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    EDGE® Pro HyPathShape Cutting ControlInstruction Manual807620|Revision 5|English

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    ArcGlide, CutPro Wizard, EDGE, HPR, HSD, Hypernet, Hypertherm, Phoenix, Powermax, Sensor, and Watch Windows 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.One of Hypertherm's long-...

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    EDGE Pro HyPath CNCInstruction Manual807620Revision 5EnglishAugust 2015Hypertherm Inc.Hanover, NH 03755 USAwww.hypertherm.com

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    Hypertherm Inc.Etna Road, P.O. Box 5010Hanover, NH 03755 USA603-643-3441 Tel (Main Office)603-643-5352 Fax (All Departments)info@hypertherm.com (Main Office Email)800-643-9878 Tel (Technical Service)technical.service@hypertherm.com (Technical Service Email)800-737-2978 Tel (Customer Service)custo...

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    EDGE Pro HyPath CNC Instruction Manual 8076205Contents 11, Safety 11,....................................................................................................................................... 11,SC-11 11,Recognize safety informa 11,tion 11,...........................................

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    6EDGE Pro HyPath CNC Instruction Manual 807620Contents 19, Product 19,Stewardship ...........................................................................................................SC-19 19,Introduction ........................................................................................

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    EDGE Pro HyPath CNC Instruction Manual 8076207Contents 25, Warranty 25,.................................................................................................................................. 25,SC-25 25,Attention ..........................................................................

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    8EDGE Pro HyPath CNC Instruction Manual 807620Contents 43,Types of grounding 43,.............................................................................................................................................................. 43, 43 43,Grounding practices 43,........................

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    EDGE Pro HyPath CNC Instruction Manual 8076209Contents 63,3 63,Operation ...................................................................................................................................... 63, 63 63,Operating the CNC 63, ............................................................

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    10EDGE Pro HyPath CNC Instruction Manual 807620Contents 82,Loading files ........................................................................................................................................................................... 82, 82 83,Wireless troubleshoot 83,ing ................

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    Safety and ComplianceSC-11SafetyRECOGNIZE SAFETY INFORMATIONDANGER WARNING CAUTIONAmerican National Standards Institute (ANSI) guidelines are used for safety signal words and symbols. The signal word DANGER or WARNING is used with a safety symbol. DANGER identifies the most serious hazards....

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    SC-12Safety and ComplianceSafetyGROUNDING SAFETYWork lead Attach the work lead securely to the workpiece or the cutting table with good metal-to-metal contact. Do not connect it to the piece that will fall away when the cut is complete.Cutting table Connect the cutting table to an earth ground, i...

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    Safety and ComplianceSC-13SafetyCUTTING CAN CAUSE FIRE OR EXPLOSIONFire prevention• Make sure the cutting area is safe before doing any cutting. Keep a fire extinguisher nearby.• Remove all flammables within 35 feet (10 m) of the cutting area.• Quench hot metal or allow it to cool before ha...

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    SC-14Safety and ComplianceSafetyCOMPRESSED GAS EQUIPMENT SAFETYGAS CYLINDERS CAN EXPLODE IF DAMAGED• Never lubricate cylinder valves or regulators with oil or grease.• Use only correct gas cylinders, regulators, hoses, and fittings designed for the specific application.• Maintain all compre...

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    Safety and ComplianceSC-15SafetyA PLASMA ARC CAN CAUSE INJURY AND BURNSInstant-on torchesA plasma arc ignites immediately when the torch switch is activated.The plasma arc will cut quickly through gloves and skin.• Keep away from the torch tip.• Do not hold metal near the cutting path.• Nev...

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    SC-16Safety and ComplianceSafetyNOISE CAN DAMAGE HEARINGCutting with a plasma arc can exceed acceptable noise levels as defined by local regulations in many applications. Prolonged exposure to excessive noise can damage hearing. Always wear proper ear protection when cutting or gouging, unless so...

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    Safety and ComplianceSC-17SafetyLASER RADIATIONExposure to the laser beam from a laser pointer can result in serious eye injury. Avoid direct eye exposure.On products that use a laser pointer for alignment, one of the following laser radiation labels has been applied on the product near where the...

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    SC-18Safety and ComplianceSafety

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    Safety and ComplianceSC-19Product StewardshipIntroductionHypertherm maintains a global Regulatory Management System to ensure that products comply with regulatory and environmental requirements.National and local safety regulationsNational and Local safety regulations shall take precedence over a...

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    SC-20Safety and ComplianceProduct StewardshipHypertherm also removes some protective devices that would cause false test results. Where required by local national regulations, a label shall be attached to the equipment to indicate that it has passed the tests prescribed by IEC 60974-4. The repair...

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    Safety and ComplianceSC-21Environmental StewardshipIntroductionThe Hypertherm Environmental Specification requires RoHS, WEEE and REACH substance information to be provided by Hypertherm’s suppliers.Product environmental compliance does not address the indoor air quality or environmental releas...

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    SC-22Safety and ComplianceEnvironmental StewardshipProper handling and safe use of chemicalsChemical 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 a...

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    Safety and ComplianceSC-23Electromagnetic Compatibility (EMC)IntroductionHypertherm’s CE-marked equipment is built in compliance with standard EN60974-10. The equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility.The limits requ...

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    SC-24Safety and ComplianceElectromagnetic 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 examp...

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    Safety and ComplianceSC-25WarrantyAttentionGenuine Hypertherm parts are the factory-recommended replacement parts for your Hypertherm system. Any damage or injury caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty, and will constitute misuse of ...

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    SC-26Safety and ComplianceWarrantyInsuranceAt 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 ri...

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    EDGE Pro HyPath CNC Instruction Manual 80762027Section 1SpecificationsMain features of an automated cutting systemFigure 1 illustrates the relationship between the components of an automated cutting system. The following topics describe these components and their relationships.Figure 1 Components...

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    28EDGE Pro HyPath CNC Instruction Manual 8076201 – SpecificationsMain features of an automated cutting systemFigure 2 illustrates a typical cutting table with an EDGE Pro CNC and other components that are described in the following topics.Figure 2 Illustration of a plasma cutting table987654321...

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    EDGE Pro HyPath CNC Instruction Manual 807620291 – SpecificationsMain features of an automated cutting systemCNCThe computerized numerical control (CNC) reads part programs and communicates with the other components of the shape cutting system. It controls which parts (shapes) are cut from the ...

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    30EDGE Pro HyPath CNC Instruction Manual 8076201 – SpecificationsMain features of an automated cutting systemTorch height controlThe THC controls the distance between the torch and the workpiece, also known as the standoff. This standoff is usually defined by height or voltage. If a Hypertherm ...

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    EDGE Pro HyPath CNC Instruction Manual 807620311 – SpecificationsOverviewOverviewThe EDGE Pro HyPath is a PC-based CNC and uses Hypertherm’s Phoenix software to control one or more cutting or marking stations.The EDGE Pro HyPath CNC has a two-station operator console, a 15-inch touchscreen, a...

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    32EDGE Pro HyPath CNC Instruction Manual 8076201 – SpecificationsFeatures of the EDGE Pro HyPath CNCFeatures of the EDGE Pro HyPath CNCTouchscreenThe touchscreen is a 15-inch LCD monitor combined with software that allows direct user input from the screen. A user makes selections on the screen ...

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    EDGE Pro HyPath CNC Instruction Manual 807620331 – SpecificationsFeatures of the EDGE Pro HyPath CNCRear panelThe rear panel of the EDGE Pro HyPath CNC has cable connectors for power, motion control, I/O, and communication ports. These connectors are clearly labeled with their function. In addi...

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    34EDGE Pro HyPath CNC Instruction Manual 8076201 – SpecificationsSystem specificationsSystem specificationsThe following table contains technical specifications for the EDGE Pro CNC.Table 1 System specifications for the EDGE Pro CNCSystem featuresProcessorIntel® ProcessorOperating systemWindow...

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    EDGE Pro HyPath CNC Instruction Manual 807620351 – SpecificationsSystem specificationsEnvironmentalTemperature-10º C to 40º C (14º F to 104º F)Humidity95% maximum relative humidityIngress ProtectionIP21SProtect the equipment from exposure to excessive moisture.AltitudeOperational up to 2000...

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    36EDGE Pro HyPath CNC Instruction Manual 8076201 – SpecificationsSystem specificationsHyPath modelsThe EDGE Pro HyPath CNC is available in multiple configurations, which are listed in Table 2.Table 2 EDGE Pro HyPath part numbersFigure 6 Rear panel of 090045Part NumberNumber of AxesNumber of I/O...

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    EDGE Pro HyPath CNC Instruction Manual 807620371 – SpecificationsSystem specificationsIntegrated Sensor THCIf your EDGE Pro configuration includes one or two optional integrated Sensor THCs, the CNC includes an analog input for each THC. For more information, see 39,Installation 39, on 39, pag...

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    38EDGE Pro HyPath CNC Instruction Manual 8076201 – SpecificationsSymbols and MarksSymbols and MarksYour 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 pro...

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    EDGE Pro HyPath CNC Instruction Manual 80762039Section 2InstallationUpon receipt•Verify that all the system components on your order have been received. Contact your supplier if any items are missing. •EDGE Pro HyPath CNC•Power cable (North America) (108884)•Power connector (all other reg...

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    40EDGE Pro HyPath CNC Instruction Manual 8076202 – InstallationMounting the CNCPlacement of system components•Place all system components in position prior to making electrical, gas and interface connections. See 40,Mounting the 40,CNC 40, on page 40,40 for details.•Ground all system com...

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    EDGE Pro HyPath CNC Instruction Manual 807620412–InstallationMounting the CNCEnclosure dimensionsFigure 8 Front and side views of the HyPath CNC36 mm(1.42 in)435 mm(17.13 in)316 mm(12.43 in)21 mm(0.82 in)228.5 mm(9.00 in)90 mm(3.50 in)58 mm(2.29 in)Use M6 x 1 hardware for side mounting. Maximum...

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    42EDGE Pro HyPath CNC Instruction Manual 8076202 – InstallationMounting the CNCMounting hole patterns on the bottom of the CNCThe EDGE Pro HyPath CNC has 10 mounting holes on the bottom of the enclosure for mounting the CNC to the cutting table. Fasten the mounting screws through the holes that...

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    EDGE Pro HyPath CNC Instruction Manual 807620432–InstallationMounting the CNCRecommended grounding and shielding practicesIntroductionThis section describes practices for grounding and shielding to protect a plasma cutting system against radio frequency interference (RFI) and electromagnetic in...

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    44EDGE Pro HyPath CNC Instruction Manual 8076202 – InstallationMounting the CNCeach 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 ...

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    EDGE Pro HyPath CNC Instruction Manual 807620452–InstallationMounting the CNCThe following picture shows an example of a cutting table ground bus. The components shown here may differ from your system.The following picture shows an example of a gantry ground bus. It is bolted to the gantry, clo...

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    46EDGE Pro HyPath CNC Instruction Manual 8076202 – InstallationMounting the CNCGrounding diagramThe following diagram shows an example of grounding the components in a plasma cutting system.Chassis and RFI groundAC earth ground123456789101112131Cutting table2Gantry3Plasma system4Table ground bu...

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    EDGE Pro HyPath CNC Instruction Manual 807620 472–InstallationX and Y axis configurationX and Y axis configurationTo configure the X and Y axes, first decide which axis on the table will be the X axis and where the home position will be.Next, define the X and Y orientation and home position in ...

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    48EDGE Pro HyPath CNC Instruction Manual 807620 2 – InstallationThe operator consoleThe operator consoleThe EDGE Pro HyPath CNC comes with a 2-station operator console that allows you to operate two cutting torches or stations.The operator console allows you to:•Start and stop the cutting pro...

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    EDGE Pro HyPath CNC Instruction Manual 807620 492–InstallationAC powerAC powerPower inputFigure 11 illustrates the power input connector on the rear of the EDGE Pro HyPath CNC.Figure 11 AC power input connectorAn AC power cable is standard equipment for North America, and is shipped with the CN...

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    50EDGE Pro HyPath CNC Instruction Manual 807620 2 – InstallationAC powerChassis groundingThe CNC must be properly grounded according to national and local electrical codes for safe operation. Use a number 16 mm2 (6 AWG) wire between the ground stud on the rear of the CNC and the star ground on ...

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    EDGE Pro HyPath CNC Instruction Manual 807620 512–InstallationCommunication interfacesCommunication interfaces 51,Figure 14 illustrates the interface ports and their location on the rear of the EDGE Pro HyPath CNC.Figure 14 Interface portsHypernet interfaceThe Hypernet interface allows the EDGE...

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    52EDGE Pro HyPath CNC Instruction Manual 807620 2 – InstallationHyPath connectionsHyPath connectionsHyPath I/OThe HyPath I/O PCB provides 24 inputs and 24 outputs. Two I/O boards can be configured in the EDGE Pro for 48 inputs and 48 outputs. Each HyPath I/O PCB has four circular plastic connec...

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    EDGE Pro HyPath CNC Instruction Manual 807620 532–InstallationHyPath connectionsInput circuit examplesFigure 16 shows a typical connection to a limit switch, a push button switch, a home switch, a station select switch (toggle switch), a relay contact, or an emergency-stop button.Figure 16 Norm...

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    54EDGE Pro HyPath CNC Instruction Manual 807620 2 – InstallationHyPath connectionsOutputsAll EDGE Pro HyPath CNC outputs use:•Relay contact closure (003179). The relay outputs are normally open contacts. Outputs can be set to normally closed by setting the output logic in the I/O screen in th...

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    EDGE Pro HyPath CNC Instruction Manual 807620 552–InstallationHyPath connectionsFigure 21 24 VDC coilFigure 22 AC relayFigure 23 shows a typical connection to an opto-isolator. The input is typical for a THC or plasma system.Figure 23 Opto-relay+24 VDCRelay 003179Output AOutput BCommonShieldCNC...

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    56EDGE Pro HyPath CNC Instruction Manual 807620 2 – InstallationHyPath connectionsFigure 24 Opto-relay – CNC sourcedI/O connectionThis section describes the HyPath I/O cables, connectors, and the I/O signals that are transmitted across them.Note: •Isolate all external commons from the chass...

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    EDGE Pro HyPath CNC Instruction Manual 807620 572–InstallationHyPath connectionsTable 4 HyPath pinouts for 24 I/OPin no.Connector J7I/O 1 – 6Connector J6I/O 7 – 12Connector J5I/O 13 – 18Connector J4I/O 19 – 241+24 VDC source+24 VDC source+24 VDC source+24 VDC source2Input 1Input 7Input ...

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    58EDGE Pro HyPath CNC Instruction Manual 807620 2 – InstallationHyPath connectionsTable 5 HyPath pinouts for 48 I/OPin no.Connector J7I/O 25 – 30Connector J6I/O 31 – 36Connector J5I/O 37 – 42Connector J4I/O 43 – 481+24 VDC source+24 VDC source+24 VDC source+24 VDC source2Input 25Input 3...

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    EDGE Pro HyPath CNC Instruction Manual 807620 592–InstallationHyPath 6-axis servo connectionHyPath 6-axis servo connectionThe HyPath 6-axis servo board provides the drive and encoder connections for up to 6 independent servo axes.The board provides three male circular connectors. Each connector...

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    60EDGE Pro HyPath CNC Instruction Manual 807620 2 – InstallationHyPath 6-axis servo connectionDrive/encoder pinoutsAxis A = Axis 1, Axis 3, Axis 5Axis B = Axis 2, Axis 4, Axis 6Note: •Z channel is the marker pulse channel which is 1 pulse/revolution.•Not all axes may be available. Verify ho...

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    EDGE Pro HyPath CNC Instruction Manual 807620 612–InstallationIntegrated THC I/O configurationIntegrated THC I/O configurationTHC I/O InterfaceFigure 28 THC1 and THC 2 InterfaceTHC I/O pinoutsPin no.THC 1 THC 2Signal1CommonCommonCommon2Input +Input +Nozzle contact sense + 3Input -Input -Nozzle ...

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    62EDGE Pro HyPath CNC Instruction Manual 807620 2 – InstallationIntegrated THC I/O configurationTHC cablesThe following list and tables provide the details for the connectors on the Sensor THC, the EDGE Pro CNC, and the voltage divider board (VDC3) (141201). Use this information to manufacture ...

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    EDGE Pro HyPath CNC Instruction Manual 80762063Section 3OperationOperating the CNCThe EDGE Pro CNC supports a touchscreen with an optional USB-connected keyboard and mouse for entering information and navigating the software. For more information, see the Phoenix Software Operator Manual (806400)...

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    64EDGE Pro HyPath CNC Instruction Manual 8076203 – OperationOperating the CNCTouchscreen LCDThe Phoenix software is designed for touchscreens with 1024 x 768 resolution. You can enter data into the software by touching the window controls and fields. Any field that requires data input automatic...

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    EDGE Pro HyPath CNC Instruction Manual 807620653–OperationOperating the CNCHelpChoose the Help soft key to display information about each screenChoose the OK soft key to exit the Help screen and return to the control screen.The Show Bookmarks soft key opens the navigation pane.View additional m...

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    66EDGE Pro HyPath CNC Instruction Manual 8076203 – OperationAutomated operationsShow bookmarksNote: Choose the Show Bookmarks soft key on the Help screen to view the list of Help topics. Click on a topic in the list to view it.Automated operationsThe Phoenix software includes two wizards that a...

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    EDGE Pro HyPath CNC Instruction Manual 807620673–OperationUpdating Phoenix softwareCutPro WizardThe CutPro Wizard automates common cutting tasks including loading a part or nest, selecting the cutting process, aligning the part or nest on the workpiece, and starting the program.The CutPro Wizar...

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    68EDGE Pro HyPath CNC Instruction Manual 8076203 – OperationUpdating Phoenix softwareHypertherm recommends saving modified cut charts as custom cut charts. When you create a custom cut chart, Phoenix creates a .usr file with a unique name. This prevents the custom cut charts from being overwrit...

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    EDGE Pro HyPath CNC Instruction Manual 80762069Section 4Maintenance and DiagnosticsIntroductionHypertherm assumes that the service personnel who perform troubleshooting testing are high-level electronic service technicians who have worked with high-voltage electro-mechanical systems. Knowledge of...

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    70EDGE Pro HyPath CNC Instruction Manual 8076204 – Maintenance and DiagnosticsDiagnostic testsDiagnostic testsMachine interface testsYou can perform diagnostic tests with the following connectors (in kit 228511) and Phoenix software to test the interface ports on the EDGE Pro HyPath CNC:•LAN ...

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    EDGE Pro HyPath CNC Instruction Manual 807620714 – Maintenance and DiagnosticsDiagnostic testsSerial testThe EDGE Pro is equipped with two serial ports. Serial 1 and 2 support RS-422 or RS-232 communications, depending on the jumper position. For more information, see 105,Utility and serial is...

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    72EDGE Pro HyPath CNC Instruction Manual 8076204 – Maintenance and DiagnosticsDiagnostic testsTo repeat this test for the USB port on the front of the CNC:1.Verify that no USB memory stick is installed.2.On the Operator Interface screen, choose the USB port on the front of the CNC.3.Follow the ...

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    EDGE Pro HyPath CNC Instruction Manual 807620734 – Maintenance and DiagnosticsDiagnostic tests•If an output has failed, you can remove a relay from a spare output on the I/O board (141070) and replace the relay at the failed output. No rewiring is required. Use Figure 33 and Table 6 to determ...

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    74EDGE Pro HyPath CNC Instruction Manual 8076204 – Maintenance and DiagnosticsDiagnostic testsAxis testThis test verifies axis operation. Conduct this test if there is: •A runaway axis•No motion•Erratic motion•A high number of position errors•Multiple parts are not cut the correct siz...

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    EDGE Pro HyPath CNC Instruction Manual 807620754 – Maintenance and DiagnosticsDiagnostic testsOperator console testPerform these tests if any function on the integrated operator console is not working as expected.Note: None of the components on the screen allow motion or any action to take plac...

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    76EDGE Pro HyPath CNC Instruction Manual 8076204 – Maintenance and DiagnosticsTroubleshootingTroubleshootingHypertherm assumes that the service personnel performing the troubleshooting are high-level electronic service technicians who have worked with high-voltage electro-mechanical systems. Kn...

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    EDGE Pro HyPath CNC Instruction Manual 807620774 – Maintenance and DiagnosticsTroubleshootingPowerThe CNC does not turn on when the ON/OFF button is pressed.1.Verify that the power cord is plugged into the back of the CNC.2.Verify that the wall circuit breaker is active.3.Verify that the fuse i...

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    78EDGE Pro HyPath CNC Instruction Manual 8076204 – Maintenance and DiagnosticsTroubleshooting3.If any of these tests fail: •Verify that I/O for the operator console is set up correctly in Phoenix software. See Phoenix Software V9 Series Installation and Setup Manual (806410) for details.•Re...

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    EDGE Pro HyPath CNC Instruction Manual 807620794 – Maintenance and DiagnosticsTroubleshootingLAN connection•Downloading part programs over the LAN is not working properly.•Previously mapped network drives are not shown when trying to load a part program.If you have the test hardware, 70,se...

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    80EDGE Pro HyPath CNC Instruction Manual 8076204 – Maintenance and DiagnosticsTroubleshooting•Pulse Magnitude = 1 V•Pulse Duration = 0.5 seconds7.Press the Test Transverse and Test Rail soft keys, one at a time, and verify that the motors move in both directions for each test. •If there i...

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    EDGE Pro HyPath CNC Instruction Manual 807620814 – Maintenance and DiagnosticsTroubleshootingTHC 1 and THC 2•Nozzle contact is not functioning properly.•IHS using ohmic contact is not sensing the workpiece properly.•The torch is firing in the air.•The torch is running into the workpiece...

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    82EDGE Pro HyPath CNC Instruction Manual 8076204 – Maintenance and DiagnosticsTroubleshootingUSB portIf the CNC is not recognizing a device in a USB port:1.Verify that another computer can read the memory stick.2.Verify that no other memory sticks are installed. The CNC can only read one memory...

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    EDGE Pro HyPath CNC Instruction Manual 807620834 – Maintenance and DiagnosticsTroubleshootingWireless troubleshootingRefer to the Phoenix Software V9 Series Installation and Setup Manual (806410) for information about networking.Follow these guidelines if you are experiencing problems using the...

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    84EDGE Pro HyPath CNC Instruction Manual 8076204 – Maintenance and DiagnosticsComponent locations and informationComponent locations and informationThe following pages provide details about the major components of the EDGE Pro HyPath CNC. Refer 109,to 109,Parts List 109, for the corresponding...

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    EDGE Pro HyPath CNC Instruction Manual 807620854 – Maintenance and DiagnosticsOperator console board (141058)Operator console board (141058)Figure 35 Operator console boardJ1J2J3J4J5J6J7J8J10J9J11J13J12J14J15J16

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    86EDGE Pro HyPath CNC Instruction Manual 8076204 – Maintenance and DiagnosticsOperator console board (141058)Table 7 Pinouts for J1 – J16Pin no.SignalPin no.SignalPin no.SignalJ1 Station 2J7 To utility PCBJ8 Joy stick1Auto select 21Start1Up2Logic ground2Stop2Down3Manual select 23Manual3Left4N...

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    EDGE Pro HyPath CNC Instruction Manual 807620874 – Maintenance and Diagnostics6-Axis MCC board (141061)6-Axis MCC board (141061)Figure 36 6-axis MCC board connectors and LEDsLEDSignalD1Axis 6 enabledD2Axis 5 enabledD3Axis 4 enabledD4Axis 3 enabledD5Axis 2 enabledD6Axis 1 enabledD7Watch dog LED ...

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    88EDGE Pro HyPath CNC Instruction Manual 8076204 – Maintenance and Diagnostics6-Axis MCC board (141061)Table 8 Pinouts for J1 – I/O 1 – 24Pin no.SignalPin no.Signal1Input 126Output 132Output 127Input 143Input 228Output 144Output 229Input 155Input 330Output 156Output 331Input 167Input 432Out...

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    EDGE Pro HyPath CNC Instruction Manual 807620894 – Maintenance and Diagnostics6-Axis MCC board (141061)Table 9 Pinouts for J2 – axis 1 – 6Pin no.SignalPin no.Signal1/Axis 1 enable21Axis 5B Ch2/Axis 2 enable22Axis 5Z Ch3/Axis 3 enable23Axis 6A Ch4/Axis 4 enable24Axis 6B Ch5/Axis 5 enable25Ax...

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    90EDGE Pro HyPath CNC Instruction Manual 8076204 – Maintenance and Diagnostics6-Axis MCC board (141061)Table 10 Pinouts for J3 – I/O 25 to 48Pin no.SignalPin no.Signal1Input 2526Output 372Output 2527Input 383Input 2628Output 384Output 2629Input 395Input 2730Output 396Output 2731Input 407Input...

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    EDGE Pro HyPath CNC Instruction Manual 807620914 – Maintenance and Diagnostics6-Axis servo board (141067)6-Axis servo board (141067)Figure 37 6-axis servo boardJ2 – From the powerdistribution boardJ1 – To and from the6-axis MCC boardJ3 – Axes 5 and 6J4 – Axes 3 and 4J5 – Axes 1 and 2

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    92EDGE Pro HyPath CNC Instruction Manual 8076204 – Maintenance and Diagnostics6-Axis servo board (141067)Table 11 Pinouts for J1 – To and from the 6-axis MCC boardTable 12 Pinouts for J2 – From the power distribution boardPin no.SignalPin no.Signal1/Axis 1 enable21Axis 5B2/Axis 2 enable22Ax...

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    EDGE Pro HyPath CNC Instruction Manual 807620934 – Maintenance and Diagnostics6-Axis servo board (141067)Table 13 Pinouts for J3 – J5 – To the encoder connectorsJ3 (axes 5 and 6) J4 (axes 3 and 4) J5 (axes 1 and 2)Pin no.for axes 1, 3, 5SignalPin no. for axes 2, 4, 61Axis shield202Encoder +...

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    94EDGE Pro HyPath CNC Instruction Manual 8076204 – Maintenance and Diagnostics24 I/O board (141070)24 I/O board (141070)Figure 38 24 I/O boardTable 14 Pinouts for J1 and J2J1 – From the power distribution boardPin no.Signal1+24 V2Field ground3+5 VJ2 – From the power distribution board1Groun...

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    EDGE Pro HyPath CNC Instruction Manual 807620954 – Maintenance and Diagnostics24 I/O board (141070)Table 15 Pinouts for J3 – To and from MCC and serial isolation boardsPin no.SignalPin no.Signal1Input 126Output 132Output 127Input 143Input 228Output 144Output 229Input 155Input 330Output 156Out...

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    96EDGE Pro HyPath CNC Instruction Manual 8076204 – Maintenance and Diagnostics24 I/O board (141070)Table 16 Pinouts for J4 – J7, I/O 1 – 24Pin no.J4 I/O 19 – 24J5 I/O 13 – 18J6 I/O 7 – 12J7 I/O 1 – 61+24 V field+24 V field+24 V field+24 V field2Input 19Input 13Input 7Input 13CommonC...

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    EDGE Pro HyPath CNC Instruction Manual 807620974 – Maintenance and DiagnosticsMotherboard (141110)Motherboard (141110)Figure 39 Motherboard4321PCI slot 2PCI slot 3PCI slot 4PCI slot 5HyPath 24 or 48 I/OWireless (141223)not usedUtility (141307)MCC (141061)HyPath 24 or 48 I/O with Sensor THCWirel...

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    98EDGE Pro HyPath CNC Instruction Manual 8076204 – Maintenance and DiagnosticsAnalog board (141125)Analog board (141125)Figure 40 Analog boardTable 17 Pinouts for J1 and J2Pin no.J1 – to THC1J2 – to THC 2Signal1CommonCommonCommon2Input 5+Input 6+Nozzle contact sense+ (relay contact)3Input 5...

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    EDGE Pro HyPath CNC Instruction Manual 807620994 – Maintenance and DiagnosticsSurge board (141134)Surge board (141134)Figure 41 Surge boardTable 18 Pinouts for J1 and J2Pin no.SignalJ1 – From AC power inlet1Neutral2LineJ2 – To power distribution board (J10)1Neutral2Line3GroundJ1 From AC pow...

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    100EDGE Pro HyPath CNC Instruction Manual 8076204 – Maintenance and DiagnosticsPower distribution board (141153)Power distribution board (141153)Figure 42 Power distribution boardNote: LED D6 is illuminated at full brightness when 220 VAC is supplied to the CNC and at half brightness when 120 V...

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    EDGE Pro HyPath CNC Instruction Manual 8076201014 – Maintenance and DiagnosticsPower distribution board (141153)Table 19 Pinouts for J1 – J12Pin no.SignalPin no.SignalJ1 – Clean DC outJ6 – Clean DC out1Logic +5 V fused1Logic +5 V fused2Logic -12 V fused2Logic -12 V fused3Logic +12 V fused...

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    102EDGE Pro HyPath CNC Instruction Manual 8076204 – Maintenance and Diagnostics4-Axis servo board (141292)4-Axis servo board (141292)Figure 43 4-Axis servo boardJ4 Axis 3 and 4J5 Axis 1 and 2J1 – To and from the 4-axis MCC boardJ2 – From the powerdistribution board

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    EDGE Pro HyPath CNC Instruction Manual 8076201034 – Maintenance and Diagnostics4-Axis servo board (141292)Table 20 Pinouts for J1 – To and from the 4-axis MCC boardTable 21 Pinouts for J2 – From the power distribution boardPin no.SignalPin no.Signal1/Axis 1 enable21Not connected2/Axis 2 ena...

  • Page 104

    104EDGE Pro HyPath CNC Instruction Manual 8076204 – Maintenance and Diagnostics4-Axis servo board (141292)Table 22 Pinouts for J4 and J5 – Encoder connectorsJ4 (axes 3 and 4)J5 (axes 1 and 2)Pin no. for axes 1 and 3SignalPin no. for axes 2 and 41Axis shield202Encoder +5 V out213Encoder common...

  • Page 105

    EDGE Pro HyPath CNC Instruction Manual 8076201054 – Maintenance and DiagnosticsUtility and serial isolation board (141307)Utility and serial isolation board (141307)Figure 44 Utility and serial isolation boardJ6 – To motherboard on/offand power distribution boardJ8 – Port B Serial 2J5 – P...

  • Page 106

    106EDGE Pro HyPath CNC Instruction Manual 8076204 – Maintenance and DiagnosticsUtility and serial isolation board (141307)Table 23 Pinouts for J1 – J8Pin no.SignalPin no.SignalJ1 – To and from the operator consoleJ5 – Serial port A, Serial 11Start1Not connected2Stop2Transmit A-3Manual3Rec...

  • Page 107

    EDGE Pro HyPath CNC Instruction Manual 8076201074 – Maintenance and DiagnosticsVDC for integrated Sensor THC (141201)VDC for integrated Sensor THC (141201)If your cutting system includes an integrated Sensor THC, you must install one of these VDC boards in each plasma system in your cutting sys...

  • Page 108

    108EDGE Pro HyPath CNC Instruction Manual 8076204 – Maintenance and DiagnosticsVDC for integrated Sensor THC (141201)

  • Page 109

    EDGE Pro HyPath CNC Instruction Manual 807620109Section 5Parts ListDiagnostic kitsCablesCable connector kitsPartKit numberDescriptionHyPath testers228511Axis tester (228496)THC tester (228536)Green I/O tester (228497), Red I/O tester (228498)Ethernet and Hypernet tester (228503)Serial interface t...

  • Page 110

    110EDGE Pro HyPath CNC Instruction Manual 8076205 – Parts ListHyPath PCB kitsHyPath PCB kitsLocationKit numberDescription1228453I/O board (141070)2428106,2284524-axis servo board (141292) 6-axis servo board (141067)3228450Operator console board (141058)4 (PCI 2)428063Wireless board (141223), in...

  • Page 111

    EDGE Pro HyPath CNC Instruction Manual 8076201115 – Parts ListHyPath PCB kitsFigure 46 HyPath PCBs10987654321

  • Page 112

    112EDGE Pro HyPath CNC Instruction Manual 8076205 – Parts ListAdditional kitsAdditional kitsPartKit numberDescriptionATX power supply 2284731 U, 400 W, with harness and bracketSubchassis cooling fan228474InternalCPU fan428012InternalRelay for 24-I/O board (141070)003197Battery for motherboard42...

  • Page 113

    EDGE Pro HyPath CNC Instruction Manual 807620113Section 6Wiring DiagramsThis 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 wirin...

  • Page 114

    114EDGE Pro HyPath CNC Instruction Manual 8076206 – Wiring DiagramsWiring diagram symbolsWiring diagram symbolsBatteryGround clampReceptacleCap, polarizedGround, chassisRelay, coilCap, not polarizedGround, earthRelay, normally closedCap, feed-throughIGBTRelay, normally openCircuit breakerInduct...

  • Page 115

    EDGE Pro HyPath CNC Instruction Manual 8076201156 – Wiring DiagramsWiring diagram symbolsSwitch, pressure,normally openTime delay open,NO/offValve, solenoidSwitch, 1 pole, 1 throwTime delay open,NC/onVoltage sourceSwitch, 1 pole, 2 throwTime delay closed,NO/offZener diodeSwitch, 1 pole, 2 throw...

  • Page 116

    116EDGE Pro HyPath CNC Instruction Manual 8076206 – Wiring DiagramsWiring diagram symbols

  • Page 117

    EDGE Pro HyPath CNC Instruction Manual 8076201176 – Wiring DiagramsPCB9ANALOG SHEET 16141125LANPORTSHEET 9HYP LANPORTSHEET 9USBPORTSHEET 9PCB86-AXIS SERVOSHEET 15 141067*PCB6I/0 1-24SHEET 14141070 PCB5 MCC 6-AXISSHEET 13 141061TOUCHSCREENSHEET 5007047 USBPORTSHEET 9POWERSWITCHSHEET 8FAN...

  • Page 118

    118 EDGE Pro HyPath CNC Instruction Manual 807620 6 – Wiring Diagrams SATA POWERSATA DATA CUSTOMER SUPPLIED1-PHASE 100-240V AC POWERSEE OPTIONSTOUCHSCREEN007047 PCB2 POWER DISTRIBUTION PCB(WITH INTEGRATED FIELD POWER SUPPLIES)141153 1 2 3 4 5 6 78 1 +5V 2 +12V 3 +12V 4 +12V 5...

  • Page 119

    EDGE Pro HyPath CNC Instruction Manual 8076201196 – Wiring DiagramsSEE SHEET 56 GROUND FLD 5 +12V FLD 4 -12V FLD 3 +5V FLD 2 +24V FLD 1 GROUND FLD 1 GROUND FLD 2 +24V FLD 3 +5V FLD 4 -12V FLD 5 +12V FLD 6 GROUND FLD FROM ATX POWER SUPPLYSEE SHT 5SEE SHT 5HYPATH 24 I/O O...

  • Page 120

    120 EDGE Pro HyPath CNC Instruction Manual 807620 6 – Wiring DiagramsPCB3 OPERATOR PANEL PCB141058 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 229277 229277 228463 228463 2292...

  • Page 121

    EDGE Pro HyPath CNC Instruction Manual 8076201216 – Wiring DiagramsBSHEET7-C5BLUBLKYEL229277 229277 YELBLKBLUBLKBLKBLKBLKBLKBLKBLKBLKBLKBLKBLKBLKBLKREDWHTBLKLED'S LOCATEDON 141058PCB SHEET7-C6BPOWER ON/OFF229252 WHTGRNBLKYELSHEET7-A3O3287DSHEET7-D4229276 STOP FORWARD ON PATH 22...

  • Page 122

    122 EDGE Pro HyPath CNC Instruction Manual 807620 6 – Wiring DiagramsNOTES: 1. (4) USB CONNECTIONS TO MOTHERBOARD MUST FOLLOW THIS DIAGRAM.2. (2) ETHERNET CONNECTIONS TO MOTHERBOARD MUST FOLLOW THIS DIAGRAMHYPERNETRJ-45 JACK108751MOTHERBOARD ON/OFFPICOPATHPCB11PCB4 UTIL/SERJ12 ATX PWR SHEET5-B1...

  • Page 123

    EDGE Pro HyPath CNC Instruction Manual 8076201236 – Wiring Diagrams100-240VACPOWERINPUTWSHEET9-D7SHEET5-B8ADAISHEET5-C3ATX DC POWER & WIRE COLOR CODEDC COMBLK+3.3 VORN+5 VRED+5 V STAND-BYVIO-5 VWHT+12 VYEL- 12 VBLU+24 V BRNPWR GOOD (PGD)GRYPS_ONGRN229348(NOT USED)MOTHERBORD AUX 12V DC POWER...

  • Page 124

    124 EDGE Pro HyPath CNC Instruction Manual 807620 6 – Wiring DiagramsRS232RS232RS422RS4225CHASSIS/SHLDREMOTE ON/OFF -4REMOTE ON/OFF +COMMONJ2 REMOTE ON/OFF5C RECT+12V123NCNCGROUND5TXDA-NCJ5 SERIAL 19C DSUBRXDA+TXDA+276NC3418RXDA-9ACSHEET5-B8SHEET9-D3ACUSHEET7-D1VSHEET9-B7CLEAN GND 1ARC VOLTS 2N...

  • Page 125

    EDGE Pro HyPath CNC Instruction Manual 8076201256 – Wiring Diagrams J2 DRIVE/ENCODER J3 I/O 25-48 J1 I/O 1-2425 INPUT 37 26 OUTPUT 37 27 INPUT 38 28 OUTPUT 38 29 INPUT 39 30 OUTPUT 39 31 INPUT 40 32 OUTPUT 40 33 INPUT 41 34 OUTPUT 41 24 OUTPUT 36 23 INPUT 36 22 OUTPUT 35...

  • Page 126

    126 EDGE Pro HyPath CNC Instruction Manual 807620 6 – Wiring Diagrams25 INPUT 13 26 OUTPUT 13 27 INPUT 14 28 OUTPUT 14 29 INPUT 15 30 OUTPUT 15 31 INPUT 16 32 OUTPUT 16 33 INPUT 17 34 OUTPUT 17 24 OUTPUT 12 23 INPUT 12 22 OUTPUT 11 21 INPUT 11 20 OUTPUT 10 18 OUTPU...

  • Page 127

    EDGE Pro HyPath CNC Instruction Manual 8076201276 – Wiring Diagrams19 AXIS 4Z CH AESHEET13-D3Q40 39 38 37 36 35 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 229255 ...

  • Page 128

    128 EDGE Pro HyPath CNC Instruction Manual 807620 6 – Wiring Diagrams NOT USED NOT USED229308 229308 PCB9 PCI ANALOG PCB141125 THC 1 THC 2 FIELD COM 1 BLKNC REDNOZZLE CONTACT SENSE 3 BLKNOZZLE CONTACT SENSE 2 WHTNOZZLE CONTACT ENABLE 5 BLKNOZZLE CONTACT ENABLE 4 GRNARC ...

  • Page 129

    EDGE Pro HyPath CNC Instruction Manual 8076201296 – Wiring Diagrams50 GROUND 49 NC 48 NC 47 GROUND 37 NC 38 NC 39 NC 40 NC 41 NC 42 NC 43 NC 44 NC 45 NC 46 NC 36 NC 35 NC 6 OUTPUT 3 5 INPUT 3 7 INPUT 4 8 OUTPUT 4 9 INPUT 5 10 OUTPUT 5 11 INPUT 6 1...

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