Questions about the Hypertherm 45

[lost_cause]

I'l planning on making the decision between the hypertherm 45 and the thermal dynamics 52 fairly soon, but I was wondering if someone can answer this one question for me: I'm planning on buying a plasma cutter with a manual torch to begin with. (eventually I intend on buying a machine torch, depending on when I feel like spending the extra). I am also beginning the legwork to get things lined up to (hopefully) build a small CNC table this summer.

I'll say right now that I know nothing about, nor have ever seen one of these small tables (which is part of the reason I am building one). I do know what happens after the fact, though - I've seen a bunch of different large CNC plate cutting machines over the years, and I've probably generated thousands of DXF files for use with those machines. I've also got a very good computer hardware background, but my electronics knowledge level is not so good.

At some point with a CNC table, the software must tell the electronics package to turn the torch on & off, and how much to adjust the torch height by getting feedback from the actual plasma cutter. with what little knowledge I have of the electronics needed to drive the table, I'm currently thinking of buying the CandCNC Bladerunner kit to make everything work, unless I find an electronics whiz in my area to help me wade through things.

With the Bladerunner (or any electronics package) I'm assuming there must be some sort of cable to give that feedback from the cutter to the hardware and software. I've seen pictures as I browse the Internet where people have disassembled the hand controller and "hotwired" it - assumedly to make all this happen. With the Hypertherm 45 is there any way to do this without dissecting the controller? I have heard people say that Hypertherm has a cable to do this, but is it a direct plugin to the machine? Will it work with the hand torch or is it only for the machine torch? And finally, what is the part nuymber and rough cost of this cable (assuming there is one) I can't seem to find anything on the Hypertherm site, though I admit I may not know what I'm looking for.

Thanks.

[jimcolt]

The Powermax45 is available with a hand torch, which has a trigger switch for hand cutting and is ergonomically designed for the average human hand, and also a machine torch which is mounted on an industry standard barrel (1-3/8" diameter) and requires some sort of remote trigger (no switch is included). Internally both of these torches are similar, and the consumables are interchangeable between them. A hand torch can be used in a mechanized application, and these torches quick disconnect from the power supply with no tools.

As far as interface signals to a cnc machine. There are typically 3 sets of signals which involve 6 wires.

1. Arc voltage feedback is used to control the torch to work distance of the torch. The Powermax45 has an analog DC voltage output available on the rear panel interface receptacle that is 1/50th of the actual arc voltage. This ration is used by many torch height control manufacturers to track torch arc length. If raw, ful voltage is required, you would have to remove the cover from the Powermax (2 screws) and follow the directions in the Hypertherm manual to make these internal connections. The Raw DC voltage can reach voltage levels of arount 250 VDC, a voltage level that exceeds CSA and CE safety regulations, so this voltage is not vaialble on the rear panel connector.

2. Arc transfer. These connections are also available on the rear panel connector. When the plasma arc is activated and electrical current starts to flow from the torch to the plate...a set of relay contacts closes inside the Powermax unit. This signal is used to indicate to the cnc that the plasma arc in on.

3. Plasma start. There are connections for plasma start on the rear panel connector....this signal is only functional if the machine torch is connected to the Powermax unit. If the hand torch is installed the start input of the rear panel is automatically disabled for safety reasons, as the hand torch has a trigger switch, and it could be dangereouse to a torch operator if a remote start was allowed for a hand torch. If you must use a hand torch for mechanized use, then the torch trigger must be bypassed internally inside the power supply, quite easy to do. The plasma starts when the cnc sends a contact closure to the plasma start input.

These signals are standard on the Hypertherm system, you can eaither make your own interface cable or you can purchase the hyperthem cable (I do not know the price, but if you need it I will look up the part no. and price) .

The Hypertherm unit is known for its reliability, and its consumable life. If you compare specs with the T-D unit you will see both a higher output duty cycle and killowatt rating....hese are two very important factors for best plasma system performance. The Hypertherm units are completely built in Hanover, NH, USA by owner/employees of Hypertherm.

Best regards, Jim Colt

[Torchhead]

Jim: Several weeks ago (and many posts) someone posted some photos of the internal connections points for accessing the Un-divided raw arc volts. I think you responded with the J numbers. I can't find that post (or yours). I am getting a lot of guys buying the new 45 and need hookup instructions. We have a diagram of how to do it with a G3 1000 but the 45 has different internals. I have had problems downloading the PDF from HT's website. If you can reference either the Zone post or get me the connection points inside then it would help customers want to use the new 45. I hate to ask this but if you could send me the PDF manual (thom(at)Tcaudle(dot)com) then I can develop a page in our DTHC setup manual for the Hypertherm 45.

We have all of the inputs needed on our interface (THC SENSOR) card. It has it's own voltage divider, balanced linetwin low pass noise filter, Isolated Arc Xfr, and Torch Switch Relay.

You assistance is greatly appreciated.

TOM caudle
www.CandCNC.com
Totally Modular CNC Electronics.

[jimcolt]

Tom,

I'll send you the Powermax45 service manual to your direct email, it has a section on interfacing and shows illustrations and connection numbers for raw arc voltage access. It also has schematics, etc. that can help with the start signal connection that has to be internally spliced in the event the customer wants to use a hand torch. As you know I cannot make recommendations on cnc use with the hand torch as the torch trigger safety circuitry must be bypassed in order to do that.

If you have any questions about the content in the manual let me know.....it is about 11megabytes so hopefully your email can accept it!

Best regards, Jim

[Torchhead]

Use the e-mail I embedded in the post. The CandCNC email address is limited to a 10M file size. Thanks.

Tom C

[jimcolt]

Your embedded email rejected the file....so I just sent you just the .pdf for the raw arc voltage kit. From that you can get the connections inside the power supply.

I downloaded these documents this morning from our website....it just took seconds. It can also be downloaded as a zip file which may be easier for some.

Jim

[Torchhead]

I'll Try the ZIP download. Do you have the link? I got the Raw Arc PDF and that will help a LOT. The full schematic will have wire colors that will help with identifying the torch switch wires.

Thanks Again

TC

[jimcolt]

Heres the link to the document library on the www.hypertherm.com site. Once you get here pick the drop down menu to choose the system, then choose manuals, then choose which manual you would like.

https://www.hypertherm.com/Xnet/libr...ntLibrary3.jsp

Jim

[Torchhead]

Originally Posted by jimcolt Heres the link to the document library on the www.hypertherm.com site. Once you get here pick the drop down menu to choose the system, then choose manuals, then choose which manual you would like. https://www.hypertherm.com/Xnet/libr...ntLibrary3.jsp Jim

Jim: Hats off to the improved website that has the advanced parametric search function. I had not seen that, and it's impressive. thanks for the help. With the two documents I will be able to give concise hookup instructions to our DTHC.

TOM C

[Torchhead]

Originally Posted by jimcolt Heres the link to the document library on the www.hypertherm.com site. Once you get here pick the drop down menu to choose the system, then choose manuals, then choose which manual you would like. https://www.hypertherm.com/Xnet/libr...ntLibrary3.jsp Jim

Jim: Hats off to the improved website that has the advanced parametric search function. I had not seen that, and it's impressive. thanks for the help. With the two documents I will be able to give concise hookup instructions to our DTHC.

TOM C

[jimcolt]

There is a ton of info about every system Hypertherm has....including most that are no longer in production. Also...if you own a piece of Hypertherm equipment you have access to the x-net site ( a tab on top of the www.hypertherm.com home page) that allows access to more info about your particualr system. The x-net is accessed using your Hypertherm plasma system serial number.

Jim Colt

[binfordw]

Originally Posted by lost_cause Thanks.

Lost cause, I use a Powermax45 with a hand torch, and a bladerunner kit on my table, so if you go that route (Def go with the Hypertherm, I cant stress that enough) I can help you if u have troubles. Just let me know

Ben W