (On) or inactive (Off).
T On/Off

HMI HypNet: Indicates whether the Hypernet connection to the HMI is active (On) or inactive (Off). On/Off

AC Power: Displays the input voltage level of the control module.

PAC HypNet: Indicates whether the Hypernet connection to the plasma system is active (On) or inactive (Off). On/Off

0 - 10: The number of lost network packets sent by the control module to the CNC, HMI, and PAC. When it first powers
up and initializes the Hypernet network, the control module sends a packet to each component in the
network. A small number such as 1 may appear next to the component, but the number will disappear after
communication is established with the component. If the control modules counts 10 lost packets it displays
an error at the top of the screen.

 The lost packet number will count upward within 100 ms so you may not see the actual
numbers increment on the display.

Screen 1 – ArcGlide control state

This screen displays the current ArcGlide control state. The heading of this screen changes during operation of the
ArcGlide to one of the following states:

Idle Park Idle Go Home Lifter Calibration

Lower Limit Upper Limit IHS Fast Approach IHS Slow Approach
Workpiece Contact Go To Transfer Ht IHS Complete Start Plasma, Wait Xfer
Go To Pierce Start Piercing Go To Puddle Jump Ht Cut Ht Accel State
V Sample State Cutting Ramp Down Manual Up
Manual Down End Of Cut Retract

136 ArcGlide THC Instruction Manual 806450

3 – Operation

See Control States on page 150 for more information.

1 IDLE PARK

Mode Auto Unit address 1

Set Volts 120 V Motor Curr 0.0 A

Arc Volts 119.3 V Position 0.001 in

Mode: Displays the operating mode of the ArcGlide THC (Auto or Manual) that was selected at the HMI or CNC.

Set Volts: Displays the voltage setting from the CNC or HMI if sample voltage mode is not enabled.

Arc Volts: Displays the measured arc voltage feedback.

Unit address: Displays the unit address of the control module. This must be the same as the unit address of the plasma
system and HMI at the same station.

Motor Curr: Displays the current draw of the lifter motor during motion.

Position: Displays the lifter position relative to the home position.

Screen 2 – Options

2 OPTIONS INPUTS

Retr Dly Dip Sw 4 Off Lift Fric Off

Dip Sw 2 Off Dip Sw 5 Off Defaults Off

Dip Sw 3 Off Lift Cycl Off

Retr Dly: Reflects an extension of Retract Delay for plasma systems that require it.

Dip Sw 2, 3, 4, 5: Reserved

Lift Cycl: Press the down arrow on the control module and turn ON power to perform mechanical tests of the lifter.
On/Off

Lift Fric: Press the up arrow on the control module and turn ON power to determine if there is binding or friction during
lifter operation. On/Off

Defaults: This option resets the stored operating parameters to their default values.

ArcGlide THC Instruction Manual 806450 137

3 – Operation

Screen 3 – Inputs from the CNC

3 CNC DRY INPUTS

Cycle Start Off IHS Sync Off

Low Gain Off Spare #1

Corner hold Off Spare #2

CNC Inputs: Shows the selected input type based on the settings of the input switches on the THC processor board
(141091). DRY/SOURCED

Cycle Start: Displays whether the CNC has initiated a plasma cut. On/Off

Low Gain: Reduced gain in voltage control loop. The value is On for stable height control during Marking. On/Off

Corner hold: Displays whether corner processing (Corner Current Percent) has been set at the CNC or HMI. On/Off

IHS Sync: Indicates whether the CNC is synchronizing IHS for more than one THC. On/Off

Spare #1 and #2: Reserved

Screen 4 – Outputs to the CNC

4 CNC OUTPUTS

IHS Complete Off THC Error Off

Retract Cmplt Off Torch Breakaway Off

Mach Motion Off Spare Off

IHS Complete: The lifter has completed IHS. On/Off

Retract Cmplt: The torch has finished retracting. On/Off

Mach Motion: The THC is ready for the table to move and to begin cutting. On/Off

THC Error: Indicates that there is an error at the THC. See Screen 11 – Last errors on page 142 for more information.
On/Off

Torch Breakaway: The breakaway sensor has detected a torch collision. On/Off

Spare: Reserved

138 ArcGlide THC Instruction Manual 806450

3 – Operation

Screen 5 – Inputs from the lifter control board

5 LIFTER INPUTS

Lower Limit Off Lifter Up Off

Upper Limit Off Lifter Dwn Off

Breakaway Off Lifter Enable On

Lower Limit: The lower limit of motion on the lifter has been reached. On/Off

Upper Limit: The upper limit of motion on the lifter has been reached. On/Off

Breakaway: The breakaway sensor has detected a torch collision. On/Off

Lifter Up: Indicates that the lifter is moving up. On/Off

Lifter Dwn: Indicates that the lifter is moving down. On/Off

Lifter Enable: Indicates that the lifter is enabled at the lifter. On/Off

Screen 6 – Outputs from the lifter control board

6 LIFTER OUTPUTS

Encoder Error No Tip Sense Off

Encoder Dir Dwn Brake Off

Enc Count 456262 Motor On

Encoder Error: Indicates that there is an error from the lifter motor. See Screen 11 – Last errors on page 142 for more
information. Yes/No

Encoder Dir: Displays the direction in which the lifter is moving. Up/Dwn.

Enc Count: Displays the distance from home that the lifter has traveled, in encoder counts.

Tip Sense: Indicates that the torch has touched the workpiece. This is active only for tip touch plate detection and the
value corresponds with the illumination of the TIP-TOUCH LED on the front of the control module. On/Off

Brake: Indicates that the lifter brake is activated. On/Off

Motor: Indicates that the lifter motor is operating. On/Off

ArcGlide THC Instruction Manual 806450 139

3 – Operation

Screen 7 – Inputs from the operator console

7 OPCON INPUTS

Sta Disable Off Torch Dwn Off

Sta Select On Spare Off

Torch Up Off

Sta Disable: Indicates whether the station is enabled at the operator console. The displayed value should be the
opposite of the value for Sta Select. On/Off

Sta Select: Indicates that the station is selected at the optional HMI or at the operator console if the operator console is
designed to select a station. The displayed value should be the opposite of the value for Sta Disable. On/Off

Torch Up: Indicates that the torch is being commanded to move up at the operator console. On/Off

Torch Dwn: Indicates that the torch is being commanded to move down at the operator console. On/Off

Spare: Reserved

Screen 8 – Outputs to the operator console

8 OPCON OUTPUTS

Torch enable On

Error Off

Spare Off

Torch Enable: Indicates that the torch is enabled at the lifter. On/Off

Error: Indicates that there is an ArcGlide error. See Screen 11 – Last errors on page 142 for more information. On/Off

Spare: Reserved

140 ArcGlide THC Instruction Manual 806450

3 – Operation

Screen 9 – Inputs from the plasma system

9 PLASMA DRY INPUTS

Motion Off Not Ready Off

Error Off CNC-RS422 Off

Rampdown Err Off RS422 R OFF T OFF

Plasma Inputs: Shows the selected input type based on the settings of the input switches on the THC processor board
(141091). DRY/SOURCED

Motion: Indicates that the torch has transferred to the workpiece and that cutting motion can begin. On/Off

Error: Indicates that there is a plasma system error. Look for plasma errors on the CNC or plasma system. On/Off

Rampdown Err: Indicates that there is an error during the plasma system rampdown. On/Off

Not Ready: Indicates that the plasma system is ready to fire the torch. This turns ON during a change in process while
the torch is purging and not ready to fire. On/Off

CNC-RS422: Indicates whether RS-422 communication is enabled. On/Off

RS422 R and T: If CNC-RS422 is On, this value indicates whether the plasma system is receiving (R On/Off) or
transmitting (T On/Off) serial communication with the CNC.

Screen 10 – Outputs to the plasma system

10 PLASMA OUTPUTS

Corner Off Start Off

Pierce Off Remote On On

Hold Off

Corner: Indicates whether corner processing (Corner Current Percent) has been set at the CNC or HMI. This value
should be the same as the value for the CNC input Corner hold (Screen 3 – Inputs from the CNC on
page 138). This function does not work over Hypernet. On/Off

Pierce: Indicates that the plasma system is using the Pierce Control output. On/Off

Hold: Indicates that the Hold output is preventing the plasma system from firing the torch. On/Off

Start: Indicates that a Start signal is being sent to the plasma system. On/Off

Remote On: Shows that the Remote ON output is active. On/Off

ArcGlide THC Instruction Manual 806450 141

3 – Operation

Screen 11 – Last errors

11 DIAGNOSTIC LAST ERRORS

1st No error

2nd No error

Last No error

Lists the most recent 3 changes in ArcGlide error conditions, including “No error.”

Screen 12 – Total lifter operating time

12 Total Lifter Operating Time

50 Hours

Service lifter every 500 hours

142 ArcGlide THC Instruction Manual 806450

3 – Operation

Operating the HMI

If your cutting machine does not include a CNC connected with Hypernet, the HMI is required so an operator can control
the ArcGlide THC. On the HMI, the operator can set parameters, read error and diagnostic messages, and manually
control the position of the torch.

If your system includes a CNC connected to Hypernet, most control and diagnostic activities will take place on the CNC.
In this case, the HMI is optional and can be used to display messages and status.

Figure 36

Auto IDLE PARK

No errors
Set Volts 133.5 V
Cut Height 0.13 in

There are four sets of information that display in the HMI parameter window:
 The Main screen provides actual information about the ArcGlide.
 The Setup screen provides information about the process setup of the ArcGlide.
 The Diagnostics screen shows the latest error message and control state of the system.
 The Installation Data screen provides access to lifter hardware specifications and the values of parameters that are
used by the control module.

The screen displays 4 lines at a time. The selection knob below the parameter window allows you to scroll up and down
through each display.

To change the value of a parameter:

1. Turn the selection knob to scroll to the parameter and highlight it.

2. Push the knob to select the parameter.

3. Turn the knob to scroll through the value options.

4. Push the knob when you have selected the appropriate option.

 If you do not select a new value in 5 seconds, the value reverts to the original entry.

All the information on the screens is described in the following sections.

For more information about the LEDs, switches, and other controls, see Specifications on page 35.

ArcGlide THC Instruction Manual 806450 143

3 – Operation

HMI screen hierarchy

Main screen

Error Message
Set Volts
Cut Height
Auto mode Pierce Height
Pierce Delay
AVC Enabled
<Setup parameters>

Sample Voltage Mode

Thick Plate Cycle
IHS Start Height
Retract Height
Preflow during IHS
Setup parameters Stall Force
Ohmic Plate Sense
Kerf Detect
Kerf Level
<Diagnostics>
<Installation data>

Error Message
Control State
Diagnostics
Hypernet Status
Switch Diagnostics

Slide Length
Max Servo Current
Encoder Counts/in
Max Speed/min
Fast Speed
Slow Speed
Installation Data IHS Speed
Relative Speed Gain
Relative Position Gain
Relative Arc Volts Gain
Arc Voltage Calibration
Display Units
Languages

144 ArcGlide THC Instruction Manual 806450

3 – Operation

Error Message
Manual mode Pierce Delay
<Setup parameters>

Sample Voltage Mode

Thick Plate Cycle
IHS Start Height
Retract Height
Preflow during IHS
Setup parameters Stall Force
Ohmic Plate Sense
Kerf Detect
Kerf Level
<Diagnostics>
<Installation data>

Error Message
Control State
Diagnostics
Hypernet Status
Switch Diagnostics

Arc Starts
Disabled mode
Arc Minutes

ArcGlide THC Instruction Manual 806450 145

3 – Operation

Main screen

The Main screen is the primary display that the operator sees during normal operation.

Figure 37

Auto IDLE PARK

No Errors
Set Volts 133.5 V
Cut Height 0.13 in

Operation mode and the current THC state: Use the AUTO/MANUAL switch to select automatic or manual
operation:

Auto: Automatic mode (Set Arc Voltage or Sample Voltage). See Control States on page 150 for more
information.

Manual: Torch height changes with manual UP/DOWN commands only.

Disabled: The torch retracts to Home position and parks. Use the ENABLE/DISABLE switch to enable or
disable the torch. In addition, if the THC is able to turn the plasma system ON and OFF, the plasma system
turns OFF.

Errors: The latest, and currently active error condition, sent from the control module.

Set Volts: 50 V – 300 V with 0.1 V resolution. This line displays only if Sample Voltage mode is not enabled.
Default = 140.0 V.

Cut Height: Inch or equivalent mm – 0.254 – 25.40 mm (0.01 – 1.0 inch) with 0.254 mm (0.01 inch) resolution.
Default = 0.15 inch.

Pierce Height: Inch or equivalent mm – 0.254 – 25.40 mm (0.01 – 1.0 inch) with 0.254 mm (0.01 inch) resolution.
Default = 0.25 inch.

Pierce Delay: 0 – 10 seconds with 0.01 second resolution. Pierce Delay is Pierce Time in Phoenix software.
Default = 0.20 second.

AVC Enabled: When AVC is enabled (ON), Automatic Height Control is active in Auto mode. When AVC is disabled
(OFF), the torch height sequences in Auto mode (IHS, Cut Height, Retract) but the torch height does not
change based on arc voltage and remains constant during the cut. Default = ON.

<Setup Parameters> Select this line to display the Setup Parameters menu.

146 ArcGlide THC Instruction Manual 806450

3 – Operation

Setup screen

The Setup screen provides data for setup and maintenance.

Figure 38

Operational Data
<back>
Sampled V Mode ON
Thick Plate Cycle OFF

<back> Select this line to return to the Main screen.

Sampled V Mode: When Sample Voltage mode is ON, the arc voltage is sampled at the beginning of the cut and this
value is averaged with previous samples to provide the setpoint for the AVC during the remainder of the cut.
When this mode is OFF, the Set Volts mode is used for AVC. Default = OFF.

Thick Plate Cycle: (For installations without Hypernet-enabled CNC) When this option is ON, the ArcGlide estimates
torch height set parameters to avoid contacting the pierce puddle that forms when cutting thicker
workpieces. In addition, Transfer Height will depend on Cut Height, Pierce Height, and Pierce Time settings.
Default = ON.

IHS Start Height: This is the height above the workpiece at which the torch speed slows to the IHS speed before
contacting the workpiece. 2.54 – 50.8 mm (0.1 – 2.0 inch) with 0.254 mm (0.01 inch) resolution.
Default = 0.75 inch.

Retract Height: This is the height above the workpiece to which the torch will retract at the end of the cut.
Default = 2.00 inch.

Preflow during IHS: When Preflow during IHS is ON, this saves cut-to-cut cycle time by allowing the plasma preflow
time to occur during the IHS process. The Plasma Start and Plasma Hold signals are applied early.
Default = YES.

Stall Force: This parameter sets a force threshold of 1 (low force limit) – 10 (high force limit). Default = 5.

Ohmic Plate Sense: When this parameter is ON, the ohmic contact sense is used. Default = ON.

Kerf Detect: When this parameter is ON, automatic kerf detection is active. When a kerf crossing is detected, AVC is
disabled and the torch position is fixed for a short period to avoid diving into the workpiece.
Default = ON.

Kerf Level: This parameter sets a sensitivity threshold to detect kerf. The range is 1 (more sensitive) – 10 (less sensitive).
Default = 5.

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<Diagnostics> Select this line to view the Diagnostics screen.

<Installation Data> Select this line to display the Installation Data screen.

<back> Select this line to return to the Main screen.

Diagnostics screen

The Diagnostics display on the HMI provides information about errors that the HMI receives from the control module, the
control state of the cutting machine, as well as whether Hypernet is enabled and diagnostics for the switches on the front
panel of the HMI. The following table provides details for the parameters that can appear on the Diagnostics display.

See Error message troubleshooting on page 191 for more information.

Figure 39

Diagnostics
<back>
NO ERRORS
Control State 0

<back> Select this line to return to the Main screen.

Errors: The latest and currently active error condition. Normal errors are cleared on the next start. Critical errors must be
corrected before the next start. See Error message troubleshooting on page 191 for more information.

Normal Errors

NO ERRORS – Ready to start.

ERR 1 FLASH SETUPS – Checksum failed on stored setups in flash memory – the THC is using default
values.

ERR 2 MAX SPEED EXCEEDED – A speed regulation problem occurred – the value for Maximum Speed
was exceeded.

ERR 3 LIFTER HOME TIMEOUT – Lifter did not return to home position within 20 seconds.

ERR 4 PLATE CONTACT AT HOME – Ohmic contact with the workpiece at home position – an invalid
condition.

ERR 5 HOME LIM DURING OPR – The lifter reached the home (upper) limit during auto operation.

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ERR 6 LOWER LIM DURING OPR – The lifter reached the lower limit during operation.

ERR 7 FAILED MOVE TO IHS START – The lifter failed to reach IHS Start Height.

ERR 8 FAILED TO CONTACT PLATE – The torch failed to contact the workpiece within 60 seconds.

ERR 9 FAILED TO CLEAR PLATE – The torch failed to retract and break ohmic contact within 10 seconds.

ERR 10 FAILED TO MOVE TO XFER HT – The torch failed to retract to Transfer Height within 10 seconds.

ERR 11 IHS SYNC TIMEOUT – The torch reached the IHS position but IHS SYNC was not released within
60 seconds.

ERR 12 TRANSFER TIMEOUT – The Transfer signal was not received from the plasma system within
60 seconds.

ERR 13 LOST TRANSFER – The plasma arc was lost during the cut.

ERR 14 FAILED MOVE TO PIERCE – The lifter failed to reach Pierce Start Height within 10 seconds.

ERR 15 FAILED MOVE CUTHEIGHT – The lifter failed to reach Cut Height during Accel Delay.

ERR 16 RAMPDOWN TIMEOUT – The Motion signal was not removed within 10 seconds.

ERR 17 RETRACT TIMEOUT – The lifter failed to retract within 20 seconds at the end of the cut.

ERR 18 ERR SAMPLED ARC VOLTS – During the sample arc voltage operation, there was an excessive
change in sample voltage.

ERR 19 EXCESS PLATE CONTACT – During the cut, the torch made excessive contact with the
workpiece.

ERR 20 PLASMA SUPPLY – Plasma system error.

ERR 21 OHMIC TIP SENSE – Nozzle Contact Sense was enabled but not sensed.

Critical Errors

ERR 23 INPUT VOLTAGE LOW – The incoming AC line voltage is more than 20% low.

ERR 24 INPUT VOLTAGE HIGH – The incoming AC line voltage is more than 15% high.

ERR 25 OVER-TEMPERATURE – The temperature of the processor has exceeded the maximum value.

ERR 26 MOTOR DRIVE – The temperature for the motor drive has exceeded the maximum value.

ERR 27 INTERLOCK TRIPPED – The safety interlock was removed.

ERR 28 BREAKAWAY TRIPPED – The torch breakaway was removed.

ERR 29 FIELD SUPPLY FAILED – The +5 V, +12 V, or -12 V supply has failed.

ERR 30 STALL CALIBRATION – Stall Calibration down motion failed after power was turned ON.

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ERR 31 NO HYPERNET CONNECTION – There is no Hypernet connection to either the HMI or CNC.

ERR 32 LOST CNC HYPERNET – The CNC Hypernet connection was lost after it was established.

ERR 33 LOST HMI HYPERNET – The HMI Hypernet connection was lost after it was established.

ERR 34 ENCODER OVERFLOW – Height position error.

ERR 35 ENCODER UNDERFLOW – Height position error.

ERR 36 HYPERNET ADDRESSING – Hypernet communication error. Check unit addressing.

ERR 37 SOFTWARE ERROR – Contact your table manufacturer.

ERR 38 SOFTWARE LOOP TIME – The Ethernet cable is loose or damaged or there is electrical
interference if ArcGlide and drives are sharing power.

ERR 39 SOFTWARE UNDEF DISPLAY – The control board in the control module is not operating
correctly.

ERR 40 SOFTWARE ANALOG INPUT – Pins on a cable connector are not transmitting the expected
signal, examine all cable connections on the control module.

ERR 41 PROTOCOL MISMATCH – Verify that compatible software and firmware is installed on all the units
of the system that are connected to Hypernet. See Update ArcGlide firmware on page 180 for more
information.

ERR 42 LOST PAC HYPERNET – Examine all Hypernet connections between the control module, the
Ethernet switch, and the plasma system.

Control States

IDLE PARK – In this state, the plasma system is OFF, the servo motor has no power, and the lifter brake is
ON. This is the low power standby state. The lifter waits for the Cycle Start input signal and enters the IHS
Slow Approach state.

IDLE – In this state, the plasma system is OFF, the servo motor has power and is holding position, and the
lifter brake is OFF. The lifter waits for the Cycle Start input signal and enters either the IHS Fast Approach
state or the IHS Slow Approach state, depending on whether the workpiece position is known. If there is no
Cycle Start signal after a 30-second timeout, the lifter enters the Idle Park state.

GO HOME – The lifter moves the torch up at the programmed Slow Speed until the upper limit switch or a
stall is detected. Then the lifter enters the Upper Limit state.

LIFTER CALIBRATION – The control module calibrates the lifter immediately after it turns on.

LOWER LIMIT – The THC enters this state after it senses the lower limit switch or when the actual position
is the programmed Slide Length. The motor is stopped and the torch maintains its position. Only up motion
is allowed during this state. An error message displays if the THC enters this state during automatic
operation.

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UPPER LIMIT – The THC enters this state when it senses the upper limit switch. The servo motor is
stopped and the torch maintains its position and the THC resets its actual position to 0 (Home). Only down
motion is allowed during this state. An error message displays if the THC enters this state during automatic
operation.

IHS FAST APPROACH – The torch moves down at the programmed Fast Speed to the Start IHS Height
then enters the IHS Slow Approach state.

IHS SLOW APPROACH – The lifter continues to move down at IHS Speed, using Stall Limit, until the lifter
receives the Tip Sense input signal or stalls. When the THC receives the Tip Sense input signal or detects a
stall, it enters the Workpiece Contact state.

WORKPIECE CONTACT – The torch lifter begins to move up slowly until ohmic sense contact is broken.
The lifter then sends the workpiece position to the control module and enters the IHS Retract state.

IHS RETRACT – The lifter moves up at the programmed Fast Speed to the Transfer Height and then enters
the IHS Complete state.

IHS COMPLETE – The lifter holds the IHS Transfer position and sends the IHS Complete output signal to
the CNC. If necessary, the THC waits for the IHS Sync input signal from the CNC to synchronize multiple
torches. Then the THC enters the Start Plasma state.

START PLASMA – The lifter holds the torch at the IHS Transfer position, waits for the Motion input signal
from the plasma system, and then enters the programmed Pierce Start state.

PIERCE START – The lifter moves the torch to Pierce Height. When the torch is in position, the lifter enters
the Piercing state.

PIERCING – The lifter holds the torch at the Pierce Height for the Pierce Delay (Pierce Time in Phoenix
software) interval. When Pierce Delay is complete, the lifter enters the Puddle Jump state.

PUDDLE JUMP – The lifter moves the torch to the Puddle Jump Height. It waits for Cut Height Delay, and
then enters the Cut Height Accel state.

CUT HT ACCEL – The lifter moves the torch to the Cut Height and sends the Machine Motion output signal
to the CNC to begin X/Y cutting motion. The THC waits for the AVC Delay and then enters either the
V Sample state or the Cutting state, depending on the operating mode.

SAMPLE – The lifter receives a new Arc Voltage sample for this cut. It modifies the operating Arc Voltage
Control setpoint and enters the Cutting state.

CUTTING – If Auto Mode is active and the Corner Hold input signal from the CNC is not active, the lifter
controls the torch height using arc voltage feedback. If ohmic contact sense is selected, the torch retracts if
it makes ohmic contact. When the cut is complete and the Cycle Start input signal from the CNC is
deactivated, the THC enters the Ramp Down state.

RAMP DOWN – The lifter holds the torch position and deactivates the Plasma Start output signal to shut
down the plasma system. The lifter waits for the plasma system to ramp down (when it loses the Motion input
signal from the plasma system). When the rampdown is complete, the lifter enters the End Cut Retract state.

MANUAL UP – The lifter initially jogs up 0.254 mm (0.01 inch). After 0.5 second, it begins continuous
upward motion at the IHS Speed. After 2 seconds, the lifter increases the speed to the programmed Slow
Speed. Outputs do not change; if the torch is already cutting, it continues to cut.

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MANUAL DOWN – The lifter initially jogs down 0.254 mm (0.01 inch). After 0.5 second, it begins
continuous downward motion at the IHS Speed. After 2 seconds, the lifter increases the speed to the
programmed Slow Speed. The lifter does not change the output signals; if the torch is already cutting, it
continues to cut.

END CUT RETRACT – The lifter moves the torch up at Full Speed to the Retract Height. When the torch is
in position at the Retract Height, the lifter activates the Retract Complete output signal to the CNC and
enters the Idle state.

Hypernet Status: ON, OFF, or PM (protocol mismatch). See Error 41 in Critical Errors on page 149 for more
information.

Switch Diagnostics: Allows the operator to test the status of the switches on the front panel of the HMI. ON or OFF
displays as each switch is pushed or moved.

<back> Select this line to return to the Main screen.

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Installation Data screen

The Installation Data screen provides information on ArcGlide hardware and firmware settings that are used by the
control module.

 The default for Display Units is inch. To view metric measurements, select mm.

Figure 40

Installation Data
<back>
Slide Length 9.4
Max Servo Current 3.0A

Slide Length: This value is the length of the lifter’s usable travel. Default = 9.50 inch.

Max Servo Current: This is the maximum continuous motor current for which the lifter motor is rated.
Default = 3.0 A.

Encoder Counts per inch: This value scales the position feedback. Default = 20320 per inch.

Maximum Speed (per minute): This parameter sets the maximum linear speed that the THC can achieve.
Default = 600 inch.

Fast Speed (per minute): This speed is used for all automatic rapid moves such as the End-of-Cut-Retract or the Initial
Approach to the workpiece. Default = 600 inch.

Slow Speed (per minute): This speed is the Homing Speed and is the fastest speed used for manual moves. It is also
the maximum speed limit used during arc voltage control. Default = 150 inch.

IHS Speed (per minute): This parameter sets the lowest speed for the final approach to the workpiece during an IHS
operation. It is also used as the low speed for manual moves. Default = 17 inch.

Relative Speed Gain: This gain value regulates the speed of the lifter. Default = 5.

Relative Position Gain: This gain is used for closed loop positioning. Default = 5

Relative ARC Volts Gain: This gain is used when the THC is operating closed-loop arc voltage control. Default = 5.

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Arc Voltage Calibration: This value is used to finely calibrate the measured arc voltage accuracy. Default = 1.000.

Display Units: The unit of measurement, inch or millimeter, that are used in the display. Default = inch.

Language: The language selected for the display. Options are English, German, Portuguese, Spanish. Default = English.

<back> Select this line to return to the Main screen.

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Manual mode

In Manual mode, only errors and Pierce Delay information is displayed.

Figure 41

Manual
NO ERRORS
Pierce Delay 1.00s
<Setup Parameters>

Error: The most recent error condition.

Pierce Delay: 0 – 10 seconds with 0.01 second resolution (Pierce Delay is Pierce Time in Phoenix software).

<Setup Parameters> Return to the Setup parameters display.

Lifter Disabled mode

When the lifter is disabled, there are only two parameters that display.

Figure 42

Disabled
Arc Starts 72
Arc Minutes 146

Arc Starts: The number of times the arc has started since the last time consumables were changed and the counter was
restarted.

Arc Minutes: The number of minutes of active cutting since the last time consumables were changed and the counter
was restarted.

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3 – Operation

ArcGlide operating parameters

The ArcGlide Process screen in Phoenix software contains a combination of plasma process and THC parameters that
control the THC operations. In this screen you can customize the operation for the duration of a single cutting operation.
After a part or nest program is complete, if the cut chart is accessed, the selections on this screen return to the values of
the selected cut chart. ArcGlide operating parameters can also be viewed in the HMI display.

Figure 43

See the Phoenix Software Operator Manual (806400) for more information on these parameters in Phoenix.

There are 4 sets of parameters on the Process screen:

 THC mode
 Cut chart values
 Options
 Automatically-set parameters

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THC mode

Height Control: In Manual mode, the torch only moves in response to manual UP/DOWN commands from the Raise
and Lower soft keys in Phoenix software, an operator console, the HMI, or the lifter. No other torch height
motion occurs. In Automatic mode, the torch moves through its programmed sequence, based on values set
on the Process screen.

Setting: Manual/Automatic

Voltage Control: The THC must be in Automatic mode. If Voltage Control is ON, the torch height is controlled by the
measured arc voltage. If Voltage Control is OFF, the torch maintains a constant position during the cut that is
independent of the arc voltage.

Setting: Off/On

Sample Voltage: The THC must be in Automatic mode and Voltage Control must be ON. When Sample Voltage is ON,
the THC measures the voltage at the end of the AVC Delay and uses it as a setpoint for the remainder of the
cut. When Sample Voltage is OFF, Set Arc Voltage is used as the setpoint for torch height control.

Setting: Off/On

Cut chart values

These fields display the values in the cut chart that is active for the process. These values can be changed here, for this
job, and the values for the automatically-set parameters will be recalculated and displayed. However, these changes are
not saved in the cut chart.

Set Arc Voltage: The ArcGlide THC must be in Automatic mode, Voltage Control must be ON, and Sample Voltage
must be OFF.

When Sample Voltage is OFF, Set Arc Voltage is used as the setpoint for torch height control.

Setting: 50 VDC to 300 VDC

Set Arc Current: This is the value for the plasma arc current. Enter the amperage needed to cut the material. This
parameter can be used only with plasma systems that communicate with the CNC.

Setting: 5 A to 1000 A

Cut Height: Determines the height at which the torch cuts the workpiece.

Setting: 0.25 mm to 25.4 mm (0.01 inch to 1.00 inch)

Pierce Height: Determines the height at which the torch pierces the workpiece. The torch moves to this height after
Transfer Height.

Setting: 0.25 mm to 25.40 mm (0.01 inch to 1.00 inch)

Pierce Time: This is the value for the Pierce Delay. During this time, the X/Y cutting motion is delayed to allow the
plasma to fully pierce the workpiece.

Setting: 0 seconds to 10 seconds

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Cut Speed: This value specifies the cutting speed.

Setting: 50 mm/min (2 in/min) to Maximum Machine Speed

Options

Nozzle Contact IHS: To set this parameter, the Height Control must be in Automatic mode. When Nozzle Contact IHS
is ON, the THC uses electrical ohmic contact to sense the workpiece. When this parameter is OFF, the THC
uses stall force to sense the workpiece. This setting is normally disabled on water tables or painted
workpieces due to the unreliability of the electrical contact.

Setting: Off/On

Nozzle Contact Cutting: Hypernet does not support this feature.

Auto Kerf Detect: To set this parameter, the THC must be in Automatic mode. When Auto Kerf Detect is active, the
THC looks for a rapid rise in the measured arc voltage that indicates that the torch is cutting across a
previously-cut kerf. This parameter temporarily disables the AVC and prevents the torch from diving into the
workpiece.

Setting: Off/On

Auto Kerf Detect Voltage: This parameter is active if Auto Kerf Detect is turned ON. The lower the voltage, the higher
the detection sensitivity. This value should be set high enough to detect normal kerf crossings but low
enough to prevent false kerf detection.

Setting: 1 V to 10 V

Corner Current Percent: Hypernet does not support this feature.

Automatically-set parameters

The CNC can automatically estimate these values for the current plasma process. On the Process screen in Phoenix
software, choose the Default All Parameters soft key to load the estimated values. Under most conditions, these
estimated values yield good results. However, you can override any of these values for special conditions. To override an
estimated value, clear the check box for that parameter and enter a new value. The CNC displays your entered value in
blue.

 If a part program reloads the cut chart, the Transfer Height, Creep Time, and Cut Height
Delay values will replaced with the cut chart values for these parameters.

Preflow During IHS: This parameter is used for Rapid Part cutting. When this parameter is active (On), the CNC issues
the Start and Hold Ignition signals to the plasma system early to allow the gas preflow to occur while the
THC is performing an IHS operation. This reduces the time required to move to the next part and start
cutting.

Setting: Off/On

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IHS Start Height: This is the height above the workpiece where the THC starts the initial height sense process. When
the torch reaches this distance above the workpiece, the following actions occur on Hypertherm CNCs:
 Speed slows from Maximum THC Speed to Fast IHS Speed.
 THC Torque Limit and Nozzle Contact Enable outputs turn ON.
 The CNC monitors the Nozzle Contact Sense input. This input activates when the torch
touches the workpiece, so the CNC knows the height of the workpiece.
 The CNC monitors the axis following error which the CNC compares to the stall force. When
the following error exceeds the stall force, the CNC knows the height of workpiece.

Setting: 2.54 mm to 50.80 mm (0.10 inch to 2.00 inch)

Skip IHS Within: This parameter optimizes production by reducing the time between cuts. If the next starting point is
within this distance of the end of the previous cut, the THC skips the IHS. When this happens, the torch
goes directly to the Transfer Height and skips contact with the workpiece. This setting can improve the
overall machine production rate. Set this parameter to 0 to disable this feature. Skip IHS will be ignored if:
 The ArcGlide is not connected to a CNC with Hypernet
 An M07 HS command is in the part program for that pierce (see the Phoenix Software Version
9 Series Programmer’s Reference (806420) for more information)
 Sample Voltage mode is active and an IHS is needed for arc voltage sampling (six arc voltage
samples are required before IHS can be skipped)
 The THC is locked out by the M50 (Height Sensor Disable) command
 The THC is not in Automatic mode

Setting: 0 to table size (mm or inch)

Transfer Height: When the arc transfers to the workpiece, it can be “stretched” to the pierce height. The transfer height
is lower than the pierce height because initiating arc transfer at a high pierce height may result in the arc not
transferring to the workpiece at all. Enter the Transfer Height as a percentage of the cut height or as an
actual transfer height distance.

Setting: 50% to 400% of Cut Height, commonly 150%

Puddle Jump Height: This value determines the height above the workpiece where the torch is raised after pierce and
before lowering to Cut Height so that the torch clears the dross puddle that can form during the pierce.
Enter a percentage of the Cut Height. The torch remains at this height until the Cut Height Delay has
elapsed. If you are not using Puddle Jump Height, set this parameter to 100%.

Setting: 50% to 500% of Cut Height

Creep Time: Specifies the amount of time after piercing the workpiece that the torch travels at Creep Speed. (See
Setups > Machine Setups > Speeds for the Creep Speed.) The torch accelerates to cut speed after the
Creep Time elapses. Creep Speed can help stabilize the arc during the transition to Cut Speed.

Setting: 0 seconds to 10 seconds

Cut Height Delay: This value sets the number of seconds to hold the torch at the Puddle Jump Height before
transitioning to the Cut Height so that the torch clears the dross puddle that can form during a pierce. If you
are not using Puddle Jump Height, set this parameter to 0.

Setting: 0 seconds to 10 seconds

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AVC Delay: This value sets a number of seconds to allow the plasma system to achieve steady-state operation at the cut
height before AVC begins. After this delay, the AVC is enabled for the remainder of the cut. If the THC is in
Sample Voltage mode, the arc voltage sample is taken after this delay.

Setting: 0 seconds to 10 seconds

Cut Off Time: This value turns off the plasma arc before or after the end of the programmed cut to improve edge quality.
If the value is negative, the torch turns off before the end of the cutting machine motion. With positive values,
the plasma arc turns off after motion stops. This parameter minimizes notches in part edges that can occur
when motion stops with the arc on.

Setting: -1 seconds to 2 seconds

Arc Off Time: This value defines the number of seconds to wait before sending a lost arc signal. This setting allows arc
loss during the remainder of the part to be ignored so the CNC can move to the next pierce point.

Setting: 0 seconds to 2 seconds

Stop Time: This parameter allows a pause at the end of a cut and delays X/Y motion to the next pierce point. This delay
can be used to retract the torch to avoid tip-ups.

Setting: 0 seconds to 10 seconds

Retract Height: This parameter specifies the height above the workpiece to which the torch retracts at the end of a cut.

Setting: 2.54 mm (0.10 inch) to the maximum lifter length

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Plasma cutting tips

The following reference guide offers several solutions to help improve cut quality.

Consider the following factors when evaluating plasma cut quality:

 Type of machine (example: XY table, punch press)
 Plasma cutting system (example: plasma system, torch, consumables)
 Motion control device (example: CNC, torch height control)
 Process variables (example: cutting speed, gas pressures, flow rates)
 External variables (example: material variability, gas purity, operator experience)

All of these factors can affect the appearance of a cut.

Cut quality issues

Angularity

Positive cut angle: More material is removed from the top of the cut surface than from the bottom.

Negative cut angle: More material is removed from the bottom of the cut surface than from the top.

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Top edge rounding: There is a slight rounding along the top edge of the cut surface.

Dross

High-speed dross: A small, linear bead of molten material attaches and hardens along the bottom edge of the cut. In
addition, S-shaped lag lines are present; dross is difficult to remove and requires grinding.

Low-speed dross: A bubbly or globular accumulation of molten material attaches and hardens along the bottom edge of
the cut. In addition, vertical lag lines may be present; dross is easy to remove and flakes off in large chunks.

Top spatter: A light spatter of molten material collects on the top edges of the cut. Usually, this spatter is
inconsequential and is most common with air plasma.

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Surface finish

Roughness: Depending on the type of metal being cut, some roughness should be expected; “roughness” describes
the texture of the cut face (the cut is not smooth).

Aluminum

Top: Air/Air
 Best for thin material under 3 mm (1/8 inch)

Bottom: H35/N2
 Excellent edge quality
 Weldable edge

Mild steel

Top: Air/Air
 Clean cut
 Nitrided edge
 Increased surface hardness

Bottom: O2
 Exceptional edge quality
 Weldable edge

Color

Color results from a chemical reaction between a metal and the plasma gas that is used to cut it. Color changes are to be
expected and vary most dramatically with stainless steel.

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Top: N2/N2

Middle: H35/N2

Bottom: Air/Air

Basic steps to improve cut quality

Step 1: Is the plasma arc cutting in the appropriate direction?

 The squarest cut angles are always on the right side in relation to the forward motion of the torch.
 Verify the direction of the cut.
 Adjust the cutting direction, if necessary. The plasma arc typically spins clockwise with standard consumables.

Contour
 The torch travels clockwise.
 The good side of the cut is to the right side of the torch, as it travels forward.

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Internal feature (hole)

 Torch travels counterclockwise.
 Good side of the cut is to the right side of the torch as it travels forward.

End point

Start point

Step 2: Was the correct process selected for the material and thickness being cut?

Refer to the cut charts in the Operation section of the Hypertherm Instruction Manual. On the CNC, choose the Cut
Chart soft key on the Main Screen to view the cut chart for the selected torch type, material and thickness.

Follow the specifications in the cut charts:

 Select the appropriate process for:
 Material type
 Material thickness
 Desired cut quality
 Productivity goals
 Select the correct plasma and shield gas.
 Select correct parameters for:
 Gas pressures (or flow rates)
 Cut height and arc voltage
 Cutting speed
 Confirm that the correct consumables are being used and verify the part numbers.

 Generally, lower amperage processes offer better angularity and surface finish. However, cutting speeds are slower
and dross levels are higher.

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Step 3: Are the consumables worn?

 Inspect consumables for wear.
 Replace worn consumables.
 Always replace the nozzle and electrode at the same time.
 Avoid over-lubricating o-rings.

 Use genuine Hypertherm consumables to ensure maximum cutting performance.

Step 4: Is the torch perpendicular to the workpiece?
 Level the workpiece.
 Make the torch perpendicular to the workpiece, both from the front and side of the torch.

 Inspect the material to see if it is bent or warped. In extreme cases this limitation cannot be corrected.
Step 5: Is the cut height set at the proper height?
 Adjust the cut height to the correct setting.
 If you are using arc voltage control, adjust the voltage.

 As consumable parts wear, arc voltage settings need continual adjustment to maintain cut height.
 Cut height can impact angularity.

Negative cut angle

Square cut

Positive cut angle

 Negative cut angle: torch too low; increase cut height.

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 Positive cut angle: torch too high; decrease cut height.

 A slight variation in cut angles may be normal if the variation is within tolerance.
Step 6: Is the cutting speed set too fast or too slow?
 Adjust cutting speed as needed.

 Cutting speed may also impact your dross levels.

 High-speed dross: The cutting speed is too fast and the arc lags behind. Reduce the cutting speed.
 Low-speed dross: The cutting speed is too slow and the arc shoots ahead. Increase the cutting speed.
 Top spatter: The cutting speed is too fast, reduce the cutting speed.

 Inup,addition to speed, both material chemistry and surface finish can impact dross levels. When the workpiece heats
more dross may form on subsequent cuts.

Step 7: Are there problems with the gas delivery system?

 Identify and repair any leaks or restrictions.
 Use properly sized regulators and gas lines.
 Use pure, high-quality gas.
 If manual purge is required, such as with the MAX200, confirm that the purging cycle was completed.
 Consult the gas distributor.

Step 8: Is there torch vibration?

 Verify that the torch is securely attached to the table gantry.
 Consult the table manufacturer, your table may require maintenance.

Step 9: Does the table need to be tuned?

 Check and ensure that the table is cutting at the specified speed.
 Consult the table manufacturer; the table speed may need tuning.

ArcGlide THC Instruction Manual 806450 167

3 – Operation

168 ArcGlide THC Instruction Manual 806450

Section 4
Maintenance

Introduction
Hypertherm assumes that the service personnel who perform the troubleshooting testing are high-level electronic service
technicians who have worked with high-voltage electro-mechanical systems. Knowledge of final isolation troubleshooting
techniques is also assumed.

In addition to being technically qualified, maintenance personnel must perform all testing with safety in mind. See Safety
on page 13 for more safety precautions.

Lifter routine maintenance

The control module and HMI do not require routine maintenance.

On the lifter, the bearings of the ball screw have permanent lubrication and do not require in-service lubrication under
normal operating conditions.

Carriage

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

Under normal operating conditions, the slide should be lubricated every 500 hours of operation. You can find the Total
Lifter Operation Hours parameter on Screen 12 on the ArcGlide control module.

To lubricate the carriage:

1. Remove the side shields and side panels to access the carriage.

2. Locate the funnel-type lubrication nipples (DIN 3405-D3) on either side of the carriage, as shown in Figure 44.

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4 – Maintenance

Figure 44

Lubrication nipples

3. Load a small grease gun with a needle-type adapter with lithium base grease. (Castrol Longtime® PD2 or equivalent
is recommended.) To lubricate with a hand press, weigh out the quantity of grease in each stroke.

4. Inject 0.7 g (0.025 oz) of grease into one of the lubrication nipples. If you are using the Hypertherm grease gun
(428259), one pump of the gun is equivalent to 0.7 g (0.025 oz). You do not need to lubricate the carriage on both
sides.

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Sealing strip

Apply oil to the sealing strip behind the carriage at every lubrication interval.

1. Remove the front panel to access the carriage and sealing strip.

2. Apply a few drops of ISO Grade 100 heavy hydraulic fluid (Shell Tellus™ 100 heavy hydraulic fluid is recommended)
to the sealing strip.

3. Install the front panel.

4. Use the UP/DOWN switch to move the carriage along length of the sealing strip and distribute the oil.

Figure 45

Apply a film of oil

Cable connections

Examine all cables regularly for chafing or unusual wear. If the outside insulation has been cut or otherwise damaged,
replace the cable. In particular, examine the ohmic contact wire.

WARNING!
ELECTRIC SHOCK CAN KILL

Do not disconnect cables when the system power is turned ON.

System grounding

Verify that all components of the system are individually grounded to a driven earth ground. See Recommended
grounding and shielding practices on page 55. Examine the work lead (+) connection, particularly where the
work lead (+) connects to the cutting machine. This must be a good, clean connection because a poor connection can
interfere with arc transfer.

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4 – Maintenance

Calibrate arc voltage

ArcGlide THC arc voltage is calibrated at the factory as part of the manufacturing process. If you need to verify or
recalibrate the arc voltage for multiple ArcGlide installations or for long torch leads, begin by adjusting the value of the
Voltage Calibration parameter on the ArcGlide Axes screen. The measured raw arc voltage input value is multiplied by the
value of this parameter before being used for either voltage control or display in the red LED display on the HMI or on
Screen 1 on the ArcGlide control module.

This calibration affects all of the ArcGlide hardware connected to this station, including the HMI display and the HPR
Hypernet plasma interface board.

WARNING!
ELECTRIC SHOCK CAN KILL

Disconnect electrical power before performing any maintenance.

All work requiring removal of the plasma system cover must be performed by
a qualified technician.
See Safety on page 13 for more safety precautions.

1. Mount a test workpiece that can be used for arc voltage calibration.

2. Verify that the test workpiece is level.

3. Switch the THC to Manual Mode.

4. Load the cut process that is recommended for the test workpiece.

5. Position the torch to the cut height that is specified for the selected cut process.

6. Start a 2-foot (0.6 m) rip cut, using the recommended cut speed for the process.

7. After the pierce completes and the torch is cutting, use a voltmeter to measure the raw arc voltage between the work
and electrode terminals on the plasma interface board (141094 or 141162) in the plasma system.

8. Compare the measured voltage with the voltage that displays in the red LED display on the HMI or on Screen 1 on
the ArcGlide control module.

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9. If the 2 values do not match, divide the raw arc voltage by the value in the display and enter the result as the value for
the Voltage Calibration parameter.
For example, if the raw arc voltage is 120 and the value in the display is 125, divide 120 by 125. The result, 0.96 is
the value for the Voltage Calibration parameter. The range of values for the Voltage Calibration parameter is 0.900 to
1.100.

10. If you cannot bring the arc voltage in the display within the range of 0.900 to 1.100, adjust the arc voltage calibration
potentiometer on the THC processor board (141091):
a. Remove the calibration and setup door on the top right front of the control module.
b. Use a small straight screwdriver to turn the slotted screw on the arc voltage potentiometer clockwise, to increase
the voltage, or counterclockwise, to decrease the voltage.

Arc voltage calibration potentiometer

DS DS

CNC PLASMA

11. Repeat the parameter and potentiometer calibration until the measured arc voltage and the displayed arc voltage are
the same.

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4 – Maintenance

Flow of ArcGlide operations

The flowchart on the following pages illustrates the sequence of states in the operation of an ArcGlide THC.
Power ON reset

Initialize uP clock, on-chip I/O,

expansion I/O.

Read stored setup parameters Setups were saved the last time the THC was
from Flash. shut down.

Display splash screen.

Immediately after the THC Both up and down Restore default setup parameters.
turns ON, hold the display display arrows?
Yes
select arrows on the front of
the control module to restore No
the defaults or to enter Up display arrow? Lifter friction test. Turn power OFF
built-in test modes. then ON to end
Yes
test mode.
No
Down display arrow? Lifter cycle test. Turn power OFF
then ON to end
Yes
test mode.
No
Initialize Hypernet links. The ArcGlide THC control module looks for
Hypernet devices on the network (CNC,
HMI, and plasma system). If it doesn’t
Initialize watchdog timer. discover the devices, the control module
assumes that the device is either not
present or has a discrete connection, and it
Main loop displays OFF as the status. If Hypernet
communications fail to initialize, cycle power
to the control module.

The Spare input activates CNC Spare2_in? Self-diagnostics

when the test fixture cables
Yes
are connected.
No
Write expansion outputs.

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Service active Hypernet links. Data is automatically copied into the operating
parameters and the status is automatically transmitted.

I/O is updated and control 10 ms interval? Service RS-422 and check Tip Touch or
loops execute at 10 ms Tip Sense (on Screen 6 of the
No
intervals. Excess time in this control module).
loop is spent servicing the Yes
RS-422 connection.
Service watchdog timer.

Service analog I/O.

Read arc voltage.
Write motor current.

Read expansion inputs.

Check for critical errors. Critical errors must be corrected before the power is
turned ON again. See Table 8 – Critical Errors on
page 204 for more information.

Operating states

CNC Hypernet link active? Use HMI operating parameters.

No Use CNC discrete wire operating signals.
Yes
Use CNC operating
parameters.
Use Hypernet CNC
operating signals.

Station disabled. Plasma remote power OFF.

Critical error?
Yes
No
Plasma remote power ON.

Plasma system Hypernet Use discrete wire plasma system operating

link active? signals and arc voltage.
No
Yes
Use Hypernet plasma system
operating signals and
arc voltage.

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4 – Maintenance

Switch to Active state. This operating state? Set state outputs.

Yes Control lifter speed and position.
No Check for errors.
Check for change to next state.
See Diagnostics screen on This operating state?
page 148 for a complete list
Yes
of states.

Main loop

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Basic flow for all ArcGlide operating states

Enter operating state.

First time in this state? No

Yes
Update motor drive and lifter
brake outputs.

Update CNC interface and

plasma system outputs,
operator console status LEDs.

Set desired torch position.

Reset state timer.

Not the first time in this state.

Error condition? Error = this error.

Yes Next state =
error state.
No
Change to new state? Next state =
new state.
Yes

Next state = this state

Exit operating state

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4 – Maintenance

Common machine-cutting faults

This section lists faults an operator can encounter and the possible causes for each fault.

The arc fails to transfer.

 The work lead is not making good contact with the cutting machine, or the cutting machine is not making good
contact with the workpiece.
 The transfer or cut height is too large.
 The surface of the workpiece is rusty, oiled, or painted.

The workpiece is not completely pierced, and there is excessive sparking on top of the workpiece.
 The metal being cut is too thick for the selected amperage.
 The Pierce Delay (Pierce Time in Phoenix software) is set too low.
 The workpiece surface is not clean of rust or paint.
 The consumables are worn and need to be replaced.
 The work lead is not making good contact with the cutting machine, or the cutting machine is not making good
contact with the workpiece.
 The current (amperage) is set too low. (Review the cut chart information.)
 The cut speed is too high. (Review the cut chart information.)

Excessive dross forms on the bottom of the cut.

 The consumables are worn and need to be replaced.
 The cutting speed is too slow. (Review the cut chart information.)
 A plasma system gas setting is not correct. (Review the cut chart information.)

The cut angle is not square.

 The torch is not perpendicular to the workpiece.
 The consumables are worn and need to be replaced.
 The direction of the torch travel is incorrect. The high-quality cut is always on the right with respect to the forward
motion of the torch.
 The cut height is too large or too small. (Review the cut chart information.)
 The cutting speed is not correct. (Review the cut chart information.)
 The current (amperage) is not correct. (Review the cut chart information.)
 The torch is damaged.

The consumable life is shortened.

 The arc current, arc voltage, travel speed, motion delay, gas flow rates, or cut height are not set as recommended in
the cut charts.
 Attempting to cut highly magnetic metal workpiece, such as one with a high nickel content. Long consumable life is
difficult to achieve when cutting a workpiece that is magnetized or becomes magnetized easily.
 Firing the torch in the air (beginning or ending the cut off of the workpiece surface). Starting at the edge is
acceptable as long as the arc makes contact with the workpiece when started.

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4 – Maintenance

 Starting a pierce with an incorrect torch height. Refer to the cut charts for the specific initial pierce height.
 The pierce time is incorrect.
 The swirl ring or retaining cap is worn and needs to be replaced.

Torch does not fire.

 The torch is not enabled. For HPR and HPRXD plasma systems, verify that Remote On is wired correctly on the
plasma interface board. See Hypernet plasma interface board (141162) on page 228 for more information.
 If your cutting machine does not include a Hypertherm plasma system, refer to the instruction manual for your plasma
system.

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4 – Maintenance

Update ArcGlide firmware

Download through Phoenix software

To download firmware updates for the ArcGlide system using Phoenix software, the ArcGlide must be turned ON and
connected to a Hypertherm CNC by Hypernet.

 To avoid a protocol mismatch error, make sure each ArcGlide unit and Hypernet-enabled
plasma system is turned ON before updating the firmware.

To update directly from the CNC:

1. Download the most current version of Phoenix software from www.hypertherm.com. Follow the instructions on the
web page or in Updating Phoenix Software in the Phoenix Software Operator Manual (806400).

2. Copy the Update.exe file onto a USB memory stick.

3. Insert the USB memory stick into the USB port in the CNC.

4. From the Main screen in Phoenix software, choose Setups > Password and enter the UPDATESOFTWARE
password.

The CNC updates the Phoenix software and sends ArcGlide firmware updates to each ArcGlide unit and
Hypernet-enabled plasma system.

Download from a laptop

If your configuration does not include a Hypertherm CNC, you can download the ArcGlide THC Firmware Update.zip file
from the Hypertherm Downloads Library. This file contains the program and script files necessary to update the ArcGlide
components.

 If your cutting machine does not have a Hypertherm CNC, before you upgrade your ArcGlide
firmware, contact your table manufacturer to ask if you should update your CNC at the same
time.

1. After you download the ArcGlide THC Firmware Update.zip file, unpack it in a directory on the laptop hard drive or on
a USB memory stick. One of the files included is EthernetSetup.vbs. There are also some program image .bin files
and Update.exe files to load the images.

2. Plug the laptop into the device that you want to

update or the Ethernet switch if you want to update
multiple units.

3. Navigate to the directory where you downloaded the

files.

4. Double click-on the EthernetSetup.vbs file. A dialog

box displays that lists the Ethernet ports that are
installed on the computer.

5. Enter the number of the adapter that you want to use to update the ArcGlide unit.

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4 – Maintenance

6. After a short delay, a dialog box displays with a list of the

devices you can update.

7. Enter the number of the device that you want to update

from the list on the dialog box. Enter 4 to update the HMI,
control module, and Hypernet-enabled plasma system.
Enter 0 to exit without updating.

8. When the update process is complete, the program

returns the network settings to their original settings and
exits.

Operator tests
The operator can perform several diagnostic tests on the lifter mechanics and initial
height sense (IHS). To test lifter mechanics:
 To test the lifter friction, push the UP arrow button on the front of the control module
when the system turns ON.
 To test the up and down cycling of the lifter, push the DOWN arrow button on the
front of the control module when the system turns ON.

The IHS test makes sure that the IHS process is operating correctly. Perform this test
when lifter parameter values need to be adjusted or verified.

To test IHS:
 On the front of the HMI, push the IHS Test button. Each successive push of the
button moves the torch between the transfer and retract heights.
 On a Hypertherm CNC, the IHS Test soft key on the Process screen performs the
same function.

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4 – Maintenance

Problems and solutions

Unable to establish communication with the CNC or plasma system.
 Examine Hypernet cables from the ArcGlide.
 Verify that the Ethernet switch is turned ON.
 Verify that the plasma control board is not receiving dual serial signals. If the CNC communicates directly with the
plasma system over a serial (RS-422) cable, verify that you are using the correct cable (123760) to connect the
control board and the ArcGlide plasma interface board.

No response to CYCLE-START-IN at THC.

 Verify that the control module is receiving power.
 Examine the line input fuses in the power module of the control module.
 Watch the Cycle Start state on the CNC input screen (Screen 3) on the THC control module display. Cycle Start
should alternate between ON and OFF as the Cycle Start input becomes active or inactive. Test the machine
interface inputs on the THC control board.
 Examine the condition of the external interlock on the THC control board. See THC control interface board (228577)
on page 215 for more information.
 Verify that the corresponding station is enabled and that the green Enable lamp on the lifter is illuminated.

Arc ignites before IHS is complete.

 Verify that the Hold signal is reaching the plasma system.
 If plasma system has a Hold signal, examine it for correct wiring.
 Verify that the Stall Force is set correctly. Adjust it if necessary.
 Verify that the plasma system coolant meets the manufacturer’s specifications.
 Look for false ohmic contact sense.
 Verify that the corresponding station is enabled on the lifter, HMI, or CNC.

The green Enable lamp on the lifter is not illuminated.

See Install the lifter on page 77 for more information.

The torch does not approach the workpiece at programmed IHS speed and Stall Force.
 Verify that the THC is in Automatic Mode. If not, change the mode to Automatic.
 Verify that Stall Force is not set too low.
 Verify that IHS Speed is not set too high.
 Look for cable and hose obstructions that may stop movement.

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Inaccurate IHS with Nozzle Ohmic Contact.

 Verify that the THC is in Automatic Mode. If not, select Automatic Mode.
 Verify that Nozzle Ohmic Contact is ON (enabled).
 Verify that the nozzle ohmic contact wire is connected at both ends.
 Verify that the torch retaining cap is tight.
 Examine the workpiece for water. If there is water, use Stall Force sensing and disable the ohmic contact.
 If you are cutting under water, use only Stall Force.
 Examine the workpiece for any type of coating, such as oil or plastic. If there is a coating, use Stall Force sensing.
 Examine the nozzle and shield and, if necessary, clean or replace them.
 Examine the work lead connection.

Inaccurate IHS with Stall Force sensing.

 Verify that Nozzle Ohmic Contact is OFF (disabled).
 Make sure the value for Transfer Height is correct.
 Verify that Stall Force is not set too high.
 Verify that the workpiece is not deflecting excessively. Examine the table supports under the workpiece. Offset
workpiece deflection by adjusting Set Cut Height and Transfer Height to achieve the improved results.

Torch fails to ignite.

 Verify that the plasma system is operational.
 Verify that the Start signal is transmitted.
 Verify that the IHS piercing height is correct for the torch.
 Verify that IHS SYNC is OFF on the control module CNC interface inputs. See Screen 3 – Inputs from the CNC on
page 138 for more information.
 Examine the torch consumables and replace them if necessary.
 Verify that the corresponding station is enabled.

Torch arc fails to transfer to workpiece.

 Verify that Transfer Height is not set too high. It is typically a percentage of Cut Height.
 Examine the work lead connection.
 Examine the torch consumables, and replace them if necessary.
 Look at the Motion input in the display window on the control module to see if it turns ON. This input confirms arc
transfer. (See Screen 9 – Inputs from the plasma system on page 141 for more information.)

Arc extinguishes immediately after transfer or creates an excessively large pierce hole.
 Verify that Pierce Time is set correctly. The delay is set too long so that the torch dwells in the piercing position too
long before machine motion.
 Verify that Machine Motion Out is active after Pierce Delay ends.

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4 – Maintenance

The laser pointer is not illuminated.

The station is not enabled or the laser is damaged and needs to be replaced.

Torch moves before workpiece is pierced all the way through.

Increase the value of Pierce Delay or Pierce Time.

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

Torch dives toward workpiece immediately after AVC begins.

 Increase Set Arc Volts.
 Increase Machine Accel Delay.
 Decrease Set Cut Height.
 Examine the torch consumables, and replace them if necessary.

Torch retracts from workpiece immediately after AVC begins.

 Decrease Set Arc Volts.
 Increase Set Cut Height.
 Examine plasma interface arc voltage wiring.
 Examine the torch consumables, and replace them if necessary.

Retract begins before arc has extinguished.

Increase Retract Delay.

Failure to retract.
 Decrease the THC Homing Speed.
 Look for obstructions in the torch path and torch lead set.

 For True Hole applications, verify that these HPRXD features are installed:

 HPRXD control board and code

 HPRXD torch
 New torch leads
 Ohmic contact wire with correct routing.

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4 – Maintenance

Troubleshooting routines

Hypertherm CNC will not communicate with HPR plasma system

Verify that all units are wired and

turned ON.

Check for a firmware update or

protocol mismatch.

Verify that Message Plasma PS

via Hypernet is selected on the
Machine screen in Phoenix.

Do you need to update Load the updated firmware. (First, make sure all
the firmware? Yes units are wired and turned ON.)
No
On the ArcGlide control
module, go to Screen 9 and
look for activity on RS-422.

Transmit activity? Verify that Station Select on the

Hypertherm CNC is either up or
No
down on the operator console
(it cannot be in the
center position).
Yes
Hypertherm CNC link failed? Done Verify that the HMI is
turned ON.
No
Yes
Receive activity? Examine HPR wiring. Remove Verify that the
termination resistors from the ENABLE/DISABLE switch on
Yes
control board and any the lifter is in the
multi-drop cables. enabled position.
No
Examine the system for Verify that the serial port
bad cables. mapped in a Hypertherm CNC
is set to None (use the Machine
Setups password).

Contact Hypertherm
Technical Support.

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4 – Maintenance

Error 19 – Excess plate contact

The Nozzle Contact Sense input, while cutting, was turning ON and OFF numerous times in succession or was ON
continuously for a period of time.

Is the nozzle touching the workpiece?

Yes No

Turn ON Arc Voltage Yes Is Arc Voltage Is there slag Yes Check the
Control Control OFF? between shield and consumables for
nozzle? damage.
No No

Verify that the Arc No Is the Arc Voltage Is the ohmic contact Yes Verify ohmic contact
Voltage setpoint set correctly? wire shorted to wire is not damaged.
matches the value ground?
the plasma cut chart.
Yes No

Verify that IHS is Yes Is Sample Arc Is the cutting table a Yes Verify that the torch
working correctly. Voltage ON? water table? is not cutting at or
below the surface of
the water and that
water is not
splashing up onto
the torch shield.

Continued on the Continued on the

next page next page

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4 – Maintenance

No No

Verify the cut speed Yes Is travel speed too Is the workpiece Yes Verify that the
in the cut chart slow? warping? workpiece is not
equals the set bowing while
program speed. cutting.
Verify the speed Turn off Nozzle
control on the Contact Cutting.
operator console is
set to 100%.
No

Verify that Torch Yes Is Torch Height

Height Disable is Disable working?
turning on when
cutting corners or
small radii.
No

On a Hypertherm Yes Is Torch Height

CNC, check the Disable supported
Torch Height Disable by the CNC?
settings on the
Speeds screen.
Verify that Torch
Height Disable
speed is the correct
percentage of cut
speed.

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4 – Maintenance

Error 21 – Ohmic tip sense

Nozzle Contact Sense input does not turn ON during initial height sense. The ArcGlide uses stall force to sense the
workpiece.

Is the nozzle touching the workpiece?

Yes No

Examine the workpiece Yes Is something on the Is the Stall Force set Yes Verify that the settings
for an oil or plastic workpiece too low? that affect the motor
coating, or too much preventing nozzle and lifter are correct
rust or dirt. contact sense? (gains for speed and
position, encoder
counts, slide length,
current limit, and stall
force).
Perform an IHS test. If
the torch is not reaching
the workpiece. Increase
the Stall Force setting
by 1. Repeat the IHS
test after each setting
change. If the problem
continues, contact
Hypertherm Technical
Service.
No No

Examine the cutting No Does the workpiece Is a mechanical bind Yes Monitor the lifter for
machine slats for have an electrical preventing the torch smooth motion.
damage or slag connection to the from reaching the Examine the lifter
build-up. cutting machine? workpiece? motion for obstructions.

Continued on
next page

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4 – Maintenance

Yes

Check the continuity No Is the lifter correctly

between the lifter and grounded to the
the cutting machine cutting machine?
table.
A separate ground
wire is required from
the lifter ground stud to
the star ground on the
gantry or cutting
machine. See
Recommended
grounding and
shielding practices on
page 55.
Yes

Examine the ohmic Yes Does the ohmic wire

contact wire for a loose have a loose
connection to the torch connection to the
or to the lifter interface torch or is it
board. damaged?
Examine the ohmic
contact wire for
damage

Continued on
next page

ArcGlide THC Instruction Manual 806450 189

4 – Maintenance

Check for correct Yes Is there a problem

consumables and that with the
the consumables are consumables?
installed correctly.
No

Check the continuity Yes Does the HPRXD

between the torch torch body have an
shield and the ohmic open internal
contact wire. connection between
the shield cap and
the ohmic contact
wire on the back of
the torch?
No

The lifter interface

board (228580) has
failed and must be
replaced.

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Error message troubleshooting

Error message displays

On the ArcGlide THC, error messages are displayed on both the HMI and the control module. In addition, on Hypertherm
CNCs, a system error message window can be set up in the Watch Window. This window displays the last 5 system
error messages. See Watch Window Setup in the Phoenix Software Operator Manual (806400).

In addition, there is an error log feature in the Phoenix software that captures error messages. See Diagnostics and
Troubleshooting in the Phoenix Software Operator Manual (806400) for more information.

ArcGlide errors

The following tables provide the text that appears in both the HMI and control module displays when an error occurs. The
tables also describe the reason for the message and the steps that you can take to correct it. See Troubleshooting
routines on page 185 for more information.

 page
Normal errors (See Table 7 on page 192) are cleared with the next Cycle Start signal. Critical errors (See Table 8 on
204) must be corrected before you can continue operation.

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Table 7 – Normal Errors

Error Description Causes Solutions
0 NO ERRORS • The system is ready to start.
1 FLASH SETUPS • When power is turned ON, the • Review all setup parameters and restore
When power is turned parameter checksum does not your setup parameter values if
OFF, all THC setup match the saved parameter necessary.
parameters are stored in checksum. Default parameters
non-volatile flash memory. will be used only for those
When power is turned ON, parameters that have changed.
the parameters are verified
with a checksum and all
values are restored from
memory.
• This message is normal after a • If the message occurred after a firmware
firmware update for new update, no action is required.
features or changes to a feature. • If this error persists with another power
cycle, replace the THC processor board
(228578) in the control module.
2 MAX SPEED EXCEEDED • Excess speed was detected • If this is a newly installed system, verify
The THC controls the lifter during operation. that these setup parameters are correct:
speed between 5% and Max Speed, Speed Gain, Encoder
100% of the maximum Counts per mm (inch).
speed value stored in the • Turn power OFF then ON to the control
ArcGlide Axis setup module and monitor operation again.
screen. In a discrete • Manually jog the lifter down while
system, if a speed greater watching the display window on the HMI
than 120% of the maximum or control module and verify that the
value is detected during position being displayed increases as
operation, motion stops the torch moves downward.
and an error displays.
• If the problem continues, contact
Hypertherm Technical Service. There
could be a faulty motor encoder or a
problem with the motor amplifier.
• Speed Gain could be set too • If this is a newly installed system, verify
high or incorrect values are that these setup parameters are correct:
being used for the Encoder Max Speed, Speed Gain, Encoder
Counts per mm (inch) Counts per mm (inch).
parameter.
• There could be a problem with • If this is an existing system that was
the motor’s encoder, faulty previously working, examine the cable
wiring in the lifter cable, or a connections to the motor encoder. Verify
faulty motor drive in the control that the set screws for the mechanical
module. coupling between the motor and lifter
slide are tightened correctly.
• If the lifter is not a Hypertherm lifter and
the installation is new, change the
encoder wiring to the control module.

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Error Description Causes Solutions

3 LIFTER HOME TIMEOUT • The slide mechanics are • Verify that the lifter moves when the
While the lifter is moving malfunctioning. motor is operating.
toward home position, the • Examine the coupling between the motor
control module is reading and the ball screw. Verify that the set
negative motion from the screws are tightened correctly.
lifter motor but the HOME • Examine the lifter cables for damage.
switch input or stall force
was not sensed after a
reasonable length of time.
4 PLATE CONTACT AT • The Nozzle Contact input is • Examine the torch tip for an electrical
HOME active while the upper limit short between the shield and nozzle.
The Nozzle Contact Sense switch is active. • Turn off Nozzle Contact IHS if the lifter is
input turns ON while the being used with a water table or water
lifter is in the home injection torch.
position. • If the torch is an HPRXD torch, ensure
the coolant is not conductive.
• The upper limit switch is faulty. • Go to the diagnostic screen in the
Hypertherm CNC, HMI, or control
module (See Screen 11 – Last errors on
page 142). Verify that the upper limit
switch is operating correctly.
• The nozzle contact wire is • Examine the ohmic contact wire for
damaged. damage, and replace it if necessary.
• There is a floating ground. • Verify that the lifter and control module
are grounded correctly. The lifter and
control module should have separate
ground wires between the ground stud
on the lifter, control module, and star
ground on the gantry or table.

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Error Description Causes Solutions

5 HOME LIM DURING OPR • The upper limit switch is faulty. • Verify that the lifter has sufficient range
The upper limit switch was of motion while cutting. Raise the torch
activated while cutting. in the mounting clamp if needed.
• Use the diagnostic screen on the
Hypertherm CNC, HMI, or control
module to monitor the I/O of the upper
limit switch and make sure it is turning
ON and OFF.
• Arc voltage feedback was lost • Monitor the actual arc voltage while
while cutting. doing a manual cut at a fixed height. If
the voltage is displayed as 0.00:
• Verify that the arc voltage input to the
plasma interface board is set
correctly.
• Perform the test again. Monitor the
arc voltage output from the plasma
interface board.
• Examine the power connections to the
plasma interface board and the cables to
and from the board. If you have a
Hypernet plasma interface board,
monitor the Hypernet communications to
the board from the control module
display. If Arc Voltage is read at the
Hypertherm CNC, HMI, or control
module, but the value is low, refer to the
instruction manual for the plasma system
for possible gas problems.
6 LOWER LIM DURING • The torch is not positioned • Verify that the torch will contact the
OPR correctly in the torch holder. workpiece while doing an IHS before the
• No torch is installed and an IHS lower limit switch is activated. If not,
During automatic operation was attempted. lower the torch in the mounting clamp.
or an IHS test, the lower • Verify that the torch is over the
• There is no workpiece under the
limit switch was activated. workpiece while doing an IHS.
torch and the IHS failed.
• The lower limit switch is faulty. • Go to the diagnostic screen on the
Hypertherm CNC, HMI, or control
module (See Screen 11 – Last errors on
page 142). Monitor the operation of the
lower limit switch.

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7 FAILED MOVE TO IHS • The IHS Start Height is set too • Verify that the value of IHS Start Height
START low. is 19.1 mm (0.75 inch) or more. Lower
During automatic operation values will work but at high speeds, the
or an IHS test, the lifter torch may not have enough travel
failed to reach the IHS distance to slow down before making
Start Height. workpiece contact.
• Disable then enable the torch station,
and perform an IHS test. The ArcGlide
calculates the travel distance.
• Perform the test again. The ArcGlide
uses the programmed IHS Start Height.
• Something on the cutting • Examine for part tip-ups or debris on the
surface is preventing the torch surface of the workpiece that can limit
from reaching the IHS Start the torch travel distance to the
Height. workpiece.
8 FAILED TO CONTACT • The IHS Start Height has a high • Decrease the IHS Start Height.
PLATE programmed value combined • Increase the IHS Speed.
The torch failed to make with a very slow IHS speed.
• Verify that the torch is tight in the
workpiece contact (either • The torch needs to be mounting clamp.
by Stall Force or by Nozzle repositioned in the torch
• Reposition the torch in the mounting
Contact) within a mounting clamp.
clamp.
reasonable period of time.
The timer starts after the • Manually lower the torch to verify that the
lifter has reached the IHS torch tip can touch the workpiece.
Start Height.
9 FAILED TO CLEAR PLATE • The ohmic contact wire is • Examine the ohmic contact wire for
The Nozzle Contact input damaged. damage, and replace it if necessary.
remains active after making • Monitor the Nozzle Contact input in the
workpiece contact and diagnostic screen of Hypertherm CNC,
while the torch is retracting HMI, or control module. If the input is
after an IHS. always ON, disconnect the ohmic
contact wire from the lifter interface
board and verify that the input is OFF. If
the input stays ON, examine the lifter
cable for damage. The lifter cable could
be faulty or there could be a faulty input
to the control module. Call Hypertherm
Technical Service for further assistance.
• The nozzle and shield are • Examine the torch tip for an electrical
shorted together or the wrong short between the shield and nozzle.
consumable combination is • Examine the consumables for damage,
installed in the torch. and make sure you are using the correct
combination.
• There is a problem with the lifter • Verify that the lifter is not binding
mechanics. mechanically and that it can retract.
• Water from a water table is • If you are using a water table or water
causing a short between the injection plasma, disable Nozzle Contact
shield and the nozzle. IHS and Nozzle Contact Cutting in the
Plasma Process screen.

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Error Description Causes Solutions

• The coolant conductivity in a • Flush the coolant system and replace
HPRXD plasma system is too the coolant filter on the HPRXD plasma
high. system.
• The workpiece is bowing during • Move the IHS to an area of the
an IHS and following the torch workpiece that is well supported by the
up while the torch is retracting. table slats.
10 FAILED TO MOVE TO • The lifter cable is damaged. • Examine the lifter cable for damage.
XFER HT • Make sure the Transfer Height setting in
The lifter failed to retract to the Plasma Process screen is correct.
the programmed Transfer
Height after a reasonable
period of time.
• The Gain settings for the lifter • If this is a new installation, make sure the
are causing unstable motion. Gain settings for the lifter are correct in
the Hypertherm CNC or in the HMI on
the Installation Data screen. See
ArcGlide axis setup parameters on
page 121.
• There is a mechanical problem • Examine the lifter for binding.
with the lifter.
• There is a problem with the • Jog the motor up and down. Verify that
encoder. the position is changing and values are
incrementing correctly (torch moving
down = positive direction).
11 IHS SYNC TIMEOUT • The CNC is not using the • If a CNC is using the IHS Sync signal,
The IHS_Sync input to the correct logic to operate this the IHS Complete output must be used.
control module was not input. • Make sure the Hold settings within the
released within a • There is a faulty input (IHS CNC are correct.
reasonable time and after Complete) or output • Monitor the IHS Sync output from the
the IHS was complete. This (IHS_Sync) at the CNC or CNC to the THC. Force the output at
error can occur when the control module. the CNC to be ON, and monitor the
ArcGlide and CNC IHS Sync input at the control module.
communicate over
• Jump out the IHS Complete output and
Hypernet or a discrete
verify that the IHS Complete input at the
connection.
CNC turns ON.
• The CNC I/O cable is • Examine the CNC I/O cable for damage.
damaged.
12 TRANSFER TIMEOUT • The torch did not produce an • Determine if the plasma system has an
The ArcGlide did not arc. error.
receive the Transfer signal • Verify that the torch is firing over the
from the plasma system workpiece.
before the transfer time • Examine the plasma interface cable for
elapsed damage.

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Error Description Causes Solutions

• There is a faulty Transfer (or • Monitor the Plasma Start input to the
Motion) output from the plasma plasma system. If the torch fires:
system. • Examine the Plasma Start wiring at
the plasma interface board.
• Verify that the torch consumables and
cutting process are correct.
• Examine the plasma interface cable
for damage.
• Verify that the Motion and Transfer
outputs from the plasma system are
working correctly.
• In a discrete system, there is a • In a discrete system:
faulty input (Transfer) to the • Monitor the Plasma Start input to the
control module. control module.
• Monitor the Transfer (or motion)
output from the plasma system.
• Monitor the Transfer input to the
control module.
13 LOST TRANSFER • When cutting scrap, the torch • Examine the consumables for damage. If
The Transfer signal was lost moves off the edge of the you are cutting scrap, this error is normal
before the Arc Glide workpiece. but will reduce the consumable life.
removed the Plasma Start • Determine if the plasma system has an
signal from the plasma error.
system. • Perform an IHS test and verify that the
torch is retracting to the pierce height
listed in the plasma system cut chart.
• Verify that the Hypertherm CNC Arc Off
Time is correct. A small time should be
used, usually no longer than 0.1
seconds. An Arc Off Time that is too
high can prevent the error from
occurring but could result in poor
consumable life.
• Verify that the arc is shutting off over
metal.
• The lead-outs are too long, • Verify that the lead-out length is correct,
especially when cutting holes especially if you are cutting holes.
and the arc is stretching out as
the slag falls into the table.
• There is a faulty connection • Verify that the workpiece, table surface,
between the workpiece, the and work lead are electrically connected.
cutting surface, and the work Heavy slag build-up on the workpiece
lead of the plasma system. can result in a poor connection between
the plasma arc and the work lead.
• The Transfer Height or Pierce • Verify that the Transfer Height (or Pierce
Height is set too high. Height) setting in the Plasma Process
screen or in the Plasma menu in the
control module is correct.

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Error Description Causes Solutions

• There is a damaged or loose • Examine the plasma system’s work lead
work lead connection on the for damage or loose connections.
plasma system.
• There is a loose connection or • Examine the plasma interface cable for
damaged plasma interface damage or loose connections.
cable.
14 FAILED MOVE TO • Pierce Height is set too high. • Verify that Pierce Height is set correctly
PIERCE in the CNC or in the HMI.
The torch failed to retract to • The Gain settings in the control • Verify the Gain settings in the
the Pierce Height after the module are set incorrectly. Hypertherm CNC or in the HMI, on the
arc transfer and after a Installation Data screen. See ArcGlide
reasonable amount of time. axis setup parameters on page 121.
The torch retracts to a • A mechanical bind is preventing • Examine the lifter for mechanical binding
Transfer Height after IHS, the torch from retracting after or slipping of the drive mechanism.
which may be equal to the arc transfer.
Pierce Height. After ignition
• A mechanical loose connection • Examine the lifter for other mechanical
and the arc transfer input
in the lifter is preventing the binds that are preventing the lifter from
activates, the torch then
torch from retracting to the moving.
retracts to Pierce Height if
pierce height after arc transfer.
the value is not equal to
Transfer Height.
15 FAILED MOVE CUT • The Cut Height is set too low or • Verify that the Cut Height is set correctly
HEIGHT too high. in the CNC or in the HMI.
The torch failed to reach • The Gain settings shown in the • Verify the Gain settings in the
the Cut Height after motion control module are set Hypertherm CNC or in the HMI, on the
started and after AVC delay incorrectly. Installation Data screen. See ArcGlide
time expired. axis setup parameters on page 121.
After Pierce Delay (Pierce • A mechanical bind is preventing • Examine the lifter for mechanical binding
Time in Phoenix software), the torch from moving to the cut or slipping of the drive mechanism.
the torch goes to puddle height position. • Examine the lifter for other mechanical
jump and motion starts. • A mechanical loose connection binds that are preventing the lifter from
The torch drops to cut in the lifter is preventing the moving.
height after the cut height torch from moving to the cut
delay. height position.
At this point the AVC delay
time begins. If the position
of the lifter is not equal to
the cut height after the
AVC delay, motion stops
and the error displays.

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16 RAMPDOWN TIMEOUT • There is a faulty or loose • Examine the cables between the control
The Transfer signal from the connection to the plasma module, the plasma interface board, and
plasma system remained system transfer (or motion the control board of the plasma system.
active at the end of the cut output). • Repair loose or damaged cables.
and remained on longer • A plasma interface cable has • In a discrete system, make sure the
than a reasonable amount been damaged. Plasma Start output from the control
of time. • In discrete systems, there is a module is ON.
faulty Transfer input to the • Make sure the Plasma Start output from
control module. the plasma interface board to the plasma
• There is a faulty Plasma Start system control module is active.
output on the plasma interface • Monitor the Transfer output on the
board or control module. plasma system control board. If the
plasma arc actually extinguishes, verify
that the transfer current sensor in the
plasma system is active.
17 RETRACT TIMEOUT • Retract Height is set too low or • Verify that the Retract Height is set
The lifter failed to retract to too high. correctly in the CNC or HMI, on the
the Retract Height at the • A mechanical bind is preventing Setup screen.
end of the cut and within a the torch from moving to the • Examine the lifter for mechanical binding
reasonable amount of time. retract height position. or slipping of the drive mechanism.
• A mechanical loose connection
in the lifter is preventing the
torch from moving to the Retract
Height.
• The Gain settings in the control • Verify that the Gain settings in the
module are set incorrectly. Hypertherm CNC or in the HMI, on the
Installation Data screen, are correct. See
ArcGlide axis setup parameters on
page 121.

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Error Description Causes Solutions

18 ERR SAMPLE ARC • The lifter is stalling before • Perform an IHS test and verify that the
VOLTAGE reaching the workpiece. torch is retracting to the transfer height
With Sample Voltage ON, accurately.
the arc voltage samples • The Stall Force is set too high. (Nozzle
from cut to cut were out of Contact is OFF.)
the sample range. This • If the problem continues and cut quality
error can occur if the arc is affected, disable Sample Voltage
voltage sample on the next mode and see if the cut quality improves.
cut is not within a given
• There is slag build-up on the • Examine the shield for slag build-up.
range from the voltage
bottom of the shield.
sample of the previous cut.
For example, if the sample • The workpiece is not lying flat • Verify that the workpiece is lying flat and
voltage of the previous cut on the table. not warping while cutting. If so, set
was 120 VDC and the Nozzle Contact Cutting to OFF in the
sample voltage of the next Plasma Process screen.
cut is 170 VDC, cutting • The consumables were • Verify that the consumable life counter
stops and the error changed and the consumable on the ArcGlide was reset after
displays. The IHS at the counter in the ArcGlide was not changing the consumables.
next pierce point could not reset. • Examine the consumables for damage,
be performed accurately. • The consumables are damaged. and verify that the cutting process is
• The wrong consumables are in correct.
the torch or the plasma system
is using the wrong cutting
process.
• There is a problem with plasma • Verify that the plasma system does not
system. have any gas leaks or restrictions.

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Error Description Causes Solutions

19 EXCESS PLATE CONTACT
The Nozzle Contact input, while cutting, was turning ON and OFF numerous times in succession or was ON
continuously for a period of time. This error can occur whether or not the nozzle is contacting the workpiece.
For a flow chart, see Error 19 – Excess plate contact on page 186.
The nozzle is contacting • Arc Voltage Control is off. • Enable Arc Voltage Control.
the workpiece
• The Arc Voltage setpoint is set • Verify that the Arc Voltage setpoint
too low. matches the value in the plasma cut
chart.
• Sample Voltage is ON and the • If Sample Voltage is ON, verify that the
IHS is inaccurate. torch height is correct by performing an
IHS test.
• The travel speed is too slow. • Verify that the cut speed equals the cut
speed in the cut chart. If the value is red,
the speed control on the operator
console is overriding the travel speed.
• The Torch Height Disable is not • In a discrete connection to the ArcGlide
turning ON when approaching control module, check the output wiring
or exiting corners, holes, cutting at the CNC and the input wiring at the
a small radius, or when crossing ArcGlide.
a kerf. Torch Height Disable • Verify the Torch Height Disable settings
should be OFF when the in the Speeds screen of the Phoenix
cutting machine is moving at software are set correctly. Torch Height
program speed. Torch Height Disable speed defines the percentage of
Disable should turn ON when the Cut Speed at which to disable the
cutting corners, a small radius, torch height control.
or other situations when the cut
speed is slower than program
speed. Torch Height Disable
should be ON when piercing.
• The workpiece is not lying flat • Verify that the workpiece is lying flat and
on the table or is warping due to not warping while cutting. If so, set
heat from the arc. Nozzle Contact Cutting to OFF in the
Plasma Process screen.
• Error occurs only when marking. • If the problem occurs while marking,
verify that these parameters are set
according to the marker cut chart:
• Marking Speed
• Marking Height
• Set Arc Voltage
The nozzle is not • There is slag build-up between • Examine the consumables for damage or
contacting the workpiece. the shield and the nozzle. slag build-up between the shield and
nozzle.
• The ohmic contact wire shorted • Examine the ohmic contact wire for
to ground after the cut started. damage to the insulation around the
wire.
• The torch is operating in a water • If you are cutting in a water table, set
table and the water is above the Nozzle Contact Cutting to OFF in the
surface of the workpiece. Plasma Process screen.

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Error Description Causes Solutions

20 PLASMA SUPPLY • The plasma system is producing • Determine if the plasma system has an
The plasma system has an error. error.
reported an error condition. • In a discrete system, there is a • Examine the Error input wiring to the
loose or damaged connection plasma interface board.
to the Error input at the control • In a discrete system, examine the plasma
module or plasma interface I/O cable for damage.
board.
• Verify that the Error output is not
continuously ON at the plasma system.
• Verify that the Error input is functioning
on the plasma interface board and
control module.
21 OHMIC TIP SENSE
Nozzle Contact Sense input does not turn on during initial height sense. The ArcGlide uses stall force to sense
the workpiece. This error can occur whether or not the nozzle is contacting the workpiece. For a flow chart,
see Error 21 – Ohmic tip sense on page 188.
The nozzle is contacting • Something on the workpiece is • Verify that the workpiece is conductive.
the workpiece preventing ohmic contact. An oil or plastic coating, or too much dirt
or rust can prevent ohmic contact.
• The workpiece does not have a • Examine the cutting machine slats for
good electrical connection to damage or slag build-up.
the cutting machine.
• The lifter is not correctly • Check the continuity between the lifter
grounded to the cutting and the cutting machine table.
machine. • A separate ground wire is required from
the lifter ground stud to the star ground
on the gantry or cutting machine.
• The ohmic contact wire has a • Examine the ohmic contact wire for a
loose or open connection to the loose connection to the torch or to the
torch or it is damaged. lifter interface board.
• Examine the ohmic contact wire for
damage.
• There is a problem with the • Check for correct consumables and that
torch consumables. the consumables are installed correctly.

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Error Description Causes Solutions

• The HPRXD torch body has an • Check the continuity between the torch
internal open connection shield (nozzle) and the ohmic contact
between the shield cap and wire.
ohmic contact wire on the back
of the torch.
• The lifter interface board • Contact Hypertherm Technical Service.
(228580) has failed and must
be replaced.
The nozzle is not • Stall Force is set too low. • Verify that the settings that affect the
contacting the workpiece. motor and lifter are correct (gains for
speed and position, encoder counts,
slide length, current limit, and stall
force).
• Perform an IHS test. If the torch is not
reaching the workpiece, increase the
Stall Force setting by 1. Repeat the IHS
test after each setting change. If the
problem continues, contact Hypertherm
Technical Service.
• A mechanical bind is preventing • Monitor the lifter for smooth motion.
the torch from reaching the • Examine the lifter motion for
workpiece. obstructions.

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Table 8 – Critical Errors

Error Description Causes Solutions
23 INPUT VOLTAGE LOW • The control module is • Verify that the control module is
The AC Input Voltage to configured for 220 VAC and configured for the line voltage being
the control module 120 VAC is being applied. applied.
exceeds the low • There is a problem with the • Verify that the incoming voltage to the
tolerance limit. incoming voltage to the control control module is correct.
module.
24 INPUT VOLTAGE HIGH • The control module is • Verify that the control module is
The AC Input Voltage to configured for 120 VAC and configured for the line voltage being
the control module 220 VAC is being applied. applied.
exceeds the high • Verify that the incoming voltage to the
tolerance limit. control module is correct.
25 OVER TEMPERATURE • The ambient temperature is too • Verify that the ambient temperature does
The temperature of the high for the control module. not exceed the recommended operating
processor in the control • There is an internal failure with temperature of -10ºC to 40ºC (14ºF to
module is too high. Allow the control module. 104ºF).
the control module to • If fans or coolers are present, verify that
cool down to within the they are functioning correctly.
normal operating • If this error occurs repeatedly, contact
temperature before Hypertherm Technical Service.
continuing operation of
the ArcGlide.
• The control module is located • If the control module is mounted inside a
inside a cabinet where the air is cabinet, measure the ambient
not circulating or the fans inside temperature inside the cabinet. Verify
the cabinet are not functioning. that air is continuously circulating inside
the cabinet.
• The control module is mounted • Verify that other heat dissipating
too close to other heat components are not mounted too close
dissipating devices or to the control module.
components.
26 MOTOR DRIVE • The ambient temperature is too • Verify that the ambient temperature does
The the temperature of high for the motor drive. not exceed the manufacturer’s
the motor drive in the • There is an internal failure with recommended operating temperature.
control module is too the control module. • If fans or coolers are present, verify that
high. Allow the control they are functioning correctly.
module to cool down to • If this error occurs repeatedly, contact
within the normal Hypertherm Technical Service.
operating temperature
before continuing to
operate the ArcGlide.
• The control module is located • If the control module is mounted inside a
inside a cabinet and the air is cabinet, measure the ambient temperate
not circulating or the fans inside within the cabinet. Verify that air is
the cabinet are not functioning. continuously circulating inside the
cabinet.

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Error Description Causes Solutions

• The control module is mounted • Verify that other heat dissipating
too close to other heat components are not mounted too close
dissipating devices or to the control module.
components.
• The lifter has a mechanical bind. • Examine the lifter and torch leads for
mechanical binding.
• A non-Hypertherm lifter is • Contact the lifter manufacturer.
drawing to much current.
27 INTERLOCK TRIPPED • An E-stop is depressed on the • Verify that all E-stops on the cutting
The interlock input is cutting machine. There is a machine are disengaged.
activated. damaged or open wire in the • Examine the E-stop circuit for damage
cutting machine’s E-stop circuit. or a loose connection. Contact your
table manufacturer.
• The interlock input was not • Wire the interlock input to the E-stop
wired as part of the CNC circuit for the cutting machine.
interface to the control module. • If this is a new installation, verify that the
• There is a loose connection to interlock input is being used and is part
the interlock input. of the CNC I/O interface to the control
module.
28 BREAKAWAY TRIPPED • The torch made excessive • Re-install the magnetic torch
The magnetic torch workpiece contact or made breakaway.
breakaway has contact with the cutting • Verify that the torch is not diving into the
separated. machine. workpiece or hitting an obstruction while
cutting.
• There is debris between the • Clean the surface of magnetic
2 halves of the magnetic torch breakaway.
breakaway.
• There is a faulty proximity switch • Verify that the proximity switch LED
in the torch breakaway. illuminates when placing a metallic
object over the switch.
• The lifter I/O cable is damaged. • Examine the lifter I/O cable for damage.
29 FIELD SUPPLY FAILED • 120 VAC is applied to the • Verify that the control module is
The +5 V, +/-12 V, or control module and control configured for the correct line voltage.
+24 V supplies are not module is configured for
within their normal 220 VAC.
operating range.
• A damaged cable is loading • Examine all cables that are plugged into
down one of the control the control module and plasma interface
module’s internal voltages. board for damage.
• The electrical load that is being • Look for excess external loading on the
applied to the 24 VDC source +24 V supply.
of the control module is too
high.
• A faulty component external to • Verify that all external components
the control module is loading (relays, proximity switches, etc.) operate
down one of the voltages. correctly.
• The unit is overheating due to • If the unit is operating at a high
high ambient temperatures. temperature, allow it to cool.

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Error Description Causes Solutions

30 LIFTER CALIBRATION • The lifter failed to home • Verify that the upper limit switch is
The lifter calibration correctly. functioning correctly.
process failed after the • Home the lifter and verify that the lifter is
lifter was homed. homing correctly.
• The Gain settings are not • Verify that the Speed Gain and Current
factory settings. Limit are correct. See ArcGlide axis
setup parameters on page 121.
• The lifter has a mechanical bind • Examine the lifter and torch leads for
or loose drive coupling. mechanical binding.
• The current limit is set too low. • Examine the motor drive and position
encoder for correct operation.
31 NO HYPERNET • The Hypernet setting in the • Verify that the Hypernet setting in the
CONNECTION CNC is set to NO. CNC is set to ON and that all ArcGlide
The control module is setup screens are correctly configured.
unable to communicate
with either the CNC or
the HMI. If an HMI is
part of the ArcGlide
system, a Hypernet
connection is required to
the control module.
• The Ethernet cable is not • Examine the Ethernet cables connecting
plugged into the Hypernet port to HMI, the CNC, and the Hypernet
of the CNC or the HMI. plasma interface board.
• Examine all cables for damage.
• The Ethernet switch is not • Verify that the Ethernet switch is
receiving power or not receiving correctly turned ON.
it correctly.
• The control module, the • Verify that all related units are turned ON
Hypernet plasma interface and addressed to the same unit number.
board, and the HMI are not
addressed correctly.
32 LOST CNC HYPERNET • The CNC is not turned ON and • Verify that the CNC has correctly turned
The CNC lost the the control module is turned ON.
Hypernet connection ON.
after it was established.
• The Hypernet setting in the • Verify that the Hypernet setting in the
CNC is set to NO. CNC is set to ON and that all ArcGlide
setup screens are correctly configured.
• An Ethernet cable is unplugged • Examine the Ethernet cables connected
or damaged. to the HMI or CNC.
• Examine the Ethernet cables for
damage.
• The Ethernet switch is not • Verify that the Ethernet switch is
receiving power or not receiving correctly turned ON.
it correctly. • Verify that all related units are turned ON
and addressed to the unit number.

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4 – Maintenance

Error Description Causes Solutions

33 LOST HMI HYPERNET • The HMI is not turned ON. • Verify that the HMI is turned ON.
The HMI lost the
Hypernet connection
after it was established.
• An Ethernet cable is unplugged • Examine the Ethernet cables connecting
or damaged. to HMI to the control module, and to the
Ethernet switch.
• Examine the Ethernet cables for
damage.
• The Ethernet switch is not • Verify that the Ethernet switch is
turned ON correctly. correctly turned ON.
• Verify that all related units are turned ON
and addressed to the unit number.
34 ENCODER • There is electrical noise on the • Verify that the lifter cable is correctly
OVERFLOW lifter cable or the cable is not shielded and grounded to the control
The internal position correctly shielded or grounded. module and to the lifter assembly.
counter has counted • The motor drive board in the • Verify that the system is correctly
beyond its maximum control module is faulty. grounded.
value.
• There is an incorrect encoder • Look at the encoder counts in the
setting in either the control control module or CNC. Verify that the
module or in the CNC. settings are the default settings. See
• The encoder on the motor is ArcGlide axis setup parameters on
faulty. page 121.
• Monitor the operation of the motor and
encoder from the diagnostic screen of
the CNC or at control module (See
Screen 6 – Outputs from the lifter
control board on page 139).
• The lifter interface cable is • Examine the lifter interface cable for
damaged. damage.
35 ENCODER • There is electrical noise on the • Verify that the lifter cable is correctly
UNDERFLOW lifter cable or the cable is not shielded and grounded to the control
The internal position correctly shielded or grounded. module and to the lifter assembly.
counter has counted • The encoder on the motor is • Verify that the system is correctly
below its minimum value. faulty. grounded.
• The motor drive board in the
control module is faulty.
• There is an incorrect encoder • Look at the encoder counts in the
setting in either the control control module or CNC. Verify that the
module or in the CNC. settings are the default settings. See
ArcGlide axis setup parameters on
page 121.
• Monitor the operation of the motor and
encoder from the diagnostic screen of
the CNC or at control module (See
Screen 6 – Outputs from the lifter
control board on page 139).

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4 – Maintenance

Error Description Causes Solutions

• The lifter interface cable is • Examine the lifter interface cable for
damaged. damage.
36 HYPERNET • The Hypernet components are • Verify that the unit addresses on all the
ADDRESSING not addressed correctly. Hypernet devices on each station have
The number of Hypernet • The Ethernet cable is loose or the same unit address.
packets that dropped damaged. • Examine all Ethernet cable connections.
out exceeded the • Examine all Ethernet cables for damage.
maximum number.
37 SOFTWARE FAILURE • The microprocessor cannot be • Restart the ArcGlide control module.
programmed. • Contact your table manufacturer to
replace the THC processor board
(228578) in the control module.
38 SOFTWARE LOOP • The Ethernet cable is loose or • Examine all Ethernet cables and cable
TIME damaged. connections to verify that they are not
The 10 ms control loop damaged or loose.
time was exceeded.
• Spare input 2 on the CNC is • Spare input 2 is reserved for factory use
being used. only. Do not use Spare input 2.
• Electrical interference can • Isolate electrical noise between
occur when the ArcGlide and ArcGlide and drive power.
drives are sharing power. • Check for low line voltage.
39 SOFTWARE UNDEF • The THC processor board in • Contact your local Hypertherm
DISPLAY the control module is not Technical Service representative to
There’s an invalid value operating correctly. replace the THC processor board or
on the Diagnostics update the ArcGlide firmware.
screen.
40 SOFTWARE ANALOG • Pins on a cable connector are • Examine all of the cable connections on
INPUT not transmitting the expected the control module.
An invalid input channel signal.
was selected.
41 PROTOCOL • Software versions are not the • Turn ON power to the CNC, plasma
MISMATCH same in all of the units that are system, ArcGlide HMI, and control
connected to Hypernet. module then update the ArcGlide
firmware. See Update ArcGlide
firmware on page 180 for instructions.
42 LOST PAC HYPERNET • The Hypernet cable is • Verify that the plasma system is
The ArcGlide control disconnected between the turned ON
module lost the control module, the Ethernet • Examine all Hypernet connections.
Hypernet connection to switch, and the plasma system.
the plasma system.

208 ArcGlide THC Instruction Manual 806450

4 – Maintenance

Printed circuit board (PCB) block diagram for a Hypernet configuration

Figure 46
Control module Lifter

THC interface board

Lifter interface Lifter interface board
Operator console interface Lifter interface
Plasma interface Motor brake encoder interface
Board interconnect Upper/lower limit switches
Tip touch
Station enable switch
Manual up/down switch
Breakaway switch
Laser pointer
Station active lamp
THC processor board
Board interconnect
LCD character module
Front panel LEDs
Hypernet interface

CNC with Hypernet

Hypernet interface
Industrial Ethernet
Key:
switch
Hypernet connection ––––––
Discrete connection ——————

HMI (optional)

HPR plasma system with Hypernet

HMI processor board

Hypernet interface
LCD character module
Front panel LEDs
Plasma interface board
7-segment display interface
Hypernet interface
Arc voltage
Contact closure outputs from THC
Contact closure inputs to THC
Plasma interface

HMI 7-segment display board

ArcGlide THC Instruction Manual 806450 209

4 – Maintenance

Printed circuit board (PCB) block diagram for a discrete configuration

Figure 47

Lifter

CNC

Lifter interface board

CNC I/O Motor brake encoder interface
Upper/lower limit switches
Tip touch
Station enable switch
Control module Manual UP/DOWN switch
Breakaway switch
THC interface board Laser pointer
Station active lamp
CNC interface
Lifter interface
Lifter interface
Operator console interface
Discrete plasma interface
Board interconnect

HMI

THC processor board

Board interconnect
LCD character module
HMI processor board
Operator console LEDs
LCD character module
Ethernet connector
Operator console LEDs
Ethernet connector
7-segment display interface

Plasma system

HMI 7-segment display board

Plasma interface board
Discrete plasma interface
Arc voltage
Contact closure outputs from THC
Contact closure inputs to THC Key:
Hypernet connection ––––––
Discrete connection ——————

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4 – Maintenance

ArcGlide PCBs

HMI processor board (228581)

Default settings = 1 1
J4 LCD character module
1
J3 Display ribbon cable TP10

1
SW6 Unit address switch,
default setting = 1 1 J7 RJ45

1
TP 33 J8 Operator console
LEDs
TP 37 TP 38
1 1
1 1

J9 Display J10 IHS test J12 Power input J11 Rotary encoder input
pushbutton

 In a Hypernet configuration, the Unit address switch (SW6) on the HMI processor board
must have the same address as the Unit address switch on the THC processor and the
Hypernet plasma interface boards. The default setting is 1.

Test points
Test point No. Signal
TP10 +2.5 VDC
TP33 +3.3 VDC
TP37 +5 VDC
TP38 Ground

J4 LCD character module

Pin No. Signal Pin No. Signal
1 DB6 2 DB7
3 DB4 4 DB5
5 DB2 6 DB3
7 DB0 8 DB1
9 WR\ 10 E1 (lines 1 and 2)
11 Vee 12 RS
13 VOC 14 Vss
15 Not connected 16 E2 (lines 3 and 4)

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4 – Maintenance

J7 RJ45
Pin No. Signal Pin No. Signal
1 Tx + (transmit data +) 2 Tx - (transmit data -)
3 Rx + (receive data +) 4 Not connected
5 Not connected 6 Rx - (receive data -)
7 Not connected 8 Not connected

J8 Front panel LEDs

Pin No. Signal Pin No. Signal
1 +LED V 2 +LED V
3 Start LED 4 Motion LED
5 Limit LED 6 AVC LED
7 Error LED 8 Contact LED
9 Spare1 LED 10 Spare1 LED

J9 Display
Pin No. Signal
1 +5 V
2 Ground
3 Not connected

J10 IHS test push button

Pin No. Signal
1 Ground
2 IHS test

J11 Front panel rotary encoder input

Pin No. Signal
1 Ground
2 Ground
3 Pushbutton-A
4 Output B
5 Output A
6 +5 V

212 ArcGlide THC Instruction Manual 806450

4 – Maintenance

J12 Power connector

Pin No. Signal
1 +5 V
2 Ground
3 Common
4 Not connected

ArcGlide THC Instruction Manual 806450 213

4 – Maintenance

HMI 7-segment display interface board (228582)

2 34
1 33

J1 Display ribbon cable connector

J3 Display ribbon cable

Pin No. Signal Pin No. Signal
1 +LED V 2 +LED V
3 Ones decimal point 4 Ones G
5 Ones F 6 Ones E
7 Ones D 8 Ones C
9 Ones B 10 Ones A
11 Tens decimal point 12 Tens G
13 Tens F 14 Tens E
15 Tens D 16 Tens C
17 Tens B 18 Tens A
19 Hundreds decimal point 20 Hundreds G
21 Hundreds F 22 Hundreds E
23 Hundreds D 24 Hundreds C
25 Hundreds B 26 Hundreds A
27 Thousands decimal point 28 Thousands G
29 Thousands F 30 Thousands E
31 Thousands D 32 Thousands C
33 Thousands B 34 Thousands A

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4 – Maintenance

THC control interface board (228577)

J3 to transformer 1

Servo Pack
Back view
(428081)

J1 Board interconnects

100 52
99 51
50 2
49 1
J5 J7
Plasma I/O (female) Operator console I/O
Front view (female)

J6 J4
CNC I/O (male) Lifter I/O (male)

J3 To transformer
Pin No. Signal
1 115 V input 1
2 115 V input 2
3 115 V input 3
4 115 V input 4
5 45 V output line 1
6 45 V output line 2
7 22 V output line 1
8 22 V output line2

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4 – Maintenance

J1 Board interconnects
Pin No. Signal Pin No. Signal
1 CNC Cycle Start input 2 CNC IHS Complete output
3 CNC IHS Disable input 4 CNC Retract Complete output
5 CNC AVC Disable input 6 CNC Machine Motion output
7 CNC IHS Sync input 8 CNC Error output
9 +5 VDC 10 Ground
11 CNC spare 1 input (Do not use) 12 CNC Breakaway output
13 CNC spare 2 input (Do not use) 14 CNC spare output
15 Interlock 16 CNC Dry Inputs 24 V
17 Not connected 18 Not connected
19 +5 VDC 20 Ground
21 Plasma Motion input 22 Plasma Corner output
23 Plasma Error input 24 Plasma Pierce output
25 Plasma Ramp Error input 26 Plasma Hold output
27 Plasma Not Ready input 28 Plasma Start output
29 +5 VDC 30 Ground
31 Plasma spare input 32 Plasma spare output
33 Plasma RS-422 RX 34 Plasma RS-422 Tx
35 Not connected 36 Plasma Dry Inputs 24 V
37 Lifter Station Enable 38 Plasma Remote On output
39 +5 VDC 40 Ground
41 Lifter Lower Limit input 42 Lifter Brake output
43 Lifter Upper Limit input 44 Not connected
45 Lifter Breakaway input 46 Not connected
47 Lifter Manual Up input 48 Not connected
49 +5 VDC 50 Ground
51 Lifter Manual Down input 52 Operator console Enabled output
53 Lifter Change Consumable 54 Operator console Error output
55 Encoder A 56 Operator console spare output
57 Encoder B 58 Not connected
59 +5 VDC 60 Ground
61 Operator console Disable input 62 1/50 Arc V -
63 Operator console Select input 64 1/50 Arc V +
65 Operator console Torch Up input 66 Ohmic contact sense -
67 Operator console Torch Down input 68 Ohmic contact sense common
69 +5 VDC 70 Ground
71 Operator console spare input 72 Power good low active
73 Not connected 74 Line Volts
75 Not connected 76 Actual current
77 Not connected 78 Not connected
79 +5 VDC 80 Ground

216 ArcGlide THC Instruction Manual 806450

4 – Maintenance

J1 Board interconnects (Continued)

Pin No. Signal Pin No. Signal
81 Torque DAC 82 +24 V
83 Drive Enable output 84 +12 V
85 Not connected 86 +5 V
87 Not connected 88 -12 V
89 +5 VDC 90 Ground
91 Drive Fail input 92 Not connected
93 Not connected 94 Reserved low active
95 Ground 96 Ground
97 Ground 98 Ground
99 +5 VDC 100 Ground

J4 Lifter interface
Pin No. Signal Pin No. Signal
1 Motor + 2 Motor -
3 Brake - 4 Common -
5 Power +24 VDC 6 Ohmic contact sense common
7 Ohmic contact sense 8 Ohmic contact sense bias +12 VDC
9 Encoder common 10 Lifter station active
11 Encoder input B - 12 Encoder input B +
13 Encoder input A - 14 Encoder input A +
15 Common - 16 Change consumables switch +
17 Lifter down switch + 18 Lifter up switch +
19 Breakaway switch + 20 Upper limit switch +
21 Lower limit switch + 22 Not connected
23 Common - 24 Not connected

J5 Plasma interface
Pin No. Signal Pin No. Signal
1 RS-422 Rx + 2 RS-422 Rx -
3 RS-422 Tx + 4 RS-422 Tx -
5 RS-422 common 6 Motion input +
7 Motion input - 8 Error input +
9 Error input - 10 Rampdown error input +
11 Rampdown error input - 12 Not ready input +
13 Not ready input - 14 Spare input +
15 Spare input - 16 Corner output A
17 Corner output B 18 Pierce output A
19 Pierce output B 20 Hold output A

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4 – Maintenance

J5 Plasma interface (Continued)

Pin No. Signal Pin No. Signal
21 Hold output B 22 Start output A
23 Start output B 24 Spare output A
25 Spare output B 26 Remote on output A
27 Remote on output B 28 Common
29 Common 30 Common
31 +24 VDC output 32 +24 VDC output
33 +24 VDC output 34 1/50 Arc voltage +
35 1/50 Arc voltage - 36 Not connected
37 Not connected

J6 CNC interface
Pin No. Signal Pin No. Signal
1 Cycle Start input + 2 Cycle Start input -
3 Low gain input + 4 Low gain input -
5 AVC Disable input + 6 AVC Disable input -
7 IHS Sync input + 8 IHS Sync input -
9 Spare input 1 + (Do not use) 10 Spare input 1 - (Do not use)
11 Spare input 2 + (Do not use) 12 Spare input 2 - (Do not use)
13 IHS Complete output A 14 IHS Complete output B
15 Retract complete output A 16 Retract complete output B
17 Machine Motion output A 18 Machine Motion output B
19 THC Error output A 20 THC Error output B
21 Torch Breakaway output A 22 Torch Breakaway output B
23 CNC spare output A 24 CNC spare output B
25 Interlock input + 26 Interlock input -
27 Interlock output A 28 Interlock output B
29 Common 30 Common
31 Common 32 Common
33 +24 VDC output 34 +24 VDC output
35 +24 VDC output 36 Not connected
37 Not connected

218 ArcGlide THC Instruction Manual 806450

4 – Maintenance

J7 Operator console interface

Pin No. Signal Pin No. Signal
1 Not connected 2 Manual disable switch input +
3 Manual select switch input + 4 Torch up switch input +
5 Torch down switch input + 6 Spare switch input +
7 Common 8 Torch enabled output A
9 Torch enabled output B 10 Error output A
11 Error output B 12 Spare output A
13 Spare output B 14 Power +24 VDC output

ArcGlide THC Instruction Manual 806450 219

4 – Maintenance

THC processor board (228578)

Dry or sourced input switches,

default setting = D (dry) 1
1 1
100 52
51 Arc voltage calibration
99
2 potentiometer
50
1 49 J3 Board interconnects 1
1 1

J4
LCD power SW3 Unit address switch,
default setting = 1
J2 J5
Operator console LCD character module
LEDs

1
J11 +5 V power
J8 Hypernet
1
1
Auxiliary DIP switch

 In a Hypernet configuration, the Unit address switch (SW3) on the THC processor board
must have the same address as the Unit address switch on the HMI processor and the
Hypernet plasma interface boards. The default setting is 1.

J2 Front panel LEDs

Pin No. Signal Pin No. Signal
1 +5 VDC 2 +5 VDC
3 Start LED 4 Motion LED
5 Limit LED 6 AVC LED
7 Error LED 8 Contact LED
9 Display backup 10 Display advance

220 ArcGlide THC Instruction Manual 806450

4 – Maintenance

J3 Board interconnects
Pin No. Signal Pin No. Signal
1 CNC Cycle Start input 2 CNC IHS Complete output
3 CNC IHS Disable input 4 CNC Retract Complete output
5 CNC AVC Disable input 6 CNC Machine Motion output
7 CNC IHS Sync input 8 CNC Error output
9 +5 VDC 10 Ground
11 CNC spare 1 input 12 CNC Breakaway output
13 CNC spare 2 input 14 CNC spare output
15 Interlock 16 CNC Dry Inputs 24 V
17 Not connected 18 Not connected
19 +5 VDC 20 Ground
21 Plasma Motion input 22 Plasma Corner output
23 Plasma Error input 24 Plasma Pierce output
25 Plasma Ramp Error input 26 Plasma Hold output
27 Plasma Not Ready input 28 Plasma Start output
29 +5 VDC 30 Ground
31 Plasma spare input 32 Plasma spare output
33 Plasma RS-422 RX 34 Plasma RS-422 Tx
35 Not connected 36 Plasma Dry Inputs 24 V
37 Lifter Station Enable 38 Plasma Remote On output
39 +5 VDC 40 Ground
41 Lifter Lower Limit input 42 Lifter Brake output
43 Lifter Upper Limit input 44 Not connected
45 Lifter Breakaway input 46 Not connected
47 Lifter Manual Up input 48 Not connected
49 +5 VDC 50 Ground
51 Lifter Manual Down input 52 Operator console enabled output
53 Lifter Change Consumable 54 Operator console error output
55 Encoder A 56 Operator console spare output
57 Encoder B 58 Not connected
59 +5 VDC 60 Ground
61 Operator console Disable input 62 1/50 Arc V -
63 Operator console Select input 64 1/50 Arc V +
65 Operator console Torch Up input 66 Ohmic contact sense -
67 Operator console Torch Down input 68 Ohmic contact sense common
69 +5 VDC 70 Ground
71 Operator console spare input 72 Power good low active
73 Not connected 74 Line volts
75 Not connected 76 Actual current
77 Not connected 78 Not connected
79 +5 VDC 80 Ground

ArcGlide THC Instruction Manual 806450 221

4 – Maintenance

J3 Board interconnects (Continued)

Pin No. Signal Pin No. Signal
81 Torque DAC 82 +24 V Field
83 Drive Enable output 84 +12 V Field
85 Not connected 86 +5 V Field
87 Not connected 88 -12 V Field
89 +5 VDC 90 Ground
91 Drive Fail input 92 Not connected
93 Not connected 94 Reserved low active
95 Ground 96 Ground
97 Ground 98 Ground
99 +5 VDC 100 Ground

J4 LCD power
Pin No. Signal
1 +5 V
2 Ground
3 Not connected

J5 LCD character module

Pin No. Signal Pin No. Signal
1 DB6 2 DB7
3 DB4 4 DB5
5 DB2 6 DB3
7 DB0 8 DB1
9 WR\ 10 E1 (lines 1 and 2)
11 Vee 12 RS
13 VOC 14 Vss
15 Not connected 16 E2 (lines 3 and 4)

222 ArcGlide THC Instruction Manual 806450

4 – Maintenance

J8 Hypernet
Pin No. Signal
1 Tx + (transmit data +)
2 Tx - (transmit data -)
3 Rx + (receive data +)
4 Not connected
5 Not connected
6 Rx - (receive data -)
7 Not connected
8 Not connected

J11 +5 V power
Pin No. Signal
1 +5 VDC
2 Ground
3 Common
4 Not connected

ArcGlide THC Instruction Manual 806450 223

4 – Maintenance

Discrete plasma interface board (141094)

You can order the discrete plasma board in 2 different kits:

Kit number Description
228576 Plasma interface board subassembly
228572 Plasma interface board subassembly and enclosure

34
18

Front view
1

J5 THC discrete
cable connector
17
33
50

J1 HPR interface

Back view J2 J3
16 16

Contact closure inputs Contact closure outputs

to the THC from the THC

1 1
Electrode -
J4 Arc voltage
Work +

LEDs*
LED No. Color Signal
D1 Green Plasma on
D2 Green Plasma start
D3 Green Arc transfer
D4 Green THC on
* If the THC control board is configured with dry contacts, LED operation on the discrete plasma interface board is reversed and
the LEDs will turn OFF when input is active. See THC processor board (228578) on page 220 for the location of this switch.

224 ArcGlide THC Instruction Manual 806450

4 – Maintenance

J1 Plasma interface
Pin No. Signal Pin No. Signal
1 HPR Rx - 2 HPR Tx -
3 RS-422 communication 4 Ground
5 Ground 6 Ground
7 Ground 8 Not connected
9 Not connected 10 Not connected
11 Not connected 12 Corner A
13 Pierce A 14 Hold A
15 Plasma start relay A 16 Rem on A
17 Not connected 18 Ground
19 Optional 24 V from HPR 20 HPR Rx +
21 HPR Tx + 22 HPR turned ON
23 Motion 24 Error
25 Ramp-down error 26 HPR NR
27 Not connected 28 Not connected
29 Not connected 30 Not connected
31 Corner B 32 Pierce B
33 Hold B 34 Plasma start relay B
35 Rem on B 36 Ground
37 Optional 24 V from HPR 38 Ground

J2 (+24 V or contact closure inputs to the THC from a generic plasma system)
Pin No. Signal Pin No. Signal
1 Motion 2 Common
3 Error 4 Common
5 Ramp error 6 Common
7 Not ready 8 Common
9 Spare input 10 Common
11 Common 12 Common
13 Common 14 Common
15 Plasma system 24 VAC line* 16 Plasma system 24 VAC neutral**
* Pin 15 can be changed to +24 VDC.
** Pin 16 can be changed to -24 VDC.

ArcGlide THC Instruction Manual 806450 225

4 – Maintenance

J3 (Relay contact outputs from the THC to a generic plasma system)

Pin No. Signal Pin No. Signal
1 Corner A 2 Corner B
3 Pierce A 4 Pierce B
5 Hold A 6 Hold B
7 Plasma start A 8 Plasma start B
9 Spare THC out A 10 Spare THC out B
11 Remote ON A 12 Remote ON B
13 Common 14 Common
15 +24 V output 16 +24 V output

 Pins 11 and 12 on connector J3 must be connected to locations 1 and 3 on terminal block 2 in an HPR plasma system.
J4 Arc voltage
Pin No. Signal
1 Electrode -
2 Work +

 The arc voltage terminals on connector J4 must be connected to the I/O board in an HPR plasma system.
Connect pins 11 and 12
to locations 1 and 3 on
terminal block 2 in an
HPR plasma system

Connect the arc voltage

terminals to the I/O
board in an HPR plasma
system.

J2 J3
J4

226 ArcGlide THC Instruction Manual 806450

4 – Maintenance

J5 Plasma I/O cable (blue)

Pin No. Signal Pin No. Signal
1 RS-422 Rx - 2 RS-422 Rx +
3 RS-422 Tx - 4 RS-422 Tx +
5 RS-422 common 6 Motion input +
7 Input common - 8 Error input +
9 Input common - 10 Rampdown error input +
11 Input common - 12 Not ready input +
13 Input common - 14 Spare input +
15 Input common - 16 Corner output A
17 Corner output B 18 Pierce output A
19 Pierce output B 20 Hold output A
21 Hold output B 22 Start output A
23 Start output B 24 Spare output A
25 Spare output B 26 Remote on output A
27 Remote on output B 28 Common
29 Common 30 Common
31 +24 VDC 32 +24 VDC
33 +24 VDC 34 1/50 Arc voltage +
35 1/50 Arc voltage - 36 Not connected
37 – 50 Not connected

ArcGlide THC Instruction Manual 806450 227

4 – Maintenance

Hypernet plasma interface board (141162)

There are multiple kits for the Hypernet plasma interface board. Order the kit that corresponds to your plasma system:
Kit number Description
228604 Hypernet upgrade kit for HPR400XD and HPR800XD
228611 Hypernet upgrade kit for HPR130XD and HPR260XD
428276 Hypernet upgrade kit for MAXPRO200

Connect the arc voltage terminals to the I/O board in the HPR plasma system.

Electrode (-) Work (+)

J4 Arc voltage

J6 Remote ON or OFF
1
Connect pins 1 and 2 to locations 1 and 3 on terminal block 2 in
2 the plasma system.

SW1
Unit address
J7
LED 1
LED 2
24 VAC input
LED 3

J3
Hypernet
J5 CNC interface

 In a Hypernet configuration, the Unit address switch (SW1) on the Hypernet interface board
must have the same address as the Unit address switch on the HMI processor and the THC
processor boards. The default setting is 1.

228 ArcGlide THC Instruction Manual 806450

4 – Maintenance

LEDs
LED No. Color Signal
1 Red Plasma system error
2 Slow blinking red HPR Hypernet is ready
3 Rapid blinking red Serial transmission

J3 Discrete interface
Pin No. Signal Pin No. Signal
1 Start + 2 Start -
3 Hold + 4 Hold -
5 Pierce + 6 Pierce -
7 Corner + 8 Corner -
9 Not ready C 10 Not ready E
11 Ramp down error C 12 Ramp down error E
13 HPR error C 14 HPR error E
15 Transfer (Motion) C 16 Transfer (Motion) C

J4 Arc voltage*
Pin No. Signal
1 Work +
2 Electrode -
* The arc voltage terminals on connector J4 must be connected to the I/O board in the plasma system.

J5 CNC interface
Pin No. Signal Pin No. Signal
1 HPR Rx - 2 HPR Tx -
3 RS-422 Common 4 Motion
5 Error 6 Rampdown error
7 HPR not ready 8 Not connected
9 Not connected 10 Not connected
11 Not connected 12 Spare
13 Pierce A 14 Hold A
15 Start A 16 Not connected
17 Not connected 18 Ground
19 Not connected 20 HPR Rx +
21 HPR Tx + 22 Not connected
23 Motion 24 Error
25 Rampdown error 26 HPR not ready

ArcGlide THC Instruction Manual 806450 229

4 – Maintenance

J5 CNC interface (Continued)

Pin No. Signal Pin No. Signal
27 Not connected 28 Not connected
29 Not connected 30 Not connected
31 Spare 32 Pierce B
33 Hold B 34 Start B
35 Not connected 36 Ground
37 Not connected

J6 Remote ON/OFF
Pin No. Signal
1 ON/OFF out +
2 ON/OFF out -

J7 24 VAC
Pin No. Signal
1 Ground
2 24 VAC

230 ArcGlide THC Instruction Manual 806450

4 – Maintenance

Lifter interface board (228580)

Top view

J10 Lifter interface

Bottom view

1 J8 Enable/disable switch
J9 Up/down switch

J7 Laser pointer
1 1

J4 Breakaway
J6 Motor brake encoder 1

J5
Torch tip (ohmic wire) J3 Lower limit switch
1

J1 Upper limit switch

1
J2 LED

J1 Upper limit switch

Pin No. Signal
1 +12 VDC
2 Upper limit switch
3 Common

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4 – Maintenance

J2 Station active LED

Pin No. Signal
1 +5 VDC
2 Common

J3 Lower limit switch

Pin No. Signal
1 +12 VDC
2 Lower limit switch
3 Common

J4 Breakaway switch
Pin No. Signal
1 +12 VDC
2 Breakaway switch
3 Common

J6 Motor brake encoder

Pin No. Signal
1 Motor +
2 Motor -
3 Not connected
4 Not connected
5 Brake +24 VDC
6 Brake switch return
7 +5 VDC
8 Phase A +
9 Phase A -
10 Phase B +
11 Phase B -
12 Common

J7 Laser pointer
Pin No. Signal
1 +5 VDC
2 Common

232 ArcGlide THC Instruction Manual 806450

4 – Maintenance

J8 ENABLE/DISABLE switch
Pin No. Signal
1 Station enable
2 Common

J9 UP/DOWN switch
Pin No. Signal
1 Up switch
2 Common
3 Down switch
4 Not connected

J10 Lifter I/O cable (red)

Pin No. Signal Pin No. Signal
1 Motor + 2 Motor -
3 Brake - 4 Common -
5 Power +24 VDC 6 Ohmic contact sense common
7 Ohmic contact sense 8 Ohmic contact sense bias -12 VDC
9 Encoder common 10 +5 V Station active
11 Encoder input B - 12 Encoder input B +
13 Encoder input A - 14 Encoder input A +
15 Field common 16 Change consumable switch +
17 Lifter down switch + 18 Lifter up switch +
19 Breakaway switch + 20 Upper limit switch +
21 Lower limit switch + 22 Not connected
23 Common 24 Not connected

ArcGlide THC Instruction Manual 806450 233

4 – Maintenance

234 ArcGlide THC Instruction Manual 806450

Section 5
Parts List

Lifter parts

2
3

Item Kit number Description Quantity

1 228588 Station Enable 5 V LED 1

2 228585 ENABLE/DISABLE switch 1

3 228584 Torch lifter UP/DOWN switch 1

4 228592 Laser pointer diode 1

ArcGlide THC Instruction Manual 806450 235

5 – Parts List

Breakaway parts

11 5 12 6 8 7

9 10

Item Kit number Description Quantity

5 228593 11.34 kg (25 lb) magnetic breakaway 1

6 228607 4.54 kg (10 lb) magnetic breakaway 1

7 228597 Pneumatic breakaway 1

8 123596 Pneumatic breakaway cable 1

9 228939 35.7 kgf (78.7 lbf) replacement magnets for 11.34 kg (25 lb) 4
magnetic breakaway

104473 35.7 kgf (78.7 lbf) replacement magnet for 11.34 kg (25 lb) 1
magnetic breakaway

10 228938 20 kgf (45 lbf) replacement magnets for 4.54 kg (10 lb) magnetic 5
breakaway

104513 20 kgf (45 lbf) replacement magnet for 4.54 kg (10 lb) magnetic 1
breakaway

11 228940 Magnetic breakaway retaining tether 1

128277 35 mm (1-3/8 inch) torch mounting block 1

120596 44.5 mm (1-3/4 inch) torch mounting block 1

120597 50 mm (2 inch) torch mounting block 1

228608 Breakaway cable and sensor 1

236 ArcGlide THC Instruction Manual 806450

5 – Parts List

Lifter motor and slide parts

7
1

6
8
9

4
10

Item Kit number Description Quantity

1 228595 Lifter motor brushes 2

2 228580 Lifter interface board 1

3 428302 Lifter motor 1

4 428259 Grease gun 1

5 228591 Lifter slide 1

6 428245 Sealing band 1

7 228587 Lifter upper limit proximity switch 1

8 228586 Lifter lower limit proximity switch 1

9 428242 Ohmic contact wire 1

10 428241 Lifter side shields 2

ArcGlide THC Instruction Manual 806450 237

5 – Parts List

Control module parts

2
3

Item Kit number Description Quantity

1 228589 LCD display 1

2 228578 THC processor board 1

3 428081 Servo amplifier module 1

4 228577 THC control interface board 1

5 228579 230 V surge board 1

6 228590 120 VAC, 5 V, 5 A, 25 W power source 1

008756 5 A, 250 V, 1/4 inch X 1-1/4 inch slow blow fuse 1

108842 Power cable connector 1

008197 AMP Pin extractor tool 1

238 ArcGlide THC Instruction Manual 806450

5 – Parts List

HMI parts

Item Kit number Description Quantity

1 228589 LCD display 1

2 228583 Momentary pushbutton switch 1

3 228582 HMI 7-segment display board 1

4 228579 230 V surge board 1

5 228590 120 VAC, 5 V, 5 A, 25 W power source 1

6 228581 HMI processor board 1

ArcGlide THC Instruction Manual 806450 239

5 – Parts List

Plasma interface boards

Item Kit number Description Quantity

1 228576 Discrete plasma interface board subassembly 1

228572 Discrete plasma interface board subassembly and metal enclosure 1

2 228604 Hypernet upgrade kit for HPR400XD and HPR800XD 1

228611 Hypernet upgrade kit for HPR130XD and HPR260XD 1

428276 Hypernet upgrade kit for MAXPRO200 1

240 ArcGlide THC Instruction Manual 806450

Section 6
Wiring Diagrams

This section contains the wiring diagrams for the system. When you trace a signal path, or reference the Parts List or
Troubleshooting sections, the following conventions will help you understand the organization of the wiring diagrams:

• Sheet numbers are located in the lower, right-hand corner of each page.
• References to other pages use the following connection symbol:

Sheet
C
4-D3

Sheet number Coordinates Reference block

Use the sheet number to find the reference sheet. Line up the coordinates A–D on the Y axis and numbers 1–4 on the
X axis of each sheet to find the reference blocks (similar to a road map).

ArcGlide THC Instruction Manual 806450 241

6 – Wiring Diagrams

Wiring diagram symbols

Battery Ground clamp Receptacle

Cap, polarized Ground, chassis Relay, coil

Cap, not polarized Ground, earth Relay, normally closed

Cap, feed-through IGBT Relay, normally open

Circuit breaker Inductor Relay, solid state, AC

Coax shield LED Relay, solid state, DC

Current sensor Lamp Relay, solid state

Current sensor MOV Resistor

DC supply Pin SCR

Diode Socket Shield

Door interlock Plug Shunt

Fan PNP transistor Spark gap

Feed-through LC Potentiometer Switch, flow

Push button, Switch, level,

Filter, AC
normally closed normally closed

Push button, Switch, pressure,

Fuse
normally open normally closed

242 ArcGlide THC Instruction Manual 806450

6 – Wiring Diagrams

Switch, pressure, Time delay open,

Valve, solenoid
normally open NO/off

Time delay open,

Switch, 1 pole, 1 throw Voltage source
NC/on

Time delay closed,

Switch, 1 pole, 2 throw Zener diode
NO/off

Switch, 1 pole, 2 throw,

Transformer
center off

Switch, temperature,
Transformer, air core
normally closed

Switch, temperature,
Transformer, coil
normally open

Terminal block Triac

Time delay closed,

VAC source
NC/off

Torch symbols

Electrode

Nozzle

Shield

Torch

Torch, HyDefinition™

ArcGlide THC Instruction Manual 806450 243

6 – Wiring Diagrams

244 ArcGlide THC Instruction Manual 806450

6 – Wiring Diagrams

1 – Lifter interface board (141097)

5 4 3 2 1

Black
229280

Brown Fe
229281

Blue UPPER SWITCH

229282
D D

J1 Black

Black
Brown +12 Vdc

Red
1

Change Consumables Sw (+)

ULMT J2
Black 2 Upper Limit Sw
Blue 3 Common Common 2

LED
Brown Fe

Tip Sense Bias (-12)

Encoder Input B (+)

Encoder Input A (+)

+5 Vdc 1

Tip Sense Common

Encoder Input B (-)

Upper Limit Sw (+)

Lower Limit Sw (+)
Encoder Input A (-)
+5V Station Active

Breakaway Sw (+)
Field Power (+24)

Encoder Common

Lifter Dwn Sw (+)

Field Common (-)

J3 Note: Torch

Lifter Up Sw (+)

Chassis Shield
Brown 1 +12 Vdc tip wire can
LLMT

Black 2 Lower Limit Sw be Blue LOWER SWITCH

Tip Sense

Reserved
Blue Common inserted into

Motor +
3

Motor -
Brake -
either pin.

J4 J6
+12 Vdc Brake Sw Return Common J5
BRKWAY

Brown 1 6 12 J10
Black 2 Breakaway Sw Brake +24Vdc 5 11 Phase B- LIFTER INTERFACE TORCH

MOTOR
Blue 3 Common Chassis Gnd 4 10 Phase B+ TIP Red
Chassis Gnd 3 9 Phase A-

10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
1
2
3
4
5
6
7
8
9

1
2
Motor - 2 8 Phase A+
Green/Yellow

Motor + 1 7 +5 Vdc LED LAMP

Drain Wire

J7 Black
Red +5 Vdc

Brown
1

Green
LSR PNT

White
White

White
Black

Black
C C

Blue
Red

Red
Black 2 Common
J9
Common

047241
SW
UP/DOWN
Common 2 4
Enable

Up Sw 1 3 Dwn Sw TORCH TIP

047241
White
Black

E/D J8

Red
2
1
Black
Red

229284

223007
LIFTER INTERFACE
031148
229285

Drain Wire
Black
White
Red

B B
Brown
Blue
Green
Red
Red

UP / DOWN SWITCH

Black

Quad Encoder Red

ENABLE/DISABLE SWITCH

COM

/A Black
A
+ - White
Black

SHIELD M White
DC
DC MOTOR
+5V

B
White

/B
223031

1 Green/Yellow

EARTH GND

A 229283 A
Red
Black BRAKE

Brown Fe Laser Pointer

Blue BREAKAWAY SWITCH Black Sheet 1 of 4

5 4 3 2 1

ArcGlide THC Instruction Manual 806450 245

6 – Wiring Diagrams

2 – THC control interface board (141088)

5 4 3 2 1

100-pin Connector to Motor

Controller Processor PCB

223007
LIFTER INTERFACE
223006
OP-CON INTERFACE
ArcGlide Motor Controller
223004
Interface PCB PLASMA INTERFACE
D 141088 223005
CNC INTERFACE
D

J4 J5 J6
Red 1 Motor + Red 1 RS422 Rx- Red 1 Cycle Start Input (+)
Black 2 Motor - Black 2 RS422 Rx+ Black 2 Cycle Start Input (-)
Black 3 Brake + White 3 RS422 Tx- White 3 Low Gain Input (+)
Brown 4 Common (-) Black 4 RS422 Tx+ Black 4 Low Gain Input (-)
Brown 5 Power +24 VDC Green 5 RS422 Common Green 5 AVC Disable Input (+)
Gray 6 Ohmic Contact Sense Common Black 6 Motion Input (+) Black 6 AVC Disable Input (-)
White 7 Ohmic Contact Sense Blue 7 Input Common (-) Blue 7 IHS Sync Input (+)
Violet 8 Ohmic Contact Sense Bias +12 VDC Black 8 Error Input (+) Black 8 IHS Sync Input (-)
Black 9 Encoder Common Yellow 9 Input Common (-) Yellow 9 Spare Input 1 (+)
Red 10 Lifter Station Active Black 10 Rampdown Error Input (+) Black 10 Spare Input 1 (-)
White/Blue 11 Encoder Input B (-) Brown 11 Input Common (-) Brown 11 Spare Input 2 (+)
Blue 12 Encoder Input B (+) Black 12 Not Ready Input (+) Black 12 Spare Input 2 (-)
C C
White/Yellow13 Encoder Input A (-) Orange 13 Input Common (-) Orange 13 IHS Complete Output A
Yellow 14 Encoder Input A (+) Black 14 Spare Input (+) Black 14 IHS Complete Output B
White/Black 15 Common (-) White 15 Input Common (-) White 15 Retract Complete Output A
White/Red 16 Change Consumables Sw (+) Red 16 Corner Output A Red 16 Retract Complete Output B
Green 17 Lifter Dwn Sw (+) Green 17 Corner Output B Green 17 Machine Motion Output A
Orange 18 Lifter Up Sw (+) Red 18 Pierce Output A Red 18 Machine Motion Output B
White/Violet 19 Breakaway Sw (+) Blue 19 Pierce Output B Blue 19 THC Error Output A
White/Orange 20 Upper Limit Sw (+) Red 20 Hold Output A Red 20 THC Error Output B
White/Green21 Lower Limit Sw (+) Yellow 21 Hold Output B Yellow 21 Torch Breakaway Output A
White/Gray 22 NC (THC test) Red 22 Start Output A Red 22 Torch Breakaway Output B
White/Brown23 Field Common (-) J7 Brown 23 Start Output B Brown 23 CNC Spare Output A
24 NC Black 1 NC Red 24 Spare Output A Red 24 CNC Spare Output B
White 2 Manual Disable SwItch (+) Orange 25 Spare Output B Orange 25 Interlock Input (+)
LIFTER INTERFACE Red 3 Manual Select Switch (+) Red 26 Remote On Output A Red 26 Interlock Input (-)
Green 4 Torch Up Switch (+) White 27 Remote On Output B White 27 Interlock Output A
Orange 5 Torch Down Switch (+) Green 28 Common Green 28 Interlock Output B
Blue 6 Spare Input Switch (+) Blue 29 Common Blue 29 Common
White/Black 7 Common Green 30 Common Green 30 Common
Red/Black 8 Torch Enabled Output A Yellow 31 +24 VDC OUTPUT Yellow 31 Common
Green/Black 9 Torch Enabled Output B Green 32 +24 VDC OUTPUT Green 32 Common
Orange/Black10 Error Output A Brown 33 +24 VDC OUTPUT Brown 33 +24 VDC Fused Output
J3 Blue/Black 11 Error Output B Green 34 1/50 Arc Voltage (+) Green 34 +24 VDC Output
4 8 Gray Black/White 12 Spare Output A Orange 35 1/50 Arc Voltage (-) Orange 35 +24 VDC Output
B 3 7 Gray Red/White 13 Spare Output B Green 36 Reserved 36 NC B
2 6 Yellow Green/White 14 Power +24 VDC Output 37 NC 37 NC
1 5 Orange
OP-CON INTERFACE PLASMA INTERFACE CNC INTERFACE

223003
+5 VDC POWER
Black 4 4
Blue/White 3 3
White 2 2
White/Black 1 1
White
White
Black
Black
C
D
B
A

014343

A 223001 A
AC Entry
J1 J2
1
Surge Board White 1 2 Black
2
1

3
2
1

Black 141134 223053 2 AC/DC Power Supply 3

GND

Torroid Transformer White/Black Black 3 229234 4

1 5 Red
6

EARTH GND Sheet 2 of 4

5 4 3 2 1

246 ArcGlide THC Instruction Manual 806450

6 – Wiring Diagrams

3 – THC Processor board (141091)

5 4 3 2 1

CNC INPUT SELECT

PLASMA INPUT SELECT

ARC VOLTAGE CALIBRATION

ETHERNET UNIT ADDRESS

D 100-pin Connector to Motor D
Controller Interface PCB

J2 J5 1 Red
2 Black
3

ArcGlide Motor Controller Processor PCB J4

LCD BACKLIGHT
141091

LED LCD

J8
C C
RESERVED RESERVED

HYPERNET

OPTIONS J11
SWITCH 1 3
RESERVED RESERVED 2 4

POWER

Red

Black
123998 ETHERNET CABLE

OVERLAY FLEX CIRCUIT

B FRONT PANEL WITH OVERLAY B

101037

223003
+5 VDC POWER

RIBBON CABLE 123999

A A

ATTACHED TWISTED PAIR LCD Display

229298

Sheet 3 of 4
5 4 3 2 1

ArcGlide THC Instruction Manual 806450 247

6 – Wiring Diagrams

4 – HMI processor board (141082)

5 4 3 2 1

RIBBON CABLE 223000

RESERVED OPTIONS RESERVED
SWITCH
J1
J4
J3
7 SEGMENT DISPLAY RESERVED
ArcGlide 7 Segment PCB RESERVED
141085
J7
D D

ArcGlide HMI PCB

141082 LCD
ETHERNET UNIT ADDRESS

HYPERNET

2Black
1Red
J10
J12

3
IHS SWITCH
4 2 J11
LCD BACKLIGHT 3 1 ROTARY INPUT
J9

2
1
POWER LED

Red
Black
C C

OVERLAY FLEX CIRCUIT

IHS PUSHBUTTON ROTARY ENCODER
229241 005630 ATTACHED RIBBON CABLE

123998 ETHERNET CABLE

AC ENTRY FRONT PANEL WITH OVERLAY

F 229248 101037

B B

223003
White
Black

Green/Yellow 1

EARTH GND

J1 J17
1
Surge Board White 1 2 Black
2
1

3
2
1

141134 223053 2 AC/DC Power Supply 3

Black 3 229234 4
5 Red
6
ETHERNET
BULKHEAD
CONNECTOR
108751
A A

RIBBON CABLE 123999

ATTACHED TWISTED PAIR LCD Display
229298

Sheet 4 of 4
5 4 3 2 1

248 ArcGlide THC Instruction Manual 806450

Appendix A

ArcGlide THC Serial Communication Protocol

Overview
The Hypertherm ArcGlide THC can communicate with a CNC using RS-422 serial communications. It uses a serial
protocol which contains commands for setting parameters within the ArcGlide THC and for setting and switching
operating modes. This section provides the command IDs, data format, and example messages and responses.

 This Appendix is intended for the development of RS-422 serial protocol for ArcGlide
THC communications. If you are replacing a Command® THC with the ArcGlide THC, no
additional coding should be required, and neither the hardware installer or machine
operator needs the information contained in this section.

ArcGlide THC Operation

Because Hypernet communications take advantage of real-time signals between the ArcGlide THC and a CNC,
Hypertherm recommends Hypernet communications. See Hypernet plasma interface board (141162) on page 91 for
Hypernet installation. RS-422 communications are for configurations where Hypernet communications are not possible.

Serial Protocol
The ArcGlide THC supports RS-422 serial communications with the CNC. If you are familiar with the Command THC,
the ArcGlide supports the same protocol, format, and commands as the Command THC. The ArcGlide also supports an
extended message set to be used to access the additional functionality that the ArcGlide provides.

The serial frame runs at the following settings:

19200 baud 1 stop bit

8 data bits no parity

ArcGlide THC Instruction Manual 806450 249

A – ArcGlide THC Serial Communication Protocol

The protocol uses ASCII characters. Each message is formatted as shown below.

 In the table below, and in other examples in this section, 0x is the designation for
hexadecimal. Any value preceded by 0x designates the next values as hexadecimal values.

Start Command ID Data Checksum End

1 character 2 characters, variable length 2 characters 1 character
capitalized
> (0x3E) < (0x3C)

The CNC sends this command to put the ArcGlide into Remote mode which enables serial communications:
>RM1D0<

The components of this command are defined below:

> = Start character

RM = Command ID (Remote mode)
1 = Data (1 = ON)
D0 = Checksum (The checksum equals the 8-bit unsigned sum of the 8 bit ASCII character equivalents of the
message contents, excluding the two framing characters “>” and “<”.)
< = End character

ArcGlide THC Responses

The ArcGlide THC response to an accepted command is ^ (0x5E). The response to an invalid command is # (0x23). For
all accepted commands, the ArcGlide THC response echoes the command ID.

The CNC can also query the ArcGlide by sending a question mark (?). For example, to query the actual arc voltage, the
CNC sends the message >AV?D6<. The ArcGlide would send the response >AV100058< which represents an actual
arc voltage of 100.0 V with a checksum of 0x58.

Calculating the Checksum

The checksum for the example message >AV100058< is calculated as follows:

Character Hex value

A 41
V 56
1 31

250 ArcGlide THC Instruction Manual 806450

A – ArcGlide THC Serial Communication Protocol

Character Hex value

0 30
0 30
0 30
Sum 158

Truncate the hex value of the sum 158 to an unsigned 8-bit limit, 58. Append the ASCII 5 and 8 to the end of the
message followed by the end framing character <. The checksum is always the last two digits of the message before the
end framing character.

ArcGlide Commands and Examples

ArcGlide commands fall into three categories:
 Setup commands are programmed once and rarely need to change.
 Operating commands control the operational mode of the ArcGlide. Some operational commands can be sent to the
ArcGlide during cutting.
 ArcGlide extended commands provide precise control of the ArcGlide mechanics.

The tables on the following pages show sample command strings that could be sent from the CNC and include the
default values for each setting. The ArcGlide is ready to accept commands when it finishes its reset after turning ON.

 Important! For best results, use the default values for the ArcGlide commands. The
defaults provide a starting point and testing will indicate if you need to adjust the
command values from the defaults.

ArcGlide THC Instruction Manual 806450 251

A – ArcGlide THC Serial Communication Protocol

Setup Commands
Use the commands in the following tables to enter setup parameters for the ArcGlide. These settings rarely need to be
changed.

Pierce Height

Command ID Data Examples

PH 50 – 400 (50% – 400%) >PH1502E< Pierce Height set to 150% of cut height.
>PH?D7< Query from the CNC.

Sets the height above the workpiece for piercing as a percentage of the cut height.
Default: Previous setting

Preflow during IHS

Command ID Data Examples

PF 0 = OFF >PF1C7< Turn on Preflow During IHS.

1 = ON >PF0C6< Turn off Preflow During IHS.
>PF?D5< Query from the CNC.

Preflow during Initial Height Sense (IHS) saves cut-to-cut cycle time by allowing the plasma preflow time to occur
during the IHS process. The Plasma Start signal is applied early. The Plasma Hold signal must be connected for this
feature to operate properly.
Default: Previous setting

IHS Stall Force

Command ID Data Examples

SC 1 – 10 (1 = least force) >SC5CB< Stall force set to 5.

>SC?D5< Query from the CNC.

This value determines the amount of force used for the stall force plate sensing which is secondary to the ohmic plate
sensing. This parameter sets a force threshold of 1 (low force limit) to 10 (high force limit).
Default: 5

252 ArcGlide THC Instruction Manual 806450

A – ArcGlide THC Serial Communication Protocol

IHS Speed

Command ID Data Examples

IV 1 – 10 (approximately >IV5D4< Sets IHS speed to a relative value of 5 out of 10.

5% – 25% of maximum speed) 5 represents approximately 15% of the maximum speed or
about 90 in/min with the standard Hypertherm lifter.
>IV?DE< Query from the CNC.

IHS Speed sets the speed for the final approach to the workpiece during an IHS operation as a relative value between
1 (slow) and 10 (fast). These values represent 5 to 25% of the maximum speed of the lifter (15,240 mm/min or
600 in/min).
Default: 2

 IHS Speed command IV sets the speed on a scale of 1 – 10 to maintain compatibility with the Command THC. To
set IHS Speed in mm/min or in/min, use the IHS Speed command IS described later in this document.

Homing Speed

Command ID Data Examples

HS 1 – 10 (40% – 80% of >HS2CD< Set home speed to a relative value of 2 out of

maximum speed) 10. 2 represents approximately 45% of the maximum speed
of 6,858 mm/min or 270 in/min.
>HS?DA< Query from the CNC

Homing speed is the maximum speed for manual moves. It also sets the maximum speed used by the ArcGlide for
Arc Voltage Control. As the ArcGlide moves up and down when maintaining the set arc voltage, it does not exceed the
homing speed.
Default: 5 (5 is 60% of maximum speed)

 Homing Speed command HS sets the speed on a scale of 1 – 10 to maintain compatibility with the Command THC.
To set Homing Speed in mm/min or in/min, use the Slow Speed command SS described later in this document.

Nozzle Contact

Command ID Data Examples

NC 0 = OFF >NC1C2< Enable ohmic contact.

1 = ON >NC0C1< Disable ohmic contact.
>NC?D0< Query from the CNC.

When Nozzle Contact is on, the ArcGlide uses ohmic contact to sense the plate. Disable Nozzle Contact to use stall
force sensing (for example, with a water table or painted workpieces where electrical contact is unreliable).
Default: Previous setting

ArcGlide THC Instruction Manual 806450 253

A – ArcGlide THC Serial Communication Protocol

Machine Acceleration Delay

Command ID Data Examples

MA 0 – 9,000 (0 – 9.000 seconds) >MA150054< Sets machine acceleration delay to

1.5 seconds.
>MA?CD< Query from the CNC.

Delays the activation of the Automatic Voltage Control so the cutting machine can reach a steady cutting speed. The
time delay begins at arc transfer. It allows the machine enough time to get up to steady state speed when motion first
initiates within a cut.
Default: Previous setting

Auto Kerf Detect

Command ID Data Examples

AK 0 = OFF >AK1BD< Turns on Auto Kerf Detect.

1 = ON >AK0BC< Turns off Auto Kerf Detect.
>AK?CB< Query from the CNC.

When Auto Kerf Detect is active, the THC looks for a rapid rise in the measured arc voltage that indicates that the torch
is cutting across a previously cut kerf. This parameter temporarily disables the Automatic Voltage Control and prevents
the torch from diving into the workpiece.

 This feature has limited ability when cutting thick metal with a large kerf crossing.
Default: Previous setting

Display Units

Command ID Data Examples

UN 0 = English >UN0D3< Sets ArcGlide to English units.

1 = metric >UN1D4< Sets ArcGlide to metric units.
>UN?E2< Query from the CNC.

Sets the units displayed on the ArcGlide control module and HMI to English or metric units.
Default: Previous setting

254 ArcGlide THC Instruction Manual 806450

A – ArcGlide THC Serial Communication Protocol

Operating Commands
The ArcGlide provides both Manual and Automatic modes of operation. For Manual mode operation, the ArcGlide HMI or
an operator console on the CNC is required.

Manual mode: The ArcGlide HMI or an operator console on the CNC controls the ArcGlide motion. To enter manual
mode, use the Remote Mode command (RM) set to 0 and the Height Control command (AA) set to 0.

Automatic Voltage Control (AVC): In AVC, also called Auto mode, the CNC controls the ArcGlide motion. To enable
Automatic Voltage Control, use the Remote Mode command (RM) set to 1 and Height Control command (AA) set to 1.
The Set Arc Voltage command (VS) provides the voltage setpoint for Automatic Voltage Control.

Sample Voltage: When Set Arc Voltage is set to 0, sample arc voltage control is enabled. After piercing, the ArcGlide
reads the arc voltage and uses the reading as the arc voltage setting. By sampling the arc voltage, the ArcGlide can
automatically compensate for consumable wear or torch lead length.

Voltage control off (AVC disabled): A discrete signal that is part of Auto mode, AVC disabled causes the ArcGlide to
position at the cut height and remain at that height regardless of the arc voltage.

See Operation on page 127 for more information.

Use the commands in the following tables to change ArcGlide settings for operational mode, cut settings, and error
recovery.

Height Control

Command ID Data Examples

AA 0 = Manual >AA1B3< Automatic Voltage Control.

1 = Automatic Voltage Control >AA0B2< Manual mode.
>AA?C1< Query from the CNC.

Selects operating mode for the ArcGlide: Automatic or Manual. You will also need to use the Set Arc Voltage command
(VS) to set the voltage for Automatic Voltage Control, or to select Sample Voltage (VS = 0 for sampled arc voltage).
Default: Previous setting

Remote Mode

Command ID Data Examples

RM 0 = OFF >RM1D0< Turns on Remote mode, serial communication

1 = ON only. The ArcGlide HMI is display-only.
>RM0CF< Turns off Remote mode. Parameter entry is
through the ArcGlide HMI only.
>RM?DE< Query from the CNC.

Set to On to allow serial communication with the ArcGlide. Set to Off to allow parameter entry from the ArcGlide HMI.
Default: OFF

ArcGlide THC Instruction Manual 806450 255

A – ArcGlide THC Serial Communication Protocol

Maintenance Mode

Command ID Data Examples

MT No data. Toggle on and off. >MTA1< Disables the station and homes the torch.
>MTA1< Enables the station.

Maintenance mode homes the torch and disables the station. This command prevents THC motion or cutting and is
used to change consumables.
Default: None

IHS Test

Command ID Data Examples

IH 0 = Run >IH0C1< Run mode.

1 = Test >IH1C2< Test IHS.

Set to 1 to perform a Test IHS (Initial Height Sensing). Set to 0 to exit the test and place the ArcGlide THC in Run
mode.
Default: None

Retract

Command ID Data Examples

RE 0 = Full >RE1C8< Partial retract to Retract Height.

1 = Partial >RE0C7< Full retract to Home position.
>RE?D6< Query from the CNC.

Selects a full or partial retract of the torch at the end of every cut. In the Full retract mode, the torch retracts to the
Home position. In the Partial retract mode, the torch retracts to the set retract distance.
Default: Previous setting

Retract Height

Command ID Data Examples

RH 0 – 8000 (0 – 8.000 inch) >RH250061< Sets Retract Height to 2.500 inch.

0 – 20,320 (0 – 203.20 mm) >RH1500090< Sets Retract Height to 150.00 mm.

Specifies height above the workpiece to which the torch retracts at the end of a cut.
Default: Previous setting

256 ArcGlide THC Instruction Manual 806450

A – ArcGlide THC Serial Communication Protocol

Cut Height

Command ID Data Examples

CH 0 – 1,000 (0 – 1.000 inch) >CH2201F< Sets cut height to 0.220 inch.

0 – 2,540 (0 – 25.40 mm) >CH60021< Sets cut height to 6.00 mm.
>CH?CA< Query from the CNC.

Sets the initial cut height before Automatic Voltage Control is activated. The torch moves to the set cut height after the
Pierce Delay (Pierce Time in Phoenix software) has elapsed.
Default: Previous setting

Set Arc Voltage

Command ID Data Examples

VS 500 – 3,000 (50.0 – 300.0 V) >VS165075< Sets voltage to 165.0 V.

>VS000069< Sets arc voltage to 0 and enables sampled
arc voltage mode.
>VS?E8< Query from the CNC.

Sets the voltage for Automatic Voltage Control. The ArcGlide adjusts its height along a cut to maintain the set arc
voltage. Use the Set Arc Voltage command (VS) to set the voltage for Automatic Voltage Control, or to select sampled
arc voltage (VS = 0 for sampled arc voltage).
Default: Previous setting

Actual Arc Voltage

Command ID Data Examples

AV Query only >AV?D6< Queries the arc voltage in the ArcGlide.

>AV14125F< ArcGlide response: 141.2 V.

Reads the actual arc voltage from the ArcGlide THC.

Default: None

Pierce Delay

Command ID Data Examples

PD 0 – 9,000 (0 – 9.000 seconds) >PD45005D< Set Pierce Delay to 4.5 seconds.

>PD?D3< Query from the CNC.

Pierce Delay inserts a time delay before motion output to allow extra time for piercing the workpiece. Use a longer
Pierce Delay for thicker workpieces. Pierce Delay is the same as Pierce Time in Phoenix software.
Default: Previous setting

ArcGlide THC Instruction Manual 806450 257

A – ArcGlide THC Serial Communication Protocol

Flush Buffers

Command ID Data Examples

FL No data >FL92< Clears buffers.

Resets the serial transmit and receive buffers. Use this command immediately after the system turns ON or resets. You
can also use it when recovering from communications errors such as when the message is rejected because the
checksum does not match.

Error Code

Command ID Data Examples

EC Query only >EC?C7< Query.

>EC3BB< Response: Tip touch error.
>EC16EF< Response: No error.

Returns a Command THC error code. See Table 9 – ArcGlide errors and equivalent Command THC errors on
page 266.

Clear Error

Command ID Data Examples

CL No data >CL8F<

Clears non-critical errors from the ArcGlide control module.

IO Rev and RT Rev

Command ID Data Examples

RI Query only >RR?E3< Query.

>RR1.731< Response: ArcGlide firmware revision 1.7.

RR Query only

The RI and RR commands are unique to the Command THC and are used to return the firmware revision levels. The
Command THC has two internal microprocessors the “I/O” processor and the Real-Time processor. These commands
originally returned the I/O processor revision level (RI) and the Real-Time Processor revision level (RR).
When the ArcGlide THC replaces the Command THC, these will both return a string representing the current ArcGlide
firmware revision level. For example the ArcGlide would return the string “1.7” to represent firmware revision 1.7.

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Step Up

Command ID Data Example

S+ No data >S+7E< Move up 0.254 mm (0.01 inch).

In Manual mode, this command moves the torch up 0.254 mm (0.01 inch). In Auto mode, each command increases the
arc voltage setpoint by 0.5 V. When using sampled arc voltage, each command increases both the voltage and the IHS
start height.
Default: None

Step Down

Command ID Data Example

S- No data >S-80< Move down 0.254 mm (0.01 inch).

In Manual mode, moves the torch down 0.254 mm (0.01 inch). In Auto mode, each command decreases the arc voltage
setpoint by 0.5 V. When using sampled arc voltage, each command decreases both the voltage and the IHS start
height.
Default: None

Jog Up

Command ID Data Example

J+ No data >J+75< (Repeat within 50 ms.)

In Manual Mode, moves the torch up continuously. In Auto mode, each command increases the arc voltage setpoint by
0.5 V. When using sampled arc voltage, each command increases both the voltage and the IHS start height. This
command must be repeated within the 50 ms motion time out.
Default: None

Jog Down

Command ID Data Example

J- No data >J-77< (Repeat within 50 ms.)

In Manual mode, moves the torch down continuously. In Auto mode, each command decreases the arc voltage setpoint
by 0.5 volts. When using sampled arc voltage, each command decreases both the voltage and the IHS start height.
The command must be repeated within the 50 ms motion time out.
Default: None

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ArcGlide THC Extended Commands

The tables below show the additional commands that are not supported by the Command THC. Use these commands to
implement the ArcGlide setup parameters.

 Important! For best results, use the default values for the ArcGlide extended commands.

Slide Length

Command ID Data Examples

SL 10 – 480 (1.00 – 48.00 inch) >SL950D< Sets Slide Length to 9.0 inch.
25.00 – 1,219.00 mm >SL24136< Sets Slide Length to 241.30 mm.
>SL?DE< Query from the CNC.

Sets the travel length of the lifter.

Default: 95 (9.5 inch)

Maximum Continuous Motor Current

Command ID Data Examples

MC 10 – 60 (1.0 – 6.0 A) >MC30F3< Sets maximum motor current to

3.0 A.
>MC?CF< Query from the CNC.

This is the maximum continuous motor current for which the lifter motor is rated, to the tenth of an amp. You can
exceed the maximum motor current to provide rapid acceleration, but only for 0.5 seconds.
Default: 30 (3.0 A)

 Use the default when using the Hypertherm lifter with the ArcGlide.

Encoder Counts

Command ID Data Examples

CI 10,000 – 50,000 counts/inch >CI2032083< Sets the encoder counts to

394 – 1,969 counts/mm 20,320 per inch.
>CI80024< Sets encoder counts to 800 per mm.
>CI?CB< Inch or metric query from the CNC.

Sets encoder 4X counts-per-inch linear motion. This value scales the position feedback.
Default: 20,320 counts/inch or 800 counts/mm

 Use the default when using the Hypertherm lifter with the ArcGlide.

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Maximum Speed

Command ID Data Examples

MD 50 – 1,000 in/min >MS60036< Sets the maximum speed to

1,270 – 25,400 mm/min 600 in/min.
>MS152409C< Sets maximum speed to
15,240 mm/min.
>MS?DF< Inch or metric query from the CNC.

Sets the maximum linear speed that the ArcGlide THC can achieve. It is also the 100% scale for servo loop
calculations.
Default: 600 inches/min or 15,240 mm/min

 Use the default when using the Hypertherm lifter with the ArcGlide.

Fast Speed

Command ID Data Examples

FS 50 – 1,000 in/min >FS6002F< Fast speed set to 600 in/min.

1,270 – 25,400 mm/min >FS1524095< Fast speed to set
15,240 mm/min.
>FS?D8< English or metric query from the CNC.

Sets the speed used for all automatic rapid moves such as the end-of-cut-retract or the initial approach to the
workpiece.
Default: 600 in/min or 15,240 mm/min

 Use the default when using the Hypertherm lifter with the ArcGlide.

Slow Speed

Command ID Data Examples

SS 30 – 500 in/min >SS1503C< Slow Speed set to 150 in/min.

762 – 12,700 mm/min >SS381072< Slow speed set to 3,810 mm/min.
>SS?E5< Inch or metric query from the CNC.

Sets the homing speed and the fastest speed used for manual moves. It is also the maximum speed limit used
during arc voltage control.
Default: 150 in/min or 3,810 mm/min

 Use the default when using the Hypertherm lifter with the ArcGlide.

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IHS Speed

Command ID Data Examples

IS 10 – 150 in/min >IS6002< IHS Speed set to 60 in/min.

254 – 3,810 mm/min >IS152468< IHS Speed set to 1,524 mm/min.
>IS?DB< Inch or metric query from the CNC.

Sets the slow speed for the final approach to the workpiece during an IHS operation and the slow speed for
manual moves.
Default: 1,524 mm/min or 60 in/min

 Use the default when using the Hypertherm lifter with the ArcGlide.

Speed Gain

Command ID Data Examples

SG 1 – 10 (1 = lowest gain) >SG5CF< Speed Gain set to 5.

>SG?D9< Query from the CNC.

This gain value regulates the speed gain of the lifter.

Default: 5

 Use the default when using the Hypertherm lifter with the ArcGlide.

Position Gain

Command ID Data Examples

PG 1 – 10 (1 = lowest gain) >PG5CC< >PG05FC< Either command sets

Position Gain to 5.
>PG?D6< Query from the CNC.

This gain is used for closed loop positioning.

Default: 5

 Use the default when using the Hypertherm lifter with the ArcGlide.

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Voltage Gain

Command ID Data Examples

VG 1 – 10 (1 = lowest gain) >VG5D2< Voltage Gain set to 5.

>VG?DC< Query from the CNC.

This gain is used for closed-loop arc voltage control.

Default: 5

 Use the default when using the Hypertherm lifter with the ArcGlide.

Voltage Calibration

Command ID Data Example

VC 900 – 1,100 (0.900 – 1.100) >VC10005A< Sets arc voltage calibration to a

value of 1.

This value calibrates the arc voltage measurement accuracy. It is the software equivalent of adjusting the
voltage divider board to correct for small unit-to-unit tolerances. The measured arc voltage is multiplied by this
correction value before it is displayed or used for voltage control.
Default: 1.000

Language

Command ID Data Example

LG 0–6 >LG0C3< Sets language to English.

0 = English, 1 = German, >LG?D2< Query from the CNC.
2 = Spanish, 3 = Italian,
4 = French, 5 = Portuguese,
6 = Dutch

Sets the language displayed on the ArcGlide HMI. The ArcGlide control module always displays messages in
English.
Default: 0 (English)

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Sample Voltage

Command ID Data Examples

SV 0 = OFF >SV1DA< Sample Voltage turned on.

1 = ON >SV?E8< Query.

Samples voltage at cut height. Height control must be in Automatic mode and the Voltage Control must be on.
When Sample Voltage is on, the ArcGlide THC measures the voltage at the end of the Accel Delay and uses it
as a setpoint for the remainder of the cut. When Sample Voltage is off, the Set Arc Voltage is used as the
setpoint for the torch height control.
Default: Off

IHS Start Height

Command ID Data Examples

SH 0 – 2,000 (0 – 2.000 inch) >SH10005C< IHS Start Height set to 1.00 inch.
0 – 5,080 (0 – 50/80 mm) >SH254066< IHS Start Height set to 15.40 mm.
>SH?DA< Inch or metric query.

This is the height above the last known workpiece position where the ArcGlide switches from fast speed to the
slower IHS speed. This height should be set high enough to avoid contacting the workpiece.
Default: 1000 (1 inch above plate)

Auto Kerf Detect Level

Command ID Data Examples

KL 1 – 10 (1 = lowest peak >KL5CC< Auto Kerf Detect Level set to 5.

voltage) >KL?D6< Query.

This parameter sets a sensitivity threshold to detect kerf. The range is 1 (more sensitive) to 10 (less sensitive).
Default: 5

Thick Plate Mode

Command ID Data Examples

TP 0 = OFF >TP0D4< Thick Plate mode set to OFF.

1 = ON >TP?E3< Query.

When Thick Plate mode is On, the ArcGlide estimates torch heights for piercing thick plate.
Default: Off

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ArcGlide Error Code

Command ID Data Examples

AE No data, query only >AE?C5< Query.

>AE27EF< Response: ERR 27 Interlock tripped.

Returns the ArcGlide Error code. Error codes appear on the HMI and the Control Module and can be displayed
on the CNC. See ArcGlide errors on page 191.
Default: None

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ArcGlide THC to Command THC error conversions

The ArcGlide THC supports a broad error message set. When you are using the ArcGlide THC as a replacement for the
Command THC, ArcGlide error codes are converted into Command THC error codes, and only the Command THC error
codes are returned with the EC command.

 When you are using the ArcGlide THC in a new installation and using the ArcGlide extended command set:
 ArcGlide errors can be returned using the AE command.
 The actual ArcGlide errors will always be displayed on the ArcGlide control module and HMI displays.
 These errors are for reference. See ArcGlide errors on page 191 for a definition of each error and suggestions
for corrective action.

Table 9 – ArcGlide errors and equivalent Command THC errors

ArcGlide Command THC

Error Code Error Message Error Code Description

0 NO ERRORS 16 ERR-NO ERROR

1 ERR 1 FLASH SETUPS 2 ERR-EEPROM checksum Error

2 ERR 2 MAX SPEED EXCEEDED 4 ERR-Motion FAIL

3 ERR 3 LIFTER HOME TIMEOUT 4 ERR-Motion FAIL

4 ERR 4 PLATE CONTACT AT HOME 7 ERR-Nozzle Contact at Home

5 ERR 5 HOME LIM DURING OPR 1 ERR-Torch is in HOME LIMIT

6 ERR 6 LOWER LIM DURING OPR 0 ERR-Torch is in LOWER LIMIT

7 ERR 7 FAILED MOVE TO CROSSOVER 4 ERR-Motion FAIL

8 ERR 8 FAILED TO CONTACT PLATE 4 ERR-Motion FAIL

9 ERR 9 FAILED TO CLEAR PLATE 4 ERR-Motion FAIL

10 ERR 10 FAILED MOVE TO XFER HT 4 ERR-Motion FAIL

11 ERR 11 IHS SYNC TIMEOUT 5 ERR-Watchdog timeout FAIL

12 ERR 12 TRANSFER TIMEOUT 5 ERR-Watchdog timeout FAIL

13 ERR 13 LOST TRANSFER 11 ERR-Plasma Cable Missing

14 ERR 14 FAILED MOVE TO PIERCE 4 ERR-Motion FAIL

15 ERR 15 FAILED MOVE CUTHEIGHT 4 ERR-Motion FAIL

16 ERR 16 RAMPDOWN TIMEOUT 5 ERR-Watchdog timeout FAIL

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ArcGlide Command THC

Error Code Error Message Error Code Description

17 ERR 17 RETRACT TIMEOUT 4 ERR-Motion FAIL

18 ERR 18 SAMPLED ARC VOLTS 10 ERR-Machine Cable Missing

19 ERR 19 EXCESS PLATE CONTACT 3 ERR-Lifter not installed

20 ERR 20 PLASMA SUPPLY 11 ERR-Plasma Cable Missing

21 ERR 21 OHMIC TIP SENSE 3 ERR-Lifter not installed

22 ERR 36 CRITICAL ERROR 10 ERR-Machine Cable Missing

23 ERR 23 INPUT VOLTAGE LOW 9 ERR-Motor Current Fault

24 ERR 24 INPUT VOLTAGE HIGH 9 ERR-Motor Current Fault

25 ERR 25 OVER-TEMPERATURE 9 ERR-Motor Current Fault

26 ERR 26 MOTOR DRIVE 9 ERR-Motor Current Fault

27 ERR 27 INTERLOCK TRIPPED 10 ERR-Machine Cable Missing

28 ERR 28 BREAKAWAY TRIPPED 3 ERR-Lifter not installed

29 ERR 29 FIELD SUPPLY FAILED 9 ERR-Motor Current Fault

30 ERR 30 STALL CALIBRATION 8 ERR-Cycle Start ON at Init

31 ERR 31 NO HYPERNET CONNECTION 6 ERR-InterProcessor Comm Fail

32 ERR 32 LOST CNC HYPERNET 6 ERR-InterProcessor Comm Fail

33 ERR 33 LOST HMI HYPERNET 6 ERR-InterProcessor Comm Fail

34 ERR 34 ENCODER OVERFLOW 4 ERR-Motion FAIL

35 ERR 35 ENCODER UNDERFLOW 4 ERR-Motion FAIL

36 ERR 36 HYPERNET ADDRESSING 6 ERR-InterProcessor Comm Fail

37 ERR 37 SOFTWARE ERROR 5 ERR-Watchdog timeout FAIL

38 ERR 38 SOFTWARE LOOP TIME 5 ERR-Watchdog timeout FAIL

39 ERR 39 SOFTWARE UNDEF DISPLAY 5 ERR-Watchdog timeout FAIL

40 ERR 40 SOFTWARE ANALOG INPUT 5 ERR-Watchdog timeout FAIL

41 ERR 41 PROTOCOL MISMATCH 6 ERR-InterProcessor Comm Fail

42 ERR 42 LOST PAC HYPERNET 6 ERR-InterProcessor Comm Fail

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268 ArcGlide THC Instruction Manual 806450

Appendix B

ArcGlide THC Serial Communication Installation

Introduction
This appendix describes the features of an ArcGlide THC that are unique to systems in which ArcGlide communication
uses the RS-422 serial protocol and in which the ArcGlide:
 Replaces a Command THC
 Is installed in new system using Command THC serial communication

For more information on the ArcGlide serial protocol, see ArcGlide THC Serial Communication Protocol on page 249.
Refer to the manufacturers’ instruction manuals for specific information about making serial, I/O, and power connections
to the CNC and plasma system in your plasma cutting machine.

Kit 228846 (Command THC replacement)

Part number Description Quantity

223253 Plasma I/O and CNC I/O to THC control module cable with 1
serial split (Z adapter)
223260 Plasma board adapter cable 1

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B – ArcGlide THC Serial Communication Installation

Kit 228851 (New ArcGlide installation)

Part number Description Quantity

223262 Plasma I/O to THC control module cable with serial split 1
(Y adapter)
074067 Quick-disconnect ground terminal 1

Specifications
An ArcGlide THC that uses RS-422 serial communication supports the following features:
 Built-in jumpers on the adapter cables that connect to the ArcGlide control module enable serial communication and
allow the rest of the system to interact with the ArcGlide THC as if it were a Command THC
 Only single-torch configurations are allowed
 The HMI is optional. However, the switches on the HMI are active and allow it to be used as an operator console to
perform the following functions:
 Enable or disable the lifter
 Raise or lower the torch
 Select Automatic or Manual mode
 Perform an IHS test
 The HMI only displays status and error messages from the control module. To allow the HMI to modify parameters in
a system that uses serial communication, you must remove the jumper between pins 14 and 15 in Connector A on
the Plasma I/O split cable (Z) (223253). For more information, see ArcGlide discrete interface signal examples on
page 117. Communication between the HMI and the ArcGlide control module is carried over a Hypernet connection.
This is the only Hypernet connection in the RS-422 serial configuration.
 Plasma I/O is carried on a discrete cable. The RS-422 signals that are sent from the plasma board on the control
module are diverted to the CNC.

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Limitations

An ArcGlide THC that uses RS-422 serial communication has the following configuration limitations:
 Real-time signals are not supported over serial RS-422 connections. Therefore, True Hole™ technology and other
interactive cutting commands and signals are not always supported. However, it is possible to implement True Hole
technology in some Command THC installations by using the discrete I/O signals in addition to the RS-422
connection.
 It cannot be configured with an HPR plasma system that uses Hypernet for communication.
 When the system is turned ON, only ArcGlide default values are used:
 ArcGlide THC standard lifter setup (9.40-inch, 25-pound breakaway)
 Loop gains for speed, position, and voltage
 Puddle Jump and Transfer Height features are not available
 There are no Automatic mode settings
 The HMI can only be used for monitoring and manual control functions unless you have removed the jumper between
pins 14 and 15 in Connector A on the Plasma I/O split cable (Z) (223253). For more information, see Adjusting
ArcGlide parameters with the HMI on page 283.

RS-422 serial protocol

The serial protocol supports the 19,200 baud, 8 data, 1 stop, no parity format. It does not support the older Command
THC 9600 baud format. This basic protocol supports all Command THC instructions with the exception of the following:
 Real Time revision (RR) returns the ArcGlide firmware revision number.
 I/O revision (RI) returns the ArcGlide firmware revision number.
 Error code (EC) returns the nearest equivalent Command THC error code.
 Lifter test (LT) is not supported.

When the ArcGlide THC replaces a Command THC, the CNC receives error and status messages as Command THC
messages.

If the ArcGlide THC is installed in a new system, extensions to the serial protocol are available to allow programmers to
edit the parameter settings for the following:
 Lifter setup: length, motor current, encoder counts
 Speed setup: maximum, fast, slow, IHS
 Loop gains: speed, position, voltage
 Height settings: Crossover, Transfer, Cut, Pierce, Puddle Jump
 Sample Voltage mode
 HMI language
 Relative kerf detect level

When the extended command set is used, both the CNC and the ArcGlide control module display ArcGlide error
messages. See ArcGlide THC Serial Communication Protocol on page 249 for the ArcGlide serial protocol command
set.

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Serial communication configurations

In a serial configuration, adapter cables are provided to accommodate the routing of serial signals to the ArcGlide THC.

When the ArcGlide THC replaces a Command THC in a system with a Hypertherm CNC, adapter cables (223253 and
223260 in kit number 228846) connect the CNC I/O and plasma I/O cables to the ArcGlide control module and the
plasma system. Both the plasma I/O and combined CNC I/O and serial cables can be the same cables that were used
for the Command THC or the table manufacturer can create them. For more information, see Cables on page 97.

In new systems, an adapter cable (223262 in kit number 228851) connects the plasma board on the ArcGlide control
module to the plasma I/O cable. This adapter cable separates the serial transmit and receive signals and sends them to
the CNC over a serial cable that is supplied by the table manufacturer.

The HMI communicates with the ArcGlide control module using the Hypernet protocol over a shielded, Ethernet Cat5e or
Cat6 cable. In a serial configuration, the HMI is optional and performs many of the same functions that the pendant
performs for the Command THC.

Figure 48

Lifter

Optional HMI ArcGlide control module

EDGE II, Voyager III,

Mariner, MicroEDGE, or Plasma system
third-party CNC
Plasma interface board

Key:
Hypernet connection

Discrete connection

Serial connection

Replacing a Command THC

The Command THC and ArcGlide THC have many of the same types of components. Therefore, replacing the Command
THC hardware with ArcGlide THC hardware is relatively straightforward. Use the corresponding descriptions that follow
for a comparison of how the 2 THCs are configured in a plasma cutting machine.

1. The optional HMI of the ArcGlide THC corresponds to the optional pendant for the Command THC with a few
differences, depending on the style of system communication:
a. Hypernet configurations – the HMI only allows the operator to monitor operations of the THC and to perform
manual control functions with the lifter.
b. Discrete configurations – the HMI communicates directly with the ArcGlide control module and can perform
diagnostic functions in addition to monitoring and manual functions.

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c. Serial configurations – the HMI performs monitoring and manual control functions only. Serial communication is
enabled by a jumper inside connector A of the Plasma I/O split cable (Z) (223253). You can disable serial
communication by removing this jumper and allowing full use of the HMI for diagnostic purposes. For more
information, see ArcGlide discrete interface signal examples on page 117.

2. Both models of THC send discrete I/O and serial signals to the CNC. When an ArcGlide THC replaces a Command
THC, the Z adapter cable (223253) connects the existing Command THC CNC I/O cable to the control module.

3. Both models of THC send discrete I/O signals to the plasma interface board in the plasma system. When an
ArcGlide THC replaces a Command THC, the Z adapter cable (223253) connects the existing Command THC
plasma I/O cable to the control module.

4. The plasma interface board adapter (223260) connects the plasma I/O cable and the ArcGlide plasma interface
board within the plasma system.

5. The ArcGlide THC uses its own lifter I/O cable between the control module and the lifter and comes with the system.

6. Both models of THC have a control module that provides arc voltage control and a motor drive. Cables to the
optional pendant or HMI, CNC, plasma system, and lifter all connect to the control module.

For more details about connecting serial, I/O, and adapter cables, see Connecting cables for a Command THC
replacement on page 276.

To allow the ArcGlide HMI to make adjustments to parameters in a system that uses serial communication, you must
remove the jumper between pins 14 and 15 in Connector A on the Plasma I/O split cable (Z) (223253). For more
information, see ArcGlide discrete interface signal examples on page 117.

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System description for a serial configuration

ArcGlide THC replacement for Command THC

Figure 49 shows an ArcGlide THC that has replaced a Command THC. In this configuration, the ArcGlide operates and
communicates with the rest of the system using the serial protocol, as if it were a Command THC, as described in
ArcGlide THC Serial Communication Installation on page 269. For more information, refer to the illustration in
Connecting cables for a Command THC replacement on page 276.

Figure 49
Key:
Hypernet connection –––––––
Discrete connection ———————–
Serial connection -----------

ArcGlide control module

Discrete signals only

HMI (optional)

Serial signals Customer-supplied operator

console (optional):
Existing CNC I/O cable, for
- Station on/off/program switch
serial and discrete signals
- Station active lamp
- Lifter UP/DOWN switch

Existing plasma I/O cable,

for arc voltage and discrete
signals

CNC

Plasma system
ArcGlide lifter

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ArcGlide THC in a new installation

Figure 50 shows an ArcGlide THC in a new installation with a third-party CNC. In this configuration, the extended set of
ArcGlide THC features are available to third-party CNCs with the ArcGlide extensions to the basic Command THC serial
protocol.

New configurations with a Hypertherm CNC must use Hypernet for communication. For more information, refer to the
illustration in Connecting cables in a new serial system on page 278.

Figure 50
Key:
Hypernet connection – – – – – ––
Discrete connection ———————
Serial connection ----------

ArcGlide control module

HMI (optional)

Customer-supplied operator
CNC I/O cable, for discrete signals console (optional):
- Station on/off/program switch
- Station active lamp
- Lifter UP/DOWN switch

Serial cable, for

serial signals
Plasma I/O cable, for arc
voltage and discrete
signals

CNC

Plasma system ArcGlide lifter

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Connect serial cables

Connecting serial cables to an ArcGlide THC depend on whether you are replacing a Command THC or installing the
ArcGlide in a new system.

Connecting cables for a Command THC replacement

Before you install your ArcGlide THC, see Placement of system components on page 54 for information about placing
ArcGlide THC components and how to connect power. See also Figure 51 on page 277.

To replace a Command THC with an ArcGlide THC:

1. Connect the Z adapter cable (223253) to the control module:

a. Insert the round connector with the blue band into the plasma I/O port on the front of the control module.
b. Insert the round connector with the yellow band into the CNC I/O port on the front of the control module.

2. Connect the CNC and plasma I/O cables to the Z adapter:

a. Connect the DB37 female connector on the end of the CNC I/O cable to the DB37 male connector with the
yellow band on the Z adapter cable. Fasten the standoffs to secure the connectors.
b. Connect the DB37 female connector on the end of the plasma I/O cable to the DB37 male connector with the
blue band on the Z adapter cable. Fasten the standoffs to secure the connectors.

3. Connect the CNC I/O cable to the I/O port on the CNC.

4. Connect the plasma board adapter cable (223260):

a. Connect the DB37 female connector on the end of the plasma I/O cable to the DB37 male connector on the
plasma board adapter cable. Fasten the standoffs to secure the connectors.
b. Connect the DB50 male connector on the end of the plasma board adapter cable to the J5 connector on the
plasma interface board in the plasma system.

For more information, see Plasma I/O split cable (Z) (223253) on page 280.

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Figure 51

CNC

1b 1a

Z adapter cable
Customer-supplied connector
(223253)
3

Command THC CNC I/O cable or

customer-supplied CNC I/O cable

RS-422 ports DB37 male

DB37 male
2a 2b
DB37 female
DB37 female

Plasma system

Command THC
plasma I/O cable or
customer-supplied
plasma I/O cable

Discrete plasma interface DB37 female

board (141094) 4a
DB37 male

Customer-supplied
serial cable DB37 (female) Plasma I/O adapter
4b cable (223260)

DB50 male

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Connecting cables in a new serial system

See Figure 52 on page 279 for an illustration of this configuration.

To add an ArcGlide THC to a new system:

1. Connect the CNC to the control module:

a. Insert the end of the CNC I/O cable with the yellow band into the CNC I/O port on the front of the control
module.
b. Connect the wires on the other end of the cable to the I/O signals on the CNC. Refer to the description of the
CNC I/O cable later in this section for details.

2. Connect the Y adapter (223262) to the control module by inserting the round connector with the blue band into the
plasma I/O port on the front of the control module.

3. Connect the serial cable:

a. Connect the DB9 female connector on the serial cable to the DB9 male connector on the Y adapter.
b. Connect the other end of the serial cable to the serial port on the CNC.

4. Connect the plasma I/O cable to the Y adapter:

a. Connect the round connector on the end of the plasma I/O cable to the round connector on the Y adapter.
b. Connect the DB50 male connector on the other end of the plasma I/O cable to the J5 connector on the plasma
interface board in the plasma system.

5. Secure the ground wires between the plasma I/O cable and the Y adapter:
a. Cut the ring terminal from the ground wire on the plasma I/O cable.
b. Strip the insulation from the cut end.
c. Crimp the male quick-disconnect terminal (074016) onto the stripped end of the ground wire.
d. Wind the ground wires in opposite directions around the joined connectors of the plasma I/O cable and the Y
adapter cable.
e. Connect the quick-disconnect terminals on the ground wires.

See Plasma I/O split cable (Y) (223262) on page 285 for more information.

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Figure 52
ArcGlide control module

CNC

1a 2
Customer-supplied connector

1b
Command THC CNC I/O cable or
customer-supplied CNC I/O cable Plasma I/O
Y adapter cable
(223262)
RS-422 ports DB9 male
3b DB9 female

Command THC CNC I/O cable or

customer-supplied CNC I/O cable 3a
4a
Plasma system

Plasma I/O
cable supplied
by customer
J5
DB37F

Discrete plasma interface

board (141094)

Customer-supplied serial
DB37 female
cable 4b

DB50 male

ArcGlide THC Instruction Manual 806450 279

B – ArcGlide THC Serial Communication Installation

Cables

Plasma I/O split cable (Z) (223253)

Connects the plasma I/O board to the plasma cable.

Length = 476.25 mm (18.75 inch) Connector C
Connector A Diameter = 12.70 mm (0.50 inch)
Bend radius = 152.40 mm (6.00 inch)
Blue
Diameter = 6.60 mm (0.26 inch)
Bend radius = 152.40 mm (6.00 inch)
Routes serial signals from the plasma I/O board to the CNC.

Yellow Black
Connects the CNC I/O board to the CNC cable.
Connector B Length = 476.25 mm (18.75 inch)
Diameter = 12.70 mm (0.50 inch) Connector D
Bend radius = 152.40 mm (6.00 inch)

Connector A

1 1 19
4 Connector C
5 9
15 20 37
10
16 22
23 28
29 33 1 19
34 37 Connector D
20 37

Connector A Connector C
Wire color Signal
Pin No. Pin No.

6 White Motion input + 28

7 Black Motion input - 9

18 White Pierce output A 13

19 Brown Pierce output B 32

280 ArcGlide THC Instruction Manual 806450

B – ArcGlide THC Serial Communication Installation

Connector A Connector C
Wire color Signal
Pin No. Pin No.

20 White Hold output A 14

21 Red Hold output B 33

22 White Start output A 15

23 Orange Start output B 34

28 White Field common 18

31 Yellow Plasma 24 V field 37

34 White 1/50 Arc Voltage + 35

35 Green 1/50 Arc Voltage - 16

Connector A Connector D
Wire color Signal
Pin No. Pin No.

1 Red RS-422 RX + 20
2 Black RS-422 RX - 1

3 White RS-422 TX + 21
4 Black RS-422 TX - 2

5 Green RS-422 common 36

Not Black Not
connected connected

ArcGlide THC Instruction Manual 806450 281

B – ArcGlide THC Serial Communication Installation

Connector B

4 1
9 5
15 10
22 16
28 23
33 29
37 34 19
1
Connector D
20 37

Connector B Connector D
Wire color Signal
Pin No. Pin No.

1 Red Cycle Start input + 28

2 Black Input common - 9

5 White AVC Disable input + 27

6 Black Input common 8

7 Green IHS Sync input + 24

8 Black Input common - 5

9 Blue Spare input 1 + 26

10 Black Input common - 7

11 Yellow Spare input 2 + 25

12 Black Input common - 6

13 Brown IHS Complete output A 29

14 Black IHS Complete output B 10

15 Orange Retract Complete output A 31

16 Black Retract Complete output B 12

17 White Machine Motion output A 34

18 Red Machine Motion output B 15

282 ArcGlide THC Instruction Manual 806450

B – ArcGlide THC Serial Communication Installation

Connector B Connector D
Wire color Signal
Pin No. Pin No.

19 Green THC Error output A 33

20 Red THC Error output B 14

23 Blue CNC Spare output A 30

24 Red CNC Spare output B 11

25 Yellow Interlock input + 35

26 Red Interlock input - 16

29 Brown Field common 18

34 Red Field 23 V 37

Adjusting ArcGlide parameters with the HMI

The jumper on pins 14 and 15 in Connector A limit the HMI to monitoring ArcGlide functions. To enable the HMI to adjust
ArcGlide parameters, you must remove pins 14 and 15 and the jumper wire from Connector A, using a contact extraction
tool (008197).

Jumper wire in Connector A:

Pin No. Signal

14 Serial enable +
15 Input common -

To remove the jumper in Connector A:

1. Remove the 2 screws from the cable clamp around the

connector.

2. Unscrew the backshell from the connector.

3. Insert the contact extraction tool into pin position 14 and

push the end of the tool to remove the pin.

4. Repeat Step 3 for pin position 15.

Jumper wire
5. Pull the jumper wire from the back of the connector.

6. Screw the backshell onto the connector.

7. Replace the cable clamp around the connector and fasten the 2 screws.

ArcGlide THC Instruction Manual 806450 283

B – ArcGlide THC Serial Communication Installation

Plasma board adapter cable (223260)

Connects the plasma cable to J5 on the plasma board.

Length = 520.70 mm (20.50 inch)
Diameter = 12.70 mm (0.50 inch)
Bend radius = 152.40 mm (6.00 inch)

19 1
1 17
18 33
34 50
Connector A Connector B
37 20

Connector A Wire Connector B

Signal
Pin No. color Pin No.

6 White Motion + 28
7 Black Input common - 9

18 White Pierce output A 13

19 Brown Pierce output B 32

20 White Hold output A 14

21 Red Hold output B 33

22 White Start output A 15

23 Orange Start output B 34

28 White Field common 18

31 Yellow Plasma 24 V field 37

34 White 1/50 Arc Voltage + 35

35 Green 1/50 Arc Voltage - 16

284 ArcGlide THC Instruction Manual 806450

B – ArcGlide THC Serial Communication Installation

Plasma I/O split cable (Y) (223262)

Connects the plasma I/O board to the plasma cable.
Length = 476.25 mm (18.75 inch)
Diameter = 12.95 mm (0.51 inch)
Bend radius = 152.40 mm (6.00 inch)

Connector A Connector B

Routes serial signals from the plasma I/O board to the CNC.
Length = 508.00 mm (20.00 inch) Connector C
Diameter = 6.60 mm (0.26 inch)
Bend radius = 152.40 mm (6.00 inch)

1 4
5 9
10 15 1 5
16 22
23 28 6 9
29 33
34 37
Connector C

Connector A

Connector A Connector C
Wire color Signal
Pin No. Pin No.

1 Red RS-422 TX + 4
2 Black RS-422 TX - 2

3 White RS-422 RX + 7
4 Black RS-422 RX - 3

5 Green RS-422 common 5

Not Black Not
connected connected

ArcGlide THC Instruction Manual 806450 285

B – ArcGlide THC Serial Communication Installation

Plasma I/O split cable (Y) (223262), continued

1 4 4 1
5 9 9 5
10 15 15 10
16 22 22 16
23 28
28 23
29 33
34 37 33 29
37 34

Connector A
Connector B

Connector A Connector B
Wire color Signal
Pin No. Pin No.

1 Not connected 1

2 Not connected 2

3 Not connected 3

4 Not connected 4

5 Not connected 5

6 Black Motion input + 6

7 Blue Input common - 7

8 Black Error input + 8

9 Yellow Input common - 9

10 Black Rampdown Error input + 10

11 Brown Input common - 11

12 Black Not Ready input + 12

13 Orange Input Common - 13

14 Black Serial enable + 14

15 White Input common - 15

16 Red Corner output A 16

286 ArcGlide THC Instruction Manual 806450

B – ArcGlide THC Serial Communication Installation

Connector A Connector B
Wire color Signal
Pin No. Pin No.

17 Green Corner output B 17

18 Red Pierce output A 18

19 Blue Pierce output B 19

20 Red Hold output A 20

21 Yellow Hold output B 21

22 Red Start output A 22

23 Brown Start output B 23

24 Red Spare output A 24

25 Orange Spare output B 25

26 Red Remote On output A 26

27 White Remote On output B 27

28 Green Field common 28

29 Blue Field common 29

30 Green Field common 30

31 Yellow Field 24 V 31
32 Green Field 24 V 32

33 Brown Field 24 V 33
34 Green 1/50 Arc Voltage + 34

35 Orange 1/50 Arc Voltage - 35

Not Green Not
connected connected

ArcGlide THC Instruction Manual 806450 287

B – ArcGlide THC Serial Communication Installation

288 ArcGlide THC Instruction Manual 806450

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