command THC

Plasma Interface
Upgrade
Kit 128503

Kit Instructions
IM-380
(P/N 803800)

Revision 0 - January 2000

Hypertherm, Inc.
Hanover, NH USA
http://www.hypertherm.com
email: [email protected]

© Copyright 2000 Hypertherm, Inc.

All Rights Reserved

Hypertherm and Command THC are trademarks of Hypertherm, Inc. and may be
registered in the United States and/or other countries.
 command THC Plasma Interface Upgrade

128408 KIT CONTENTS

128494 Command THC Plasma Interface Assembly

081029 Real Time Microprocessor

081030 Interface Microprocessor

Command THC 802780 X-Y Command THC Instruction Manual

Instruction Manual
Command THC
Instruction Manual
8022510 Robotic Command THC Instruction Manual

380.05

PURPOSE
To replace the plasma interface assembly or the interface PCB, the command THC must be upgraded with a
new plasma interface assembly. The upgrade requirements include installing the new plasma interface
assembly, installing 2 new control module microprocessors and recalibration of the THC system.

MAX200, HT2000 and HT2000LHF Initial Height Sensing (IHS)

Initial height sensing (IHS) for the MAX200, HT2000 and HT2000LHF systems can now be accomplished
using the new Command THC torch Ohmic Contact Sensing function. To take advantage of this
enhancement, you will need a new torch retaining cap and a THC ohmic contact wire. See the applicable
setup section of the instruction manual (802780) included with this kit for parts and installation requirements.

128503 Kit Instructions Page 1

 command THC Plasma Interface Upgrade

INSTRUCTIONS

WARNING
ELECTRIC SHOCK CAN KILL
• Turn off the power and remove the input power plug from its receptacle before
removing any access cover. If the power supply is directly connected to a line
disconnect box, switch the line disconnect to OFF (O). In the U.S., use a "lock-out
/ tag-out" procedure until the service or maintenance work is complete. In other
countries, follow appropriate national or local safety procedures.
• Do not touch live electrical parts! If power is required for servicing, use extreme
caution when working near live electrical circuits. Dangerous voltages exist inside
the THC control module that can cause serious injury or death.
STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS
• Put on a grounded wrist strap BEFORE handling PC boards.

All work must be performed by a Hypertherm Distributor or a qualified technician.

Tools Needed

Flat Screw Driver Small, Flat Screw Driver

Digital Volt Meter #2 Phillips Screw Driver

128503 Kit Instructions Page 2

 command THC Plasma Interface Upgrade

Procedure

1. Turn off the power to the power supply.

2 Turn off the power to the THC system and remove power cord.

3 Remove the THC control module cover.

3

IM380.02

128503 Kit Instructions Page 3

 command THC Plasma Interface Upgrade

4 Remove and discard the 2 microprocessors from the control PCB.

081030
Rev

INTERFACE MICROPROCESSOR

RS-422 MACHINE INTERFACE PENDANT PLASMA INTERFACE

J1 J4 J5 J6

1 1 1 1

MACHINE INTERFACE INPUTS J10 J11 PLASMA INTERFACE INPUTS

D9 10 11 12 13 14 15 D17 18 19 20 21 22 23
G G G G G G G G G G G G G G
D16
CYCLE START IN
AUTO HEIGHT ON/OFF
RESERVED 1
RESERVED 2
IHS SYNC IN
RESERVED 3
MACHINE CABLE

EXT INTER-

TRANSFER IN
PILOT ARC IN
NOZZLE CONTACT IN
PLASMA SPARE IN 1
ALT-TORCH-SEL-IN
ALT-TORCH-IN-POS
PLASMA CABLE
G
LOCK OK

P1
MACHINE INTERFACE OUTPUTS
D25 26 27 28 29 30 31 PLASMA INTERFACE OUTPUTS
R R R R R R Y ARC VOLTAGE D32 33 34 35 36 37 38
ADJUST R R R R R R Y
MACH MOTION OUT
THC ERROR OUT
PILOT ARC OUT
RETRACT COMPLETE

MACH SPARE OUT 1

IHS COMPLETE
ERROR #1

PLASMA START OUT

HOLD IGNITION OUT

PIERCE COMPLETE OUT
PLASMA SPARE OUT 1
PLASMA SPARE OUT 2
PLASMA SPARE OUT 3
ERROR #2
041507 TP2 TP1
J2
CONTROL PCB

MOTOR DRIVE INSTALLED

RS-232

MOTOR CURRENT CHECK

HOME POSITION SWITCH
ASYMETRIC-RESPONSE
DIAGNOSTIC PORT

LOWER LIMIT SWITCH

ERROR-RESOLUTION
SPEED-RESPONSE

LIFTER SPARE IN 4

LIFTER SPARE IN 5
CRASH DETECT
1

ENCODER A
ENCODER B
D41 D42 D43 D44

DRIVE ID 1
DRIVE ID 2
DRIVE ID 4
1 +24V -12V +12V +5V
U36
G G G G
INTERFACE MICROPROCESSOR

D45 46 47 48 49 50 51 52 53 54 55 56 57 58 59
TP3 TP7 G G G G G G G G G G G G G G G
GND +5V
MOTOR DRIVE INTERFACE
TP4 TP5 TP6 1 U48
+24V -12V +12V
REAL-TIME MICROPROCESSOR
J3 EXPANSION PORT J8 DC POWER IN J7 TO MOTOR DRIVE PCB

1
1 1

IM380.04

081029
Rev

REAL TIME MICROPROCESSOR

1
2

128503 Kit Instructions Page 4

 command THC Plasma Interface Upgrade

5 Install the new microprocessors into the control PCB.

081030
Rev H

INTERFACE MICROPROCESSOR

RS-422 MACHINE INTERFACE PENDANT PLASMA INTERFACE

J1 J4 J5 J6

1 1 1 1

MACHINE INTERFACE INPUTS J10 J11 PLASMA INTERFACE INPUTS

D9 10 11 12 13 14 15 D17 18 19 20 21 22 23
G G G G G G G G G G G G G G
D16
CYCLE START IN
AUTO HEIGHT ON/OFF
RESERVED 1
RESERVED 2
IHS SYNC IN
RESERVED 3
MACHINE CABLE

EXT INTER-

TRANSFER IN
PILOT ARC IN
NOZZLE CONTACT IN
PLASMA SPARE IN 1
ALT-TORCH-SEL-IN
ALT-TORCH-IN-POS
PLASMA CABLE
G
LOCK OK

P1
MACHINE INTERFACE OUTPUTS
D25 26 27 28 29 30 31 PLASMA INTERFACE OUTPUTS
R R R R R R Y ARC VOLTAGE D32 33 34 35 36 37 38
ADJUST R R R R R R Y
MACH MOTION OUT
THC ERROR OUT
PILOT ARC OUT
RETRACT COMPLETE

MACH SPARE OUT 1

IHS COMPLETE
ERROR #1

PLASMA START OUT

HOLD IGNITION OUT

PIERCE COMPLETE OUT
PLASMA SPARE OUT 1
PLASMA SPARE OUT 2
PLASMA SPARE OUT 3
ERROR #2
041507 TP2 TP1
J2
CONTROL PCB

MOTOR DRIVE INSTALLED

RS-232

MOTOR CURRENT CHECK

HOME POSITION SWITCH
ASYMETRIC-RESPONSE
DIAGNOSTIC PORT

LOWER LIMIT SWITCH

ERROR-RESOLUTION
SPEED-RESPONSE

LIFTER SPARE IN 4

LIFTER SPARE IN 5
CRASH DETECT
1

ENCODER A
ENCODER B
D41 D42 D43 D44

DRIVE ID 1
DRIVE ID 2
DRIVE ID 4
1 +24V -12V +12V +5V
U36
G G G G
INTERFACE MICROPROCESSOR

D45 46 47 48 49 50 51 52 53 54 55 56 57 58 59
TP3 TP7 G G G G G G G G G G G G G G G
GND +5V
MOTOR DRIVE INTERFACE
TP4 TP5 TP6 1 U48
+24V -12V +12V
REAL-TIME MICROPROCESSOR
J3 EXPANSION PORT J8 DC POWER IN J7 TO MOTOR DRIVE PCB

1
1 1

IM380.01

081029
Rev H

REAL TIME MICROPROCESSOR

Align the dot on the microprocessor

with the number 1 on the control PCB.

128503 Kit Instructions Page 5

 command THC Plasma Interface Upgrade
6. Before removing the old plasma interface assembly, mark all of the wire connections so that they can
be reinstalled correctly.

802510
7 Discard your existing Command THC OR
Instruction Manual.
802780

Command THC
Instruction Manual
Revisions 1 thru 4

8 Remove the old interface assembly.

9 Install the new interface assembly per the

revised instruction manual included with
this kit.

IM308.06

802780 802510
X-Y Robotic
Command THC - OR - Command THC
Instruction Manual Instruction Manual

128503 Kit Instructions Page 6

 command THC Plasma Interface Upgrade

10 Attach the volt meter to measure the arc voltage between J5-2 and J5-3 in the plasma interface
assembly.

GN
EL D

1
EC
TR
OD
E

2
WO
RK

3
4
5
J5

THC.91

11 Replace the power cord to the THC control module.

12 Turn on the power to the THC.

13 Turn on the power to the power supply.

IM380.03

128503 Kit Instructions Page 7

 command THC Plasma Interface Upgrade

14. Put the Command THC in MANUAL MODE.

15. Begin a cutting process and compare the voltage displayed on the volt meter to the arc voltage
displayed on the CNC or THC pendant.

16 Adjust the potentiometer on the PC board so that the

voltage displayed on the volt meter is the same as the arc
voltage displayed on the CNC or THC pendant.

IM380.07

17. Turn off power to power supply and to THC system.

18. Remove volt meter from the plasma interface assembly.

19 Install the access cover to the

THC plasma interface assembly
and the control module.

IM380.08

128503 Kit Instructions Page 8