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Thread: Help locating correct Powermax45 trigger wires for remote CNC start

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    Help locating correct Powermax45 trigger wires for remote CNC start

    It seems that it is not easy to located the correct trigger wires for remote start. I used a multimeter and found the wires in the handle that connect when the trigger is pulled. That did not work. I am updating my cnc plasma table with a new Hyperherm Powermax45. I need to connect the remote start connectors on my CandCnc DTHC card to the wires coming from the start trigger on the hand torch. The wiring diagram shows that the pulling the trigger connects the violet to the blue wire. (#1 to #3 wire). I put a vampire tap on each of the wires (inside of the case) and run wires back to my DTCH card and plug them onto the correct spot. Upon testing I get a "torch stuck on/off" error message on the Powermax45. This same technique worked fine on my older Thermal Dynamics machine. The Hypertherm has a safety switch in the handle that is bypassed when I use this method and I assume the error is a resulting from bypassing the safety switch. Should I tape the trigger on the hand torch closed and wire my remote start "inline" on the single trigger wire? I sure would appreciate comments from anyone who has wired up one of these Powermax45 for CNC applications. I do have the manuals from their website but it does not help on how to do this. Also I have read 2 articles from this forum but they did not cover this topic.
    Thanks in advance.

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    The Hypertherm Powermax units (45, 1000, 1250 and 1650) all have available machine torches.....,when the machine torch is plugged into the quick connect receptacle, the power supply recognizes it and allows for the remote start signal to be accessed on the interface connector on the rear panel....this connector also has a 50:1 divided arc voltage output and an arc transferred signal.

    The Hypertherm hand torches have a safety trigger switch, and a safety circuit that attempts to not allow having a separate remote start switch attached at the same time the hand torch is attached. This is done for safety reasons...Imagine a remote switch firing the hand torch when you did not want it to fire...such as when you are changing consumables, or when the torch is setting next to a high pressure gas cylinder. Hypertherm made these safety decisions a few years ago after an accident in the field caused a serious fire in a shop....because of misuse of a remote start input.

    There are many in the field that have bypassed this circuitry......and it involves cutting and splicing wires in the torch handle, or in the power supply....unfortunately, because this circuit is designed as a safety circuit, I cannot offer you advice on how best to defeat it! I recomend either using the machine torch for machine cutting applications....or, if you use the hand torch you must modify the wiring to the trigger circuit at your wn risk.

    Jim Colt Hypertherm.



    Quote Originally Posted by jerryrigge View Post
    It seems that it is not easy to located the correct trigger wires for remote start. I used a multimeter and found the wires in the handle that connect when the trigger is pulled. That did not work. I am updating my cnc plasma table with a new Hyperherm Powermax45. I need to connect the remote start connectors on my CandCnc DTHC card to the wires coming from the start trigger on the hand torch. The wiring diagram shows that the pulling the trigger connects the violet to the blue wire. (#1 to #3 wire). I put a vampire tap on each of the wires (inside of the case) and run wires back to my DTCH card and plug them onto the correct spot. Upon testing I get a "torch stuck on/off" error message on the Powermax45. This same technique worked fine on my older Thermal Dynamics machine. The Hypertherm has a safety switch in the handle that is bypassed when I use this method and I assume the error is a resulting from bypassing the safety switch. Should I tape the trigger on the hand torch closed and wire my remote start "inline" on the single trigger wire? I sure would appreciate comments from anyone who has wired up one of these Powermax45 for CNC applications. I do have the manuals from their website but it does not help on how to do this. Also I have read 2 articles from this forum but they did not cover this topic.
    Thanks in advance.




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    Using a hand torch in cnc application is not inherently unsafe.

    The reality is that most cnc tables will use the hand torch because of cost and availability. Hypertherm is aware of this. If they truely were concerned about safety, they would make the machine torch available at a more reasonalble price instead of $600 more than the hand torch, the cost of production is probably not much different. Companies are concerned about product liability more than safety. So we result in a less safe situation for the customer but the company is not liable. This is the way some things are so I accept it and move on.

    jr



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    jim colt never said u cant do it.. but he said he wont tell you how to do it because he works for hypertherm. that safety feature can be bypassed if you search on the board for hypertherm 45 lots others did it and they did put up detailed info on how to do it..



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    You are correct on the liability issue.....the whole reason that we have the safety feature is due to the fact that a user stored his hand torch by wrapping it around a high pressure cylinder of acetylene. The operator thought he had the torch mounted on a track burner, pushed the remote start button....and the hand torch ignited the cylinder...no one was seriously hurt....but in typical court fashion...the company with the deepest pockets pays! The new building was rather expensive...and if someone had gotten seriously hurt or killed...the situation would have been much worse. It was a dumb mistake on the operators part....Hypertherm had to pay for it!

    The safety trigger is there for a reason on hand torches.....and while it gets bypassed often....I cannot offer you advise on how to bypass it, as I like my job at Hypertherm.

    In the real world...over 90% of the Powermax units are sold with hand torches....only a small number of hand torches are actually used on CNC machines. The machine torch has a lot of advantages.....yet is produced in very low volumes...and manuafcturing cost is considerably higher. If you compare list prices...the difference between a hand torch and a machine torch for the Powermax45 is about $300.

    Personally, I would love to see the machine torch be offered at a lower price...however that is in the control of bean counters that calculate selling prices based on manufacturing costs.

    And.....it is very clear to me that Hypertherm has operator safety on our mind before anything else. Liability and safety are often recorded under the same topics. Take a look at our products and you will see more safety features than any other brand of plasma systems...bar none. This particular safety feature would have been implemented regardless of any liability issues...it truly makes sense.

    Best regards, Jim Colt

    Quote Originally Posted by jerryrigge View Post
    The reality is that most cnc tables will use the hand torch because of cost and availability. Hypertherm is aware of this. If they truely were concerned about safety, they would make the machine torch available at a more reasonalble price instead of $600 more than the hand torch, the cost of production is probably not much different. Companies are concerned about product liability more than safety. So we result in a less safe situation for the customer but the company is not liable. This is the way some things are so I accept it and move on.

    jr




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    what I don't inderstand is that if there is only a 300 dollar difference between the hand torch and the machine torch, why then can I buy a powermax 45 for $1550 with the hand torch but if I try to buy the powermax 45 with a machine torch ( no hand torch) it costs over $2000. It should only be $1850. Thats what really burns me.



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    Suggested retail price for a Powermax45 with a hand torch (I don't have the exact number right at the moment) is around $2200, suggested retail with a machine torch is roughly $300 more than that. A few differences are that the machine torch versions have an interface cable, and slightly different consumables kits.

    Distributors get discounts from the factory based on their purchasing volume, and since hand torch systems are over 90% of the total of the Powermax systems purchased, then hand torch systems have better discounts. Some distributors choose to sell their inventory in higher volume and with lower profit margins, usually over the internet. Internet sales often mean that the distributor does not have to pay a counter man, a sales man, and a delivery guy, and often avoids training the customer. This allows them to discount the unit to the max. Since they sell more hand systems than mechanized....the price on the hand systems is better.

    So, if a distributor buys 1000's of hand systems annually, and maybe 100 mechanized systems annually, they will offer the hand system at a lower price. How a distributor can sell a hand held Powermax45 at just over $1500 and still stay in business is beyond me!


    Jim



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    Thats the standard price from my local Norco. It would be cool if hypertherm would take the hand torch back from the dealer and exchange for the machine torch+ $300. My current torch has been fired once, any chance they would exchange it?



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    Here is an interesting video I found on you tube for converting a Powermax 45 for CNC.

    [nomedia="http://www.youtube.com/watch?v=cr0WJ_1OaIY"]YouTube - PowerMax45 for CNC[/nomedia]



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    Maybe your distributor will do that for you? Hypertherm is the engineering and the manufacturing, all sales are through OEM's (machine manufacturers) and distributors.

    I'll forward the suggestion on to our manual systems team.

    jim



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    PowerMax45 for CNC

    YouTube PowerMax45 for CNC

    Long story short - It works
    I asked myself:
    Why are there no comments on the video? Is it just BS and they try to F-up your system? The answer is: Not too many people are trying to have a Powermax 45 Handtorch linked to a Torchmate 2x4 System.
    Since there were no better solutions other than tapping into the "Trigger"
    I purchased the plug(only) for a machine torch ($20) at my hypertherm supplier.
    I follow the video and: It works. I am glad to be the first on this one. Somebody will be happy. TTYS



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    Can you say more about how you hooked up just the plug for the machine torch? Did you switch it out with the original plug on the 45 hand torch.
    thanks



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