ARONSON TECHNICAL MANUAL

KOIKE ARONSON, INC.

635 W. Main St., Arcade NY, 14009-0307(585) 492 2400, Fax (585) 457 3517
Visit us at www.koike.com

MONOGRAPH MILLENNIUM /CUTTER II

INSTRUCTION MANUAL MI0556A

Subject to Change Without Notice
November 26, 2008
REV. D
 CONTENTS
MONOGRAPH MILLENNIUM/CUTTER II

SECTION 1 SAFETY PRECAUTIONS

Section 1.1 General Safety........................................................................... 4

Section 1.2 General Safety, Plasma Cutting................................................. 5
Section 1.3 General, Miscellaneous ............................................................. 7
Section 1.4 Work Area Layout ..................................................................... 9

SECTION 2 General Introduction

Section 2.1 Scope ...................................................................................... 10

Section 2.2 Description............................................................................... 10
Section 2.3 Axis Definition .......................................................................... 10
Section 2.4 Saddle Assembly ..................................................................... 10
Section 2.5 Transverse Beam Assembly (X-Drive)..................................... 10
Section 2.6 X-Drive Assembly .................................................................... 10
Section 2.7 Y-Drive Assembly .................................................................... 11
Section 2.8 Operator Control Console ........................................................ 11
Section 2.9 Limit Switches.......................................................................... 11
Section 2.10 Electrical Features ................................................................... 11

SECTION 3 Pre-installation Requirements

Section 3.1 Pre-installation Safety.............................................................. 13

Section 3.2 Sight Location .......................................................................... 13
Section 3.3 Sight Preparation ..................................................................... 13
Section 3.4 Electrical Requirements ........................................................... 14
Section 3.5 Compressed Air ....................................................................... 14

SECTION 4 Installation

Section 4.1 Installation Safety Precaution .................................................. 16

Section 4.2 Handling and Storage .............................................................. 16
Section 4.3 Machine Installation ................................................................. 16
Section 4.4 Unpacking and Cleaning.......................................................... 16
Section 4.5 Motor/Gear Unit Installation ..................................................... 17
Section 4.6 CNC Interface .......................................................................... 17
Section 4.7 Utilities ..................................................................................... 17
Section 4.8 General Plasma Connections .................................................. 17

SECTION 5 Operation

Section 5.1 Operational Safety ................................................................... 18

Section 5.2 General Operation ................................................................... 18

SECTION 6 Maintenance

Section 6.1 Safety Precautions................................................................... 19

Section 6.2 General Information ................................................................. 19
Section 6.3 Preventative Maintenance Schedule ....................................... 19
Section 6.3.1 Each Shift ................................................................................ 20
Section 6.3.2 Each Fifty (50) Operation Hours .............................................. 20
Section 6.3.3 Each Two Hundred Fifty (250) Hours ...................................... 20
Section 6.3.4 Each One Thousand (1000) Hours .......................................... 20
Section 6.4 Guide Roller Adjustment .......................................................... 20
Section 6.5 Rail Cleaning ........................................................................... 20
Section 6.6 Roller Cleaning ........................................................................ 20
Section 6.7 Wheel Cleaning ....................................................................... 20
Section 6.8 Gears and Pinions ................................................................... 21
Section 6.9 Drive Tuning Procedure ........................................................... 21

SECTION 7 Replacement Parts ................................................................ 22

SECTION 8 Optional Features .................................................................. 34

Section 8.1 Torch Lifter Options ................................................................. 34

Section 8.2 Cutting Systems....................................................................... 34

LIST OF ILLUSTRATIONS /TABLES

Figure 1.1 Machine Safety Frame............................................................... 9

Figure 2.1 MONOGRAPH MILLENNIUM/CUTTER II Machine Layout ..... 12
Table 2.1 MONOGRAPH MILLENNIUM/CUTTER II Specifications ........ 12
Figure 3.1 General ground Layout ............................................................ 15
Figure 7.1 Machine ................................................................................... 22
Figure 7.2 Saddle Assembly ..................................................................... 23
Figure 7.3 Y-Axis Drive Saddle................................................................. 24
Figure 7.4 X-axis Drive Carriage .............................................................. 25
Figure 7.5 Outboard Roller Assembly ....................................................... 26
Figure 7.6 Leveling foot ............................................................................ 27
Figure 7.7 Lifter Assembly ....................................................................... 28
Figure 7.8 PHC Height Controller ............................................................. 29
Figure 7.9 Optional Floating Head ............................................................ 30
Figure 7.10 KARCNC Replacement Parts .................................................. 31

Appendix A List of Terms and Abbreviations .............................................. A1

Appendix F Plasma Operation .................................................................... F1
Appendix L PHC Operation and Set Up Guide ........................................... L1
Safety

SECTION 1
SAFETY PRECAUTIONS
USER RESPONSIBILITY - This equipment will perform in conformity with the
description thereof in this manual and accompanying labels and/or inserts when
installed, operated, maintained and repaired in accordance with the instructions
provided. This equipment must be checked periodically. Defective equipment should
not be used. Parts that are broken, missing, plainly worn, distorted or contaminated
should be replaced immediately. Should repair or replacement become necessary,
KOIKE ARONSON recommends that a request for service be made to the KOIKE
ARONSON Authorized Distributor from whom purchased or directly to the KOIKE
ARONSON Service Department.

This equipment or any of its parts should not be altered without prior written
approval of KOIKE ARONSON. The user of this equipment shall have sole
responsibility for any malfunction, which results from improper use, faulty
maintenance, damage, improper repair or alteration by anyone other than KOIKE
ARONSON or a facility, designated by KOIKE ARONSON, INC.

NOTES, CAUTIONS & WARNINGS

Throughout this manual, notes, cautions, and warnings are used to describe
situations that require additional information. The following formats are used
for each:

Notes: A note offers additional information, such as an operating tip, that aids the user in
operating the equipment.

Caution: A caution describes a situation that may cause damage to the machine and offers
advice to avoid or rectify the situation.

WARNING

A warning describes a situation that presents a physical danger to the operator, and
offers advice to avoid or rectify the situation. Each type of warning displays an
applicable danger symbol, such as a fire, explosion or electrical shock.

1
Safety

KOIKE ARONSON SYMBOL LIBRARY

SYMBOL MEANING

GENERAL INFORMATION

ELECTRICAL SHOCK CAN KILL

POISON/TOXIC

FLAMMABLE/COMBUSTIBLE

EXPLOSION HAZARD

DO NOT WATCH THE ARC

OPEN GEARING

GROUND THIS EQUIPMENT

COMPRESSED GAS

2
Safety

SYMBOL MEANING

EYE PROTECTION REQUIRED

USE AN APPROVED RESPIRATOR

WEAR APPROVED EAR PROTECTION

INSULATED GLOVES REQUIRED

INSULATED FOOTWARE REQUIRED

NO OPEN FLAME

HOT SURFACE DO NOT TOUCH

DO NOT REMOVE GUARDS

WEAR PROPER EYE PROTECTION WHEN PLASMA CUTTING

WEAR PROTECTIVE CLOTHING

3
Safety
Before using this equipment and its options each person operating, maintaining or
supervising the use of this equipment must read the following safety instructions.
1.1 GENERAL SAFETY
Operation of this machine involves various
moving and rotating parts that could prove
to be dangerous. Follow the precautions in
this General Safety Section, as well as
those throughout this manual, for your
personal safety and the safety of people in
the area that may be affected. Failure to
observe these safety practices may cause
serious injury or death.
1. Install and operate this machine only in
a well-ventilated area.
2. Connect and maintain electrical grounds
to the equipment according to local
codes and the National Electrical Code.
3. Check gas and electrical connections for
tightness after installation and on a
regular basis thereafter.
4. Keep combustibles away from the work
area or protect them from sparks and
flames.
5. Never use oxygen to ventilate the area
or clean off clothing.
6. Replace hoses that are damaged by
physical abuse or by sparks, heat or
open flame.
4
7. Examine hoses at regular intervals for
leaks, wear, loose connections or other
hazards.
8. Coil excess hose and place it out of the
way to prevent damage and to eliminate
tripping danger.
9. Maintain all pressure regulators in proper
working condition.
10. Wear filter-lens safety eye protection.
Wear gauntlet gloves, safety shoes,
flame-retardant clothing, and no-cuff
trousers. Do not wear loose clothing
around this machinery as they can catch
on the machine.
11. Shut off power and air supplies
whenever leaving the machine
unattended or before servicing.
12. Keep equipment clean and in good
operating condition.
13. Read accessory instruction manuals
supplied for these items for additional
safety and operating guidelines before
operating this equipment.
14. No repair should ever be undertaken or
attempted by anyone other than a
KOIKE ARONSON designated
technician.
Safety

15. Read and understand further detailed Arc Current US Shade No. ISO 4850
safety precautions throughout this Up to 100 Amps 8 11
manual. 100 to 200 Amps 10 11-12
200 to 400 Amps 12 13
Over 400 Amps 14 14
1.2 GENERAL SAFETY, PLASMA
CUTTING
5. Do not use helmet or hand shields that
are not in good condition. Repair or
Plasma Arc cutting is a high intensity
replace promptly. Protect colored filter
source of visible light emission as well as
plates with a clear glass cover plate.
ultraviolet and infrared radiation. It can
cause severe eye damage and inflict burns
6. Warn other people in the area not to look
on exposed skin when those portions of the
directly at the arc unless they wear
body are not suitably protected. Follow the
glasses/goggles or a helmet.
precautions in this General Safety Section
and read the supplied plasma equipment
7. Never, start the plasma arc without
instruction manual for additional and more
determining that nearby personnel are
detailed safety precautions.
wearing adequate protective equipment.
1. Facilities should be available for the
8. All areas of the body must be covered by
medical treatment of arc flashes or
burns to the eyes.

2. Provide radiation protection for the

operator and for personnel in the
adjacent area. dark substantial clothing (preferably
flame retardant) to protect against arc
burn, sparks and flying hot metal.

9. The plasma operation should be located

3. Do not, under any circumstances, look
at a plasma arc without full eye
protection. When near plasma cutting
equipment always wear flash goggles
with side shields and containing No. 4
filter lenses.
4. The operator must use in addition to
flash goggles, a suitable helmet for eye
and face protection when cutting. The
helmet must be equipped with a number
filter plate as indicated:
in an area where protection for other
personal may be readily provided.
Portable non-combustible reflecting
screens or enclosures with non-reflecting
walls may be used. Screens and
enclosures should permit free circulation
of air at floor level.
10. Do not cut in the presence of
atmospheres containing even minute
amounts of chlorinated solvents such as
Trichloroethylene and
Perchloroethylene since the heat and
ultraviolet radiation can decompose
these vapors to form Phosgene, a highly
toxic gas, and other irritating
decomposition products.
11. Do not cut in atmospheres containing
explosive dust or vapors.

5
Safety
12. Keep the cutting area well ventilated.
13. Wear proper breathing mask when
cutting galvanized metal and use
proper ventilation.
14. Do not cut pressurized cylinders or any
closed container.
15. Make fire extinguishers available in the
cutting area.
16. Remove combustible material from the
immediate cutting area.
17. Quench freshly cut metal or allow metal
to cool before handling it or bringing it
in contact with combustible materials.
18. To prevent electric shock keep your
body and clothing dry.
19. Do not stand in, sit on or lie on any wet
surface when using the plasma system.
20. Maintain proper insulation against
electrical shock. If you must work in or
near a damp area, use extreme
6
caution. Wear insulated gloves and
boots.
21. Provide a wall mounted disconnect
switch with proper size fuses close to
the power supply. This switch allows the
operator to turn the power supply off
quickly in an emergency situation.
22. Conform to all local codes for primary
wiring sizes and types.
23. Inspect the primary power cord
frequently for damage or cracking of the
cover. Bare wiring can kill. Do not use
the system with a damaged power cord.
If a power cord is damaged, replace it
immediately.
24. Inspect the torch leads. Replace if frayed
or damaged.
25. Never operate the plasma system unless
the power supply unit covers are in
place. Exposed power supply
connections present a severe electrical
hazard.
26. Do not pick up the work piece, including
the waste cutoff, while you cut. Leave
the work-piece in place or on the
worktable with the work cable attached
at all times.
27. Before changing the torch parts,
disconnect the main power supply. After
changing the torch parts and returning
the retaining cap to its operating
position, plug the power supply in again.
28. Never, bypass or shortcut the safety
interlocks.
29. Before removing a power supply cover
for maintenance use approved lockout
procedures, disconnect the main power
at the wall, shut off switch or unplug the
power supply. To avoid exposure to
severe electrical hazard, wait five (5)
Safety
minutes after disconnecting the main
power to allow capacitor discharge to
occur. Test for zero volts.
30. Be sure the power cord is plugged into
a properly grounded outlet or that the
power cord ground wire is properly
connected to the ground in the
disconnect box.
31. If installation of the plasma system
involves connecting the power cord to
the power supply, ensure that the
power cord ground wire is properly
connected. Conform to CSA standards
by placing the power cord ground wire
on the stud first; then place the other
ground wires on top of the power cord
ground. Fasten the retaining nut tightly.
32. Make sure that all electrical connections
are tight to avoid excessive heating.
33. Clamp the work cable with good metal-
to-metal contact to the work-piece (not
the portion that will fall away) or to the
worktable.
34. Connect the worktable to a good earth
ground. Consult the National Electrical
Code, Grounding Electrode System, or
other appropriate national or local
codes.
35. Plasma cutting operation noise levels
may be high enough to require ear
protection for the operator and other
personnel in the adjacent area.
7
36. When using a water table to confine
slag while plasma arc cutting plate,
especially aluminum or magnesium,
cutting may cause an accumulation of
explosive gas below the plate. Do not
allow aluminum or magnesium dross to
accumulate in a water table. Prior to
cutting, raise and lower the water level
several times to dissipate trapped
gases. Do not leave plate on the table
for extended periods, such as overnight
or weekends. When the table is not in
use, keep the water level down. Do not
cut these materials under water. Read
additional cautions in the related
manuals.
37. No repair should ever be under taken or
attempted by anyone other than a
KOIKE ARONSON designated
technician.
1.3 GENERAL SAFETY,
MISCELLANEOUS
1. Keep the working area dry to avoid an
electrical shock.
2. Check that the machine voltage and
supply voltages are the same before
turning on the power switch.
3. Never, operate this machine unless all
electrical box covers are attached.
Exposed electrical connections present
a severe electrical hazard.
Safety

4. When replacing or cleaning a torch tip
during cutting be sure to give the tip
sufficient time to cool. The tip will be
very hot.
7. During the cutting operation never touch
the plasma arc.
8. Do not climb on the cutting table, as it is
possible to slip and cause injury.

9. Take care not to climb on or over the rail

as it has rack attached to it and can
cause injury.

5. After cutting never touch the work-piece

or scrap until they cool. You can be
burned.

6. During the piercing operation of heavier

plate, (25mm or larger) there can be a
good deal of spatter. Be sure to stay
away from the torch and stay in the
operation zone to prevent exposure to
burn from the spatter.

WARNING
Protect yourself and others. Read and understand these instructions. FUMES AND
GASES can be dangerous to your health. HEAT RAYS (INFRARED &
ULTRAVIOLET) from flame, arc or hot metal can injure eyes. Read and understand
the manufacturers’ instructions and your employer's safety practices. Use enough
ventilation/exhaust at the flame/arc, or both, to keep fumes and gases from your
breathing zone, and the general area. Keep your head out of the fumes.

8
Safety
Figure 1.1 Machine Safety Frame
1.4 WORK AREA LAYOUT
1. The working area shown in Figure 1.1 is
required to ensure safe operation. This
area should have a fireproof floor, must
provide adequate clearance around the
machine for proper operation and
personal safety per local code and
should be clearly marked with
appropriate warnings.
2. This machine moves in multiple directions
and at various speeds. All personanel,
materials and equipment not involved in
the production process must be kept
clear of the work area.
9
3. Only qualified personnel should operate
or service this equipment. The work
area must be checked for personal and
obstructions prior to starting machine or
initiating machine motion.
4. Machine operation and monitoring of the
cutting process should be performed
from the operator station, at the control
console.
5. Consumables should be changed in the
Flame Adjustment Area in front of the
machine noted above.

SECTION 2
GENERAL INTRODUCTION
2.1 SCOPE
This manual provides general installation,
operation and service information for the
KOIKE ARONSON MONOGRAPH
MILLENNIUM/CUTTER II series of cutting
machines. This manual includes an illustrated
part listing to aid in ordering parts.
2.2 DESCRIPTION
Your MONOGRAPH MILLENNIUM/CUTTER II
Series is designed with time proven
construction techniques. This machine uses
the latest in electronic and mechanical
technologies. Speed, accuracy, versatility and
durability have been engineered into the
MILLENNIUM for demanding production jobs.
The CNC programmable control allows for
ease of operation and precision cutting of plate
steel. In addition, accessories for specific
purposes are available to further enhance the
versatility of the MONOGRAPH
MILLENNIUM/CUTTER II.
The Koike Aronson Inc. MONOGRAPH
MILLENNIUM/CUTTER II is designed to meet
your cutting requirements of steel plate.
The MONOGRAPH MILLENNIUM incorporates
two 1.2KW AC servo drive systems into its dual
processor controlled KARCNC. The CNC is
equipped with torch control for one plasma
system.
2.3 AXIS DEFINITION
To avoid confusion in determining direction and
aid in identifying part locations:
1. The X-axis is parallel to the transverse
(main) beam.
General Introduction
2. The Y-axis is parallel to the longitudinal rail
system.
2.4 SADDLE ASSEMBLY
One saddle assembly, located on the operators
control side of the machine, travels on the Y-
axis rail system driven by a Y-axis drive motor
and planetary gearbox assembly mounted on
the outboard side of the carriage. Two (2) wheel
assemblies support the saddle, one on the
forward end and one on the aft end of the
saddle to provide stability. The saddle utilizes
two sets of rollers to provide guidance down the
rail system. The inboard roller, facing the front
of the machine, is essential to adjust to the
guide rail and maintain positive machine
alignment. A single roller for simplicity supports
the opposing end of the transverse beam
assembly and rides on the Y-axis rail system.
2.5 TRANSVERSE BEAM ASSEMBLY
(X-drive)
The beam assembly consists of structural
tubing extending in a left to right direction facing
the machine and supported by the saddle and
roller assemblies. The beam is factory squared
to both assemblies, pinned in position and
bolted.
2.6 X-AXIS DRIVE ASSEMBLY
The X-axis drive carriage supports one plasma
torch station. The drive is located on the
transverse beam carriage. A motor and
planetary gear assembly drives the carriage
along the X-axis. The X-axis pinion engages to
a rack assembly mounted to the transverse
beam to provide precise motion.
10

2.7 Y-AXIS DRIVE ASSEMBLY
The Y-axis drive assembly is mounted in the
center of the saddle assembly facing out. A
pivot mount assembly supports the motor and
planetary gear unit.
2.8 OPERATOR CONTROL CONSOLE
The operator control console is mounted
directly to the end of the rail on the left front
corner of the machine. This offers a good view
of the work piece and keeps the operator a
safe distance from the transverse beam
assembly.
11
General Introduction
2.9 LIMIT SWITCHES
Two (2) limit switches are mounted on the
transverse beam assembly. The limit switches
prevents an over-travel condition of the X-axis
drive unit. A limit switch mounted to the saddle
limits Y-axis travel. Should a limit switch be
tripped, the drive signal is interrupted, and all
cutting operations are stopped. To recover from
a limit trip see the operation section of this
manual.
2.10 ELECTRICAL FEATURES
The MONOGRAPH MILLENNIUM SERIES
KARCNCtm incorporates dual microprocessor
architecture for true muti-tasking. One
processor is dedicated for motion control, while
the other is dedicated to Windows functionality.
Two AC brushless servo systems capable of
delivering 1.2 KW of power are incorporated
into the CNC.
 General Introduction

Figure 2.1 Machine Layout

Monograph/CUTTER II Specifications
Effective Cutting Area 5'x10'
Maximum Plate Thickness 5/8 inches (production capacity 3/8 inch)
Rapid Traverse Speed 1400 IPM
Machine Height 63-3/4
Machine Width 83-1/4
Machine Length 191 inches
Drive (AC) 210 watt motors
Drive (DC) 480 watt motors
Power 115VAC@ 15Amps
Air (for plasma system) 100 psi of dry, clean air
Planetary gear units X and Y axis; 9 arc-min backlash
Approximate shipping weight 2500 pounds

12

SECTION 3
PRE-INSTALLATION REQUIREMENTS
3.1 PRE-INSTALLATION SAFETY
All equipment must be installed in
accordance with local requirements and the
National Electrical Code. Connect and
maintain good electrical grounds, as per
article 250 of the NEC, to the supply ground
wire, cutting machine and cutting table. Do
not ground to electrical conduit, or pipes
carrying gases or flammable liquids. Use
only correct sizes of electrical cable.
Plan to provide ventilation. Proper ventilation
is vital for safety, good visibility and personal
comfort.
Equipment necessary for lifting the machine
weight must be available at the time of
installation, for example, an overhead crane,
forklift, and so forth.
All normal safety precautions used in
working with flammable gases, electrical
equipment and heavy machinery, as well as
procedures listed in your company safety
manual, must be followed to prevent
possible injury.
CAUTION
When welding, DO NOT ground to the
machine, the rail system or the burning
table, to avoid damage to electronic
components. Evidence of welding to the
cutting machine equipment will void all
warranties.
NOTE: The following preparations should
be complete before the arrival of the
installing technician.
13
Pre-Installation Requirement
3.2 SITE LOCATION
The machine requires a space where floor
vibration is at a minimum. Precision
operation is necessary for accurate part
processing. Avoid areas where vibrations
caused by drop hammers, heavy
machinery and punch presses are used.
Position the unit close to the production
line, with adequate lighting and ventilation.
Special consideration must be used in the
selection of a site for machine operation.
Gas supply, electrical power, clean dry
shop air and water in the immediate vicinity
are essential for economical operation of
the machine. Material handling is important
for safe loading and unloading of the parts.
3.3 SITE PREPARATION
This machine should only be installed
indoors on a clean dry surface.
Solid, secure and accurate machine
installation is critical to insure maximum
accuracy for the cutting plasma machine.
The floor for the machine installation the
floor should be level within 9.5mm (3/8”)
over the entire length and width. The floor
area supporting the machine should be
specified by a contractor and be free from
cracks or other imperfections.
If a possibility of equipment vibration
exists, the machine should be provided
with an adequate isolation pad.
 Pre-Installation Requirement

3.4 ELECTRICAL REQUIREMENTS exceed 4ft. (1.2M) in length. The ground

rod for machines with a plasma system of
The position of cables is very important for 100 amperes or more should be 3/4in.
proper operation of the system. Use care (19mm) diameter solid copper, 14ft. (4.5M)
when routing electrical wires and cables to in length. If you cannot drive a 14ft. (4.5M)
avoid pinching or chafing against metallic or ground rod you may use two (2) 8ft. (2.5M)
other abrasive objects. ground rods connected to each other with
4/0 cable and then to the Star ground. The
Local codes asCAUTION
well as the National wire to the Star ground connection will be a
Electrical minimum of 4/0 cable and should not
The AC power to the be
Standard must followed
cutting for all
machine
power exceed 4ft. (1.2M) in length.
must and
comegrounding installations.
from a dedicated source. No
other machinery or equipment should be
Note: Ground rods must be installed
connected to this line.
according to the National Electrical
Code Standards.
Cutting machine electrical requirements are
115 Volts AC (±10%), 50-60 Hz, single All ground connections must make intimate
phase, 20 Amps. Koike Aronson provides contact with the components they are
the machine main power cable. Koike grounding. All rusted or painted surfaces
Aronson recommends all power cables be must be cleaned and the connections
kept as far as possible from auxiliary made should be tight. Any grounding strap
components such as machine control boxes should be sized to current load per article
and solenoids. Avoid random placement of 250 of the NEC.
wiring.
Keep all wiring as short as possible, DO 3.5 COMPRESSED AIR
NOT COIL ANY CABLES. Make sure all
supply hoses and cables are long enough Compressed air for general blow down and
for the type of carrier system used. clean up should be dry, clean and oil free
with a 5-micron maximum particle size.
CAUTION
Proper grounding of the cutting machine
and peripheral equipment is critical for
reliable and safe operation of the
system.

The machine requires careful and proper

installation of ground rods with associated
wire connections. Ground wires will connect
to a mono-post ground connection. Ground
rod size for plasma systems of 100 amperes
or less should be 1/2in. (12mm) diameter
solid copper, 8ft. (2.5M) in length. The wire
connection to the Star ground should be a
proper sized stranded wire, and should not

14
 Pre-Installation Requirement

Figure 3.1 General Ground

Layout

15
15
 Installation
SECTION 4
INSTALLATION
4.1 INSTALLATION SAFETY
PRECAUTION
WARNING
Voltages used with this machine can be
injurious to personnel if improperly
used. All equipment must be installed
and maintained in accordance with local
requirements and the National Electric
Code.
Connect and maintain suitable electrical
grounds to the supply ground wire. Do not
connect ground to electrical conduit or to pipes
carrying gases or flammable liquids. Use only
the recommended size of electrical cable, in
accordance with article 250 of the NEC.
If it was necessary to install forced ventilation,
operate the cutting machine only when such
ventilation is running to prevent harmful and
dangerous accumulations of fumes.
Avoid enclosing areas where fuel gas leaks
may occur, or insure that such leaks cannot
occur in lines passing through or ending in
confined spaces.
Use normal precautions when loading or
operating heavy equipment. Follow the
procedures in your company safety manual.
4.2 HANDLING AND STORAGE
When the shipment arrives at your location,
accompany the driver in counting all the
cartons indicated on the driver's waybill.
Inspect each piece for signs of mishandling or
apparent damage. If discrepancies exist or any
evidence of damage exists, note it BOLDLY
16
across the face of the waybill BEFORE YOU
SIGN IT. Sign the waybill only after this
inspection. If you note discrepancies on the
delivery ticket, DO NOT open the cartons.
Call the freight carrier’s local office and ask
that a claims investigator be sent as soon as
possible to verify the status of the shipment.
Also, call your Koike Aronson representative.
Try to arrange the meeting so that the claims
investigator and the representative will be
present when the damage/shortage is verified.
The freight carrier will supply you with the
necessary claims forms if required. Freight
claims are the receivers’ responsibility. Please
follow these instructions carefully; Koike
Aronson and your distributor will support you
fully in the unlikely event that a freight claim is
necessary.
Handle the packing cartons carefully, right side
up as marked. Store cartons in a dry location
until ready to install.
4.3 MACHINE INSTALLATION
Refer to Koike Aronson MONOGRAPH
/CUTTER II Setup and training CD for
complete installation instructions.
4.4 UNPACKING AND CLEANING
The equipment has been packaged to prevent
damage in transit. Unpack carefully to prevent
accidental damage by uncrating tools. After
uncrating, examine the equipment for signs of
damage, particularly to control knobs, switches
and electrical components. Report any damage
to the freight carrier and Koike Aronson
immediately.
Remove preservation coating from all
unpainted surfaces, as components are
needed for installation, with WD-40®, LPS-1®
or mineral spirits.
 Installation

4.5 MACHINE LEVELING

Once the machine is in place use the

four leveling feet to ensure that the WARNING
machine is as close to level as possible
for optimal cutting precision and
performance. This machine has open gearing.
Keep hands clear when the machine
is being operated.

4.6 CNC INTERFACE

The CNC control has been removed from the

machine for shipment. Unpack it CAREFULLY
and install the CNC in the operator control.
Connect the proper cable assembly to the
CNC. All cable assemblies are labeled at Koike
Connect the air hose to the main valve unit
Aronson as to where they connect to the CNC.
marked “air”.
4.7 UTILITIES
4.8 GENERAL PLASMA MACHINE
The machine is supplied with a flexible main CONNECTIONS
cable carrier system. Route all supply hoses
and cables through the carrier system in a neat Refer to the Koike Aronson MONOGRAPH
and orderly fashion; using tie-wraps, tie each /CUTTER II Setup and training CD for
cable and hose to the tie-plates located at each complete plasma machine installation
end of the cable carrier. instructions.

Connect the power cable from a properly fused

dedicated source (review Section 3 Pre-
Installation) to the power disconnect on the
machine. Check to see that the power source
is off and/or tagged Out of Service to avoid a
potential electrical shock.

17
 Operationn
SECTION 5 OPERATION
5.1 OPERATIONAL SAFETY
Follow the precautions in the SAFETY section
and throughout this manual for your personal
safety and the safety of people near the
equipment.
1. Operate cutting equipment only in a well-
ventilated area.
2. Keep combustibles away from the work
area or protected from sparks and flames.
3. Wear appropriate eye protection safety
goggles with filter lens.
18
MI0545A
4. Keep equipment clean and in good
operating condition.
5. WELDING: DO NOT ground to the machine,
the rail system or to the cutting table at any
time to avoid damage to electronic
components. Failure to follow this warning
may void all manufacturers’ warranty.
5.2 GENERAL OPERATIONS
1. For machine control operations, refer to
the KARCNC Operation Manual.
 Maintenance
SECTION 6
MAINTENANCE
6.1 SAFETY PRECAUTIONS
1. Shut OFF main power switch, pull fuses, or
lock and red tag switch before attempting
work on electrical circuits. Do not touch
electrically CHARGED parts or those with
residual voltage, such as capacitors until
they have been grounded and their electric
charge dissipated.
2. Keep power cables dry, free of oil and
grease, and protected at all times from
damage by hot metal and sparks. DO NOT
use any power cable with worn or damaged
insulation, repair or replace immediately.
3. Equipment that is not functioning properly
should NOT be used until all repairs have
been completed and the equipment has
been tested to ascertain that it is in proper
operating condition.
4. WELDING: DO NOT ground to the machine,
the rail system, or to the cutting table at any
time to avoid damage to electronic
components. Failure to follow this warning
may void manufacturer's warranty.
5. Except for inspection and maintenance listed
in this manual, it is recommended that an
authorized Koike Aronson, Inc. service
technician do all other servicing.
6. Goggles with correct filter lenses must be
worn whenever torches are lit. Suitable
protective clothing must be worn where
necessary.
Comply with these and other safety procedures
listed in this manual. Refer to appropriate
manuals, furnished by the manufacturer, for
safety procedures for plasma, drive, CNC or
other optional equipment.
19
6.2 GENERAL INFORMATION
This manual provides standard preventative
maintenance procedures required for accurate
and proper operation of the
MONOGRAPH/CUTTER II cutting machine.
Follow these procedures to maintain machine
operation at peak efficiency and to extend the
useful life of the machine.
The machine has been assembled, properly
adjusted and factory tested before shipment.
Factory settings, other than those listed in the
installation section of this manual, should not
be changed. If the machine performance is
unsatisfactory, contact a Koike Aronson, Inc.
authorized service representative for advice.
Keep the machine clean, in good condition and
free of oil, grease and other combustibles. If
replacement parts are required, it is
recommended that they be purchased from
Koike Aronson, Inc. through an authorized
distributor.
The manufacturer for optional items such as
plasma systems, microprocessor controls and
certain other components have furnished
separate manuals listing maintenance
procedures.
6.3 PREVENTATIVE MAINTENANCE
SCHEDULE
Although this machine does not require a great
deal of maintenance, the following procedures
should be preformed routinely based on
operation hours. The following maintenance
guidelines are solely the responsibility of the
operator (customer). Failure to comply with
these guidelines for your machine can result in
poor cut quality, a rough running machine or
service calls at the expense of the customer
and are not covered under machine warranty
neither by the Distributor nor by Koike
Aronson, Inc.
 Maintenance
6.3.1 EACH EIGHT (8) OPERATION
HOURS
1. Blow off rails, rollers and wheels with low-
pressure shop air (Not Oxygen).
2. Spray a clean cloth lightly with WD-40®or
LPS-1®, and wipe the wheels, rollers,
gears, rails and rack.
3. Ensure that the main saddle side guide
rollers are tight to the side of the rail. The
outside rollers are non-adjusting; the inside
rollers are adjustable.
4. Clean plasma torch and tip.
6.3.2 EACH FIFTY (50) OPERATION
HOURS
1. Check for damage to the gear rack. Repair
with a file or replace if damage is
excessive.
2. Remove wheel guards located on the
outside of the saddles and clean main
wheels.
3. Clean and readjust the plasma torch holder.
4. Check roller bearings on X- axis carriage
for smooth operation. Clean and lube if
necessary.
6.3.3 EACH TWO HUNDRED FIFTY
(250) HOURS
Check for backlash in X and Y drive pinions
to the rack. Make sure the pinion is not
worn. If backlash exists, check the rack for
wear.
20
6.3.4 EACH ONE THOUSAND (1000)
HOURS
Clean and dust off all electrical equipment.
6.4 GUIDE ROLLER ADJUSTMENT
After prolonged usage, the main saddle
eccentric guide rollers may require adjustment.
Adjust eccentric bolts until rollers can just be
turned, using thumb and forefinger, against the
side of the rail. Check that all guide rollers turn
easily as the machine is moved.
6.5 RAIL CLEANING
Spray a clean cloth lightly with WD-40®or LPS-
1®, and wipe the top, sides and rack clean.
When cutting splatter settles on the rails, clean
or chip off with a steel flat tool. Be sure not to
damage the rail or rack.
File off larger burrs that may appear on the
rails as they could affect cutting performance.
6.6 ROLLER CLEANING
At least once each shift, remove dirt buildup
from small rollers, main carriage side guide
rollers and torch carriage rollers as follows:
a. Hold a steel flat bar (1.6 x 25 mm cross
section or a steel pocket rule) flat on rail
edge against roller surface.
b. Move the carriage in a direction away from
the bar, holding the bar against the roller for
at least one complete revolution to scrape
off dirt build up.
6.7 WHEEL CLEANING
At least once each shift, remove dirt buildup
from wheels on the Y-axis saddle.
 Maintenance

Roll the carriage one wheel revolution scraping

off buildup from the wheels with the edge of a
steel flat bar (1.6 x 25 mm, or steel pocket
rule).

6.8 GEARS AND PINIONS

At least each shift remove debris from gears

and pinions using a stiff wire brush. Spray on a
light film of LPS-1®.

6.9 DRIVE TUNING PROCEDURE

The MONOGRAPH/CUTTER II uses AC servo

drives. No electrical adjustments are required.
The parameters for each drive are factory set
and must not be changed without consulting
Koike Aronson, Inc.

21
 Replacement Parts

SECTION 7
REPLACEMENT PARTS
To assure minimum down time, it is recommended that spare parts noted by an asterisk
* be kept on hand. To assure proper operation, it is recommended that only genuine
KOIKE ARONSON parts and products be used with this equipment.

To order replacement parts:

a. Provide Sales Order (SO#), serial number and model of equipment from the Serial
Tag located on the main beam.
b. Provide part number, description and quantity of part.
c. Indicate any special shipping instructions.

Figure 7.1 MONOGRAPH MILLENIUM/CUTTER II

22
Replacement Parts

Figure 7.2 Saddle Assembly

MAIN ROLLER
BALL BEARING
1138-3506-00

GUIDE
ROLLER
BALL BEARING

23
 Replacement Parts

Figure 7.3 Y-Axis Drive Saddle

AC Motor
9983-0342-02

Planetary
Gearbox
0868-9230-00

DC Motor
0868-5763-06

Planetary
Gearbox
0868-8769-00

Drive Pinion Drive Rack

0868-8814-00 1138-4163-00
(1000mm LONG)

Limit Switch
(Includes Arm)
9982-0060-02
Cable Carrier
0868-8926-00

24
 Replacement Parts

Figure 7.4 X-Axis Drive Carriage

AC Motor
9983-0342-02
DC Motor
0868-5763-06

Planetary
Gearbox
0868-8769-00 Planetary
Gearbox
0868-9230-00

Drive Pinion
0868-8814-00

Cable Carrier
0868-8926-00

Over Travel
Limit Switch
Carriage Roller 9982-0060-02
Ball Bearing (six total)
1138-3509-00
Drive Rack
1138-4163-00(1000mm Long)
1115-1016-00(820mm Long)

25
Replacement Parts

Figure 7.5 Outboard Roller Assembly

BALL BEARING
1138-3506-00

26
Replacement Parts

Figure 7.6 Leveling Foot

LEVELING FOOT
0868-8444-00

27
Replacement Parts

Figure 7.7 Lifter Assembly

For Lifter Part Number and

Information See Appendix L

28
Replacement Parts

Figure 7.8 PHC Height Controller

For PHC controller

information see Appendix L

29
Replacement Parts
Figure 7.9 Optional Floating Head

Pneumatic Cylinder
0868-8779-00

Floating Head
0868-2984-00

Transfer Rollers
0868-6557-00

30
 Replacement Parts

Figure 7.10 KARCNC Replacement Parts

KPKA1904 SERVO INTERFACE PCB

ZPKA2901 PLATEPRO CARD KPROM017 HARD DISK

ZPROM2121 KPROM3306
PROCESSOR CARD Motherboard

ZPROM2123
FET CARD

ZPROM2122
D/A CARD

ZPKA1900 POWER CARD

ZPROM009 PC POWER SUPPLY

ZPKA2902 SWITCH CARD

Part
Number Description
ZPROMxxxx 1.CPU Px4 (with Celeron M processor, 256MB memory w/fan)
ZPROMxxxx 2.CPU PAx (with PIII processor, memory, CF memory and fan)
ZPROM3520 2,5" Hard Drive
ZPROM005 Hard Drive Cable
ZPROM2213 12" LCD Display
ZPROM2601 LCD Display Inverter
ZPROM3310 LVDS Converter
ZPROM2898 Display Cable for 1.CPU
ZPROM3111 USB Cable
ZPROM009 ATX PC Power Supply 300W
ZPKA1900 Power Card (ver1.7)
ZPKA1903 Monograph interface card (ver1.6)
ZPKA1902 Monograph Switch Card (ver1.1)

31
Replacement Parts

Part
Number Description
ZPKA1006 Para2D push-button card
ZPROM2121 PCint Processor Card
ZPROM2123 PCint Fet Card
ZPROM2122 PCint DA-Card
ZPROM3145 AC Servo Interface Card (two channel)
ZPKA1045 Zeller AC Servo Drive
ZPKA1043 Small Transformer SCL 115/115//8V/15/15/19
ZPKA1011 Cabinet
ZPROM2870 AC Servo Backwall Plate (two channel)
ZPROM3553 Monograph Interface Backwall Plate AC
ZPROM2877 Monograph Door (for ITX boards)
ZPROM2868 ITX Assembly Plate
ZPROM2874 Hard Drive Plate (for ITX Plate)
ZPROM2281 Plastic Bezel
ZPKA1001 Switch Panel Bezel CNC
ZPKA1013 Label KAR CNC
ZPKA1019 Rack for 2.CPU
ZPKA1020 bracket for pc power
ZPROM2312 Door hinge
ZPROM040 latch
ZPROM041 clamp
ZPROM042 locking bar
ZPROM074B Speed potentiometer + nut
ZPROM074 Knob for speed potentiometer
ZPROM097 hexagonal locking screw 3x10 mm
ZPROM3240 E-stop button
ZPROM3241 Contack block + body (E-stop)
ZPROM3242 Contact block (E-stop)
ZPROM2271 Switch mom-off-mom (main switch)
ZPROM2505 Rubber boot for switch
ZPKA1009 Silicone push button (square)
ZPKA1010 Silicone push button (joystick)
ZPKA1008 text label set for buttons
ZPROM106 polycarbonate window
ZPROM2284 rubber floppy door seal
ZPROM2317 screw for floppy door seal
ZPROM2675 Mouse
ZPROM2278 Mouse pad
ZPROM3230 power inlet
ZPKA1022 Earthing connector
ZPROM060 gasket tape
ZPROM3216 Windows XP english
ZPROM2200 Keepener for ribbon cables
ZPROM3220 cable ties
ZPROM2505 fuse 6.3A
ZPROM2505 fuse 10 A
ZPROM2505 fuse 5A
ZPROM2505 fuse 500mA
ZPROM2505 fuse 200 mA
ZPROM2505 fuse 2,5A
ZPROM3244 RJ45 Mounting for Ethernet cable
ZPROM3245 Locking piece for RJ45 mounting
ZPROM3295 Snap in Ferrite Sleeve

32
Replacement Parts

Part
Number Description
ZPROM2802 to dac cable DJ1 from back wall interface card
ZPROM2886 from dac cable DJ6 to AC-amplifier interface board
ZPROM2804 jx6 cable
ZPROM2800 rs232 cable
ZPROMxxxx serial cable
ZPROM2890 encoder cable to AC-amplifier interface board
ZPROM2883 Keyboard cable (from ITX board)
ZPROM2882 Mouse cable (from ITX board)
ZPROM2888 AC Servo Power Cable (2axis)
ZPROM2889 AC Servo DC Bus Cable
ZPROM2887 IO Cable to AC-amplifier
ZPROM2891 AC Servo RS232 Cable
ZPROM2893 AC Servo Motion Cable to back wall intrface board
ZPROM2807 PC-INT inputs cable
ZPROM2808 switches cable
ZPROM2813 monograph cable 3 pole line connector
ZPROM2810 PC-INT outputs cable
ZPROM2824 0-8vac cable 2 pole line connector
ZPROM2818 0-50vac cable 2 pole line connector
ZPROM2826 0-19vac cable 2 pole line connector
ZPROM2820 12-0-12vac cable 3 pole line connector
ZPROM2821 trafo cable 2 pole line connector
ZPROM2823 12012 jump wire
ZPROM2816 em switch cable 4 pole line connector
ZPROM2819 main sw cable 3 pole line connector
ZPROM2822 power inlet cable 2 pole line connector
ZPROM2828 backside PE wire
ZPROM2827 door PE wire
ZPROM2835 ethernet RJ45 cable
ZPROM2829 para2 cable
ZPROM2809 speed pot. cable
ZPROM2834 gh01 inverter cable
ZPROMxxxx 2 cpu

33
 Optional Features

SECTION 8
OPTIONAL FEATURES

8.1 TORCH LIFTING OPTIONS 8.2 CUTTING SYSTEMS

The Monograph Millennium is available with a
high-speed model "H" motorized torch lifter or a
pneumatic floating head. The motorized torch
lifter version comes with initial height sensing
and utilizes an Innerlogic ATC for arc voltage
feed back position control. The pneumatic
floating head version is recommended for light
gauge only applications.
Cutting systems that are supported on the
Monograph Millennium include the Hypertherm
Powermax 1000, 1250 and 1650 plasma cutting
systems. These systems support production
cutting of 3/8" mild steel with limited cutting of
5/8" plate.

34
 APPENDIX A
MONOGRAPH MILLENNIUM /CUTTER II

List of Terms and Abbreviations

Abbreviation Term

AC Alternating Current
amp(s) Ampere(s)
BTU British Thermal Units
ccw Counter-Clockwise
CGA Compressed Gas Association
CSA Canadian Standards Association
cw Clockwise
dia. Diameter
DVM Digital Volt Meter
E-Stop Emergency Stop
HHCS Hex Head Cap Screw
Hz Hertz
in Inches
INC. Incorporated
ipm Inches per Minute
kPa Kilopascals
L/H Left Hand
M Meter
MFD Microfarad
mm Millimeter
NC Normally Closed
NEC National Electric Code
No. Number
NO Normally Open
NPT National Pipe Thread
oxy Oxygen
oz Ounces
PLC Programmable Logic Controller
psi Pounds Per Square Inch
PWM Pulse Width Modulator
Recpt Receptacle
R/H Right Hand
SO# Sales Order Number
TP Test Point
vdc Volts direct current
“ Inches
--F Female
--M Male

A-1
Page left intentionally blank
 APPENDIX F

PLASMA OPERATION

GENERAL PLASMA CUTTING INFORMATION

Prior to cutting with plasma, you must have the gas settings for the plate thickness,
arc voltage, current, speed settings in the CNC set correctly.

WARNING
Ensure all safety precautions and warnings are adhered to. All plasma cutting
radiates high levels of light and noise.

SINGLE PLASMA

Single plasma operation starts by selecting plasma one (1) on the operators’ control
unit. The button selected enables all functions for the plasma station. This includes
start, torch height control and machine motion. Machine motion is a signal generated
from the plasma system when the main arc from the plasma system starts. The
signals, plasma START and torch height control are signals generated from the CNC
to the PLC and controlled from the parameters for plasma setups. The CNC must be
set for plasma cutting with the correct settings for the plasma type and height control
used. The signals to plasma start and height control and from the plasma to the
machine go through the PLC for the selected plasma. Selecting start from the CNC
starts the cutting process.

F-1
Page left intentionally blank
 APPENDIX L
Hypertherm Automation
5 Technology Drive, Suite 300
W. Lebanon, NH 03784 USA
Phone: 603-298-7970
Fax: 603-298-7977

Automation

Hypertherm Sensor™ PHC

Plasma Height Control
On KAR MONOGRAPH
MILLENNIUM
Operation & Set Up Guide

Making people and machines more productive through process Automation

L-1
DISCLAIMER The information in this document is subject to change without notice and
should not be construed as a commitment by Hypertherm Automation®.
Hypertherm Automation® assumes no responsibility for any errors that may
appear.

TRADEMARKS Hypertherm Automation is a wholly owned subsidiary of Hypertherm®, Inc.

Sensor™ is a trademark of Hypertherm Automation.
HyDefinition® Plasma is a reg. trademark of Hypertherm®, Inc.
HyPerformance™ Plasma is a trademark of Hypertherm Automation.
Other trademarks are properties of their respective owners.

COPYRIGHT ©2006 by Hypertherm Automation. All rights Reserved

Printed in USA

L-2
SAFETY.......................................................................................................................................... 5

SECTION 1: OVERVIEW ............................................................................................................. 6

Features ...................................................................................................................................................... 7
System Specifications*................................................................................................................................ 8
Connections................................................................................................................................................. 9
PHC to CNC Signals ............................................................................................................................. 10
PHC to Plasma Signals ......................................................................................................................... 10
PHC to Lifter Signals ............................................................................................................................ 10
Sensor™ PHC Front Panel Indicators .................................................................................................. 11
Sensor™ PHC Front Panel Controls..................................................................................................... 11
Control Module (9984-1000-01) ................................................................................................................ 12
Plasma Interface Assembly (9984-1000-03).............................................................................................. 13
Standard Lifter Assembly......................................................................................................................... 14
SECTION 2: INSTALLATION AND SETUP............................................................................ 15
Standard components ............................................................................................................................... 15
PHC Control Module ............................................................................................................................. 15
Optional components ................................................................................................................................ 15
Claims ....................................................................................................................................................... 15
Claims for damage during shipment..................................................................................................... 15
Claims for defective or missing merchandise........................................................................................ 15
Power Requirements................................................................................................................................. 16
Control Unit Mounting (9984-1000-01) .................................................................................................... 17
Control Unit Mounting from Rear......................................................................................................... 17
Control Unit Mounting from Front ....................................................................................................... 18
Plasma Interface Assembly Mounting (9984-1000-03) ............................................................................. 19
Lifter Interface and Enclosure (9984-1000-01)......................................................................................... 20
Torch Breakaway Assembly (Optional) .................................................................................................... 21
(0868-9146-01) .......................................................................................................................................... 21
Grounding Requirements ......................................................................................................................... 23
Grounding Requirements ......................................................................................................................... 23
PHC Interface Signals .............................................................................................................................. 24
CNC Interface Signals .............................................................................................................................. 25
CNC Signal Descriptions .......................................................................................................................... 25
Cycle Start............................................................................................................................................. 25
Auto Disable / Corner Hold ................................................................................................................... 25
IHS Sync................................................................................................................................................ 26
IHS Complete ........................................................................................................................................ 26
Motion ................................................................................................................................................... 26
Retract Complete................................................................................................................................... 26
Error ...................................................................................................................................................... 26
Interlock ................................................................................................................................................ 26
Plasma Interface Signals .......................................................................................................................... 28
Hold Ignition ......................................................................................................................................... 30
Transfer ................................................................................................................................................. 30
Lifter Interface Signals............................................................................................................................. 31
Lower Limit Switch ............................................................................................................................... 31
Upper Limit Switch............................................................................................................................... 31
Breakaway Switch................................................................................................................................. 31

L-3
 Lifter Power Connections ......................................................................................................................... 32
Motor Power .......................................................................................................................................... 32
Lifter Brake........................................................................................................................................... 32
DIP Switch Setup...................................................................................................................................... 33
Switch Settings...................................................................................................................................... 33
Calibration Pot Setup ............................................................................................................................... 37
ARC - Arc Voltage Calibration .............................................................................................................. 37
KERF - Auto Kerf Detection Level........................................................................................................ 37
STALL - IHS Stall Sensing Level.......................................................................................................... 37
SECTION 3: OPERATION ......................................................................................................... 38
Automatic Operation ................................................................................................................................ 39
Set Arc Voltage...................................................................................................................................... 39
Set IHS Retract or Pierce Height .......................................................................................................... 39
Set Pierce Delay Time ........................................................................................................................... 39
Manual Operation..................................................................................................................................... 40
Manual Jog............................................................................................................................................ 40
Slow Manual Motion ............................................................................................................................. 40
Fast Manual Motion.............................................................................................................................. 40
SECTION 4: TROUBLESHOOTING ........................................................................................ 41
Error Indications ...................................................................................................................................... 41
E.01 CYCLE_START at power up Error............................................................................................... 41
E.02 Plate Contact at Home Error ........................................................................................................ 41
E.03 Lifter Timeout Error ..................................................................................................................... 42
E.04 Limit Reached during Auto Operation ......................................................................................... 42
E.05 IHS SYNC Timeout....................................................................................................................... 42
E.06 Transfer Timeout Error ................................................................................................................ 42
E.07 Lost Plasma Arc Error .................................................................................................................. 42
E.08 Torch Breakaway Error ................................................................................................................ 42
E.09 Low Input Power Error ................................................................................................................. 43
E.10 High Input Voltage Error.............................................................................................................. 43
E.11 Over Temperature Error............................................................................................................... 43
E.12 Interlock Tripped Error ................................................................................................................ 43
E.13 Excess Plate Contact Error ........................................................................................................... 43
E.99 Internal Software Error ................................................................................................................ 43
Troubleshooting Guide.............................................................................................................................. 44

L-4
Safety
Read This Manual
Read and understand this instructional manual, the cutting machine manuals, and your employer’s
safety practices. Note: This product is not designed to be field serviceable. Please return to an
authorized repair center for any required service.

Dangerous Machinery

Operation and maintenance of automated equipment involves potential hazards. Personnel should
take precautions to avoid injury.

Injury and entanglement may occur if hands and limbs come in contact with moving machinery.

KEEP HANDS CLEAR of dangerous moving machinery. All control, including manual, can be
affected using the remote interface

Loose fitting clothing or ties may become entangled in the machinery. These items should not be
worn while operating or servicing the machine.

High Voltages

Electric shock can kill. Be sure this equipment is safely installed in accordance with the enclosed
procedures and specifications.

Avoid contact with electrical wires and cabling while power is on.

This equipment should only be opened by trained service personnel.

Please refer to the appropriate appendix in the Installation Guide provided with your control for
details on safety certification for that product.

L-5
Section 1: Overview
Hypertherm’s Sensor™ PHC (SPHC-0001) is an economical plasma torch height control/initial height
sensing (THC/IHS) system designed for conventional plasma cutting applications on an X-Y cutting
table. The system uses the plasma arc voltage to control the physical stand-off (distance) between
the torch and work piece during plasma arc cutting. Initial Height Sense (IHS) is accomplished by
ohmic contact sensing or by a limited force stall detection method. The Sensor™ PHC has been
optimized for conventional plasma at or below 200 amps. The system is not recommended for
HyDefinition® or HyPerformance™ cutting or for higher power applications. The system is not
recommended for use on a water table.

The Sensor™ PHC system includes the following:

THC Control Module

The THC control module (ASSY-0214) houses a microcontroller, an operator control panel, and a
Lifter motor drive. This unit provides initial height sensing, arc voltage control and interfaces with the
torch Lifter, the CNC machine, and the plasma power supply through standard discrete I/O
interfaces. The operator interface includes an LED display for set and actual arc voltage as well as
error codes. The control unit main functions are: arc voltage control/manual position mode, end of
cut retract, IHS test, pierce height, voltage controlled cut height, pierce delay; and access to setup
and calibration adjustments. See Figure 2, Page 7.

Plasma Interface Assembly

The plasma interface (ASSY-0215) provides a clean standardized connection between the PHC
control module and the plasma power supply. The assembly can be mounted either to the back of or
internal to the plasma power supply. The voltage divider provides a filtered low voltage signal which
is derived from the cutting arc voltage. The interface also provides an enclosed terminal block for
easy connection to the interface signals. This interface assembly is not required on the newer (G3)
Powermax® supplies since it is built-in to the supply. A Sensor™ PHC to Powermax® interface cable
is all that is required. See Figure 3, Page 8.

Lifter Assembly
The torch lifter station (ASSY-0224), under control of the PHC control module, positions a torch head
vertically above the work piece. Its maximum stroke is 6 inches (152 mm) between the home and
lower limit. It is driven by a DC motor attached to a leadscrew. The control will interface to an
optional lower limit switch to detect maximum travel in the downward direction. The control will also
interface to an optional home switch to detect when the lifter is in the uppermost position. The
standard lifter does not use limit switches but has been designed to allow for hard stop limit
detection. A power-off brake disables power off motion of the torch. A torch breakaway is an
integral part of the lifter and provides a level of protection for the torch, lifter and X-Y table. Upon
impact, the breakaway releases from the locked position and allows the torch to float. A breakaway
switch detects when this protection has tripped and signals both the PHC control and the CNC
machine. See Figure 4, Page 14.

L-6
 Features
Sensor™ PHC Plasma Height Control is an advanced and economical automated height control
system for plasma shape cutting applications. This product utilizes advanced microprocessor
technology to automatically detect the plate and adjust torch position to a desired arc voltage set
point during plasma cutting operations. This reduces operator input, improves accuracy and
increases productivity. The design of the Sensor™ PHC has been optimized for lower power
conventional plasma operation.

Features
 Sensor™ PHC can be used with any CNC
 Easy setup & operation
 Both manual & automatic operation modes
 Microprocessor control for increased sensitivity and control
 High positioning speeds possible with up to 6 amps continuous current and linear
adjustment over full range
 Built-in Torch Breakaway protection
 Built-in diagnostic and fault detection features
 Auto retract on plate contact
 7 Segment LED display for set/actual arc voltage & error displays
 Power On Indicator
 Upper Limit Indicator
 Lower Limit Indicator
 In Position Indicator
 Attention / Error Indicator
 Torch Position Hold Indicator
 Plate Contact Indicator

Options
 Interface Cables
 Torch Mounting Clamps -1 3/8 ”, 1 3/4” and 2” diameters available.

L-7
 System Specifications*

Compatible Motors: DC PM 24Vdc, 2 Amps to 6 Amps

Max Power Output: 150W
Standard Lifter Range: Linear 5” (152mm)
Motor Output: Full “H” bridge PWM with current & voltage sensing
Accuracy: 0.01” (.25mm ) or 0.5 Volt **
Voltage Control Range: 50 Vdc to 210 Vdc
IHS Range: 0.05 inches (1.2 mm) to 0.5 inches (12 mm) **
Operator Controls: Arc Voltage, IHS Height, & Pierce Delay control knobs
Operator Switches: IHS Test, Auto / Manual, & Manual Up / Down
Operator Display: 3 digit 7 segment display for Set Volts, Actual Volts, & Error
Calibration Adjustments: Arc Voltage, Stall Force, Auto Kerf Detect Level
Setup DIP Switches: Max Motor Current, Arc Voltage Response, IHS Speed, Auto
Delay, Int/Ext Pierce Delay, End of Cut Retract Height, Auto
Kerf Detect, Preflow during IHS, Limit Switches, Breakaway
Switch, Arc Voltage Calibration
Measuring Technology: Arc Voltage Feedback & Ohmic contact sensing
Interface Inputs/ Outputs: 8 outputs and 6 inputs optically isolated on “D” connectors
Control Dimensions: 6.2”(157mm)W x 4.3”(1.9mm)D x 10.4”(264mm)H
Control Weight: 9 lbs
Control Power: 115VAC 0r 230VAC +/- 10% 50/60 Hz – switch selectable
Standard Lifter 6”(152mm)W x 3.15”(80mm)D x 21.5”(546mm) **
Dimensions:
Standard Lifter Weight: 19 lbs **
Operating Environment: 0 to 50C; 95% relative humidity (non-condensing)

*Information subject to change without notice.

** With Standard supplied lifter mechanics

L-8
 Connections
All connections to the Sensor™ PHC are made through four connectors on the bottom of the control
unit. See figure below.

Lifter Signal Computer

Connections Controller I/O

Input Power
115/230 Vac Plasma
System I/O

Ground

Figure 1: Connections
Fuse and Voltage Lifter Motor &
Selector w/ switch Brake Power

WARNING! For safety and proper operation this unit must be connected to ground

L-9
PHC to CNC Signals
All signals to the CNC are connected through the 25 pin D-sub connector on the control unit. For
detailed interfacing information, refer to the sections on PHC Interface Signals and CNC Interface
Signals.

Outputs to CNC:
Digital IHS Complete Output
Digital Motion Output
Digital Retract Complete Output
Digital Error Output

Inputs from CNC:

Digital Cycle Start Input
Digital Corner Hold Input
Digital IHS Sync Input
Interlock

PHC to Plasma Signals

All signals to the plasma interface are connected through the 15 pin D-sub connector on the control
unit. These signals are easily connected through the Plasma Interface Unit or directly to a
Powermax® G3 supply using a G3 Interface Cable. For more detailed information, refer to the
section on Plasma Interface.

Outputs to Plasma:
Digital Plasma Start Output
Digital Hold Ignition Output

Inputs from Plasma:

Digital Transfer Input
Analog Attenuated Arc Voltage

PHC to Lifter Signals

All signals to the lifter are connected through the 9 pin D-Sub connector on the control unit. For more
detailed information refer to the section on lifter Interface.

Inputs from Lifter:

Digital Upper Limit Switch
Digital Lower Limit Switch
Digital Breakaway Switch
Analog Tip Touch Sense

PHC to Lifter Power Connections

All power connections to the lifter are coupled through the 7 pin circular connector on the control unit.
For more detailed information, refer to the section on lifter Interface.

Outputs to Lifter:
Motor Drive 24V PWM
Power Off Brake 24Vdc

L-10
Sensor™ PHC Front Panel Indicators
Green Power
Yellow Upper Limit
Green In Position
Yellow Lower Limit
Red Attention / Error Code
Yellow Corner / Kerf Hold
Red Plate Contact
Red 3 digit Set / Actual Arc Voltage – Error Number – Set Pierce Height & Delay

Sensor™ PHC Front Panel Controls

Multiturn Rotary Pot Set Arc Voltage
Rotary Pot Pierce Height Retract
Rotary Pot Pierce Delay Time
Momentary Toggle Sw IHS Test
Toggle Sw Auto / Manual
Momentary 3 pos Toggle Manual Up / Down

L-11
 Control Module (9984-1000-01)
Electrical
Input Power (switch selected dual range)................................ 115 VAC or 230 VAC, 1 Phase,
50/60 Hz
Parallel Digital I/O ................................................................... + 12 Vdc
Motor Drive Output Voltage ………………………..................... 24 Vdc
Motor Drive Output Current ………………………..................... 2,3,4,6 Amps Max DIP Switch
Selectable
Motor Brake Output ………………………………...................... +24 Vdc ½ Amp

Torch Position
Hold
Power

Display Actual /
Set Arc Voltage
Upper Limit & Errors

Voltage In Plate Contact LED

Control

Set Arc Voltage

Lower Limit

Error

Set Pierce
Delay Time
Set IHS
Height

IHS Test
Manual Up /
Down
Manual / Auto

Calibration
and Setup

Figure 2: Control Module

L-12
 Plasma Interface Assembly (9984-1000-03)

Electrical
Parallel Digital I/O.....................................................................+12 Vdc to +24 Vdc
Interface Signals……………………………………...................Plasma Start, Hold Ignition, Transfer
Voltage divider function............................................................Arc Voltage (attenuated and filtered)

Plasma Interface
Signals

Electrode Voltage
(Negative)

Work Connection
(Positive Ground)

Figure 3: Plasma Interface (Cover Removed)

L-13
 Standard Lifter Assembly(0868-9140-02)

Electrical
Motor ..............................................................................+ 24 Vdc, 3 Amps
Motor Brake ……………………………………… .............+ 24 Vdc ½ Amp
Limit Switches..................................................................not used – hard stop limit detection
Breakaway Switch ……..……………………………..........+ 12 Vdc Proximity

Lifter Control Function

Motor Drive.......................................................................DC full bridge, PWM chopped current source
Lifter Speed Feedback.....................................................Motor Voltage
Maximum Lifter Speed......................................................200 Inches (508 cm) per minute
Maximum Lifter Stroke......................................................6- Inches (152 mm)

Torch Lift Motor

9984-0405-00

Figure 4: Lifter Assembly

L-14
Section 2: Installation and Setup
Upon receipt, the PHC system should include the following standard and optional components, if
ordered:

Standard components
PHC Control Module
Power cord - 6.5 ft./2 m
Lifter assembly with torch breakaway
Plasma Interface Assembly
Interface cables
 Lifter motor drive cable
 Lifter Interface cable
 Plasma Interface Cable
 Ohmic contact wire
 CNC Interface cable
Sensor™ PHC system instruction manual

Optional components

Interface Cables
Torch Mounting Clamps -1 3/8 ”, 1 3/4” and 2” diameters available.

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, please
contact your Hypertherm Customer Service agent.

Claims for defective or missing merchandise

If any of the merchandise is defective or missing, call your authorized Hypertherm distributor. If you
need additional assistance, please contact your Hypertherm Customer Service agent.

L-15
Power Requirements
The PHC can be connected to either 115 Vac or 230 Vac 50/60 Hz. Depending on the input voltage,
Slow Blow fuses of the correct size should be installed. For 115 Vac, install a 2 Amp fuse and for
230 Vac, a 1 Amp fuse should be used. The power input voltage is selected by installing the fuse
block into the power input module so that the correct voltage is displayed through the power input
module window. Refer to Figure 5 for input voltage selection.

If the line cord plug is removed and the unit is directly wired then the connections should be made as
follows.
 Blue Wire AC Neutral
 Brown Wire AC Hot
 Green Wire ground-chassis

WARNING!
Configure for the correct
input voltage. 115V or
230V should be
displayed in the window.

Figure 5: Power Connection and Fuse

L-16
Control Unit Mounting (9984-1000-01)
Before interconnecting the PHC system, mount the units as required, using customer-supplied
hardware. Do not allow the units to lie unsecured on top of cabinets or on the floor. The control units
can be mounted from either the rear or the front as shown in Figure 6 and Figure 7.

Control Unit Mounting from Rear

Mount the PHC Control Unit close to the machine operator console for easy access to the operator
panel. The unit should be mounted to provide easy access and visibility to the PHC controls and
display. There are four mounting holes for #10-32 inch or M4 mm fasteners.

NOTE: For reliable operation the ground must be connected.

Figure 6: Control Unit Rear Mounting

L-17
Control Unit Mounting from Front
Mount the PHC Control Unit close to the machine operator console for easy access to the operator
panel. The unit should be mounted to provide easy access and visibility to the PHC controls and
display. There are six mounting holes available.

NOTE: For reliable operation the ground must be connected.

WARNING!
Connect Ground Here

Figure 7: Control Unit Front Mounting

L-18
Plasma Interface Assembly Mounting (9984-1000-03)
Mount the plasma interface assembly close to the plasma power supply for easy connection of arc
voltage and signal wires between the units. The unit can be mounted in any position and can be
mounted directly to the back or inside of the power supply. The mounting holes are sized for #6 or
M3 fasteners. See Figure 8.

NOTE: For reliable operation the ground terminal must be connected to the plasma
power supply positive ground. This connection provides the grounded positive arc voltage
sense point.

WARNING!
Connect to WORK
(positive ground)

Figure 8: Plasma Interface Mounting

L-19
 Lifter Interface and Enclosure (9984-1000-01)
Optional Safety
Mount

Plasma Torch Cap

Lifter
Interface Plug

Figure 9: Interface

L-20
Torch Breakaway Assembly (Optional)

(0868-9146-01)

The torch breakaway prevents damage to the plasma torch. The breakaway is pneumatically
operated with a normally closed internal electronic switch. When a collision occurs between an object
and the torch the normally closed switch is opened and the CNC controller goes into a stop condition
protecting the torch. When the collision is fixed the breakaway is self-resetting.

Figure 10: Torch Breakaway

L-21
 Connection Diagram
Install system cables as shown in Figure 12. All cables should be properly shielded with shield
connections at both ends of the cables. If possible, route all PHC cables away from high power
plasma cables. If both the plasma high power and PHC cables must share a cable track, it is
recommended that they are separated as much as possible in the cable track. For reliable operation,
all grounds must be connected to machine grounds as directly as possible.

Figure 11: PHC Connection Diagram

L-22
Grounding Requirements

WARNING!
To ensure personal safety, proper operation and to reduce electromagnetic interference (EMI), the
PHC system must be properly grounded.

Power cord grounding

The PHC control module must be properly grounded through the power cord according to national or
local electrical codes.

Protective earth ground

Install protective earth (PE) grounding cables to the (3) PHC components (lifter, plasma interface,
control unit) as shown in Figure 13. Grounding must comply with national or local electrical
requirements.

Note: The PE (Ground) cables must be supplied by the customer.

Figure 12: System Grounding

L-23
PHC Interface Signals
Most of the PHC interface signals are through optoisolators. Figure 14 below shows the details of
connecting the IO to external switches, relays, transistors, and other circuitry. The figure shows
examples using both the internally available isolated +12V source and using an external voltage
source. Do not use an external voltage higher than +24V with inputs without adding some additional
series resistance. Note: The “Plasma Start” Output to the plasma power supply is a relay dry contact
closure.

WARNING!
Do not exceed 24V or 30mA in or out of any optoisolator. Use care to observe correct signal polarity
or damage may occur!

Example Inputs Sensor PHC Internal Circuitry Example Outputs

External Circuitry Inputs Outputs External Circuitry

Use Internal PHC +12V Supply +12V Field Use Internal PHC +12V Supply
+12V Field
SWITCH +OUT RESISTOR LED
3300 -OUT
+IN
-IN

Use External +24V Supply

Use External +24V Supply
+
+OUT 24V
3300 -OUT
+IN
-IN RESISTOR

GND_External
OPTO ISOLATOR
+ OPTO ISOLATOR
24V GND_External

Use External +24V Supply Use External +24V Supply

3300 +OUT
+IN -OUT
-IN +
+ 24V
24V
RELAY DIODE
RELAY

GND_External GND_External

Figure 13: General Interfacing Examples

L-24
CNC Interface Signals
CNC Interface Signals 25 pin D-Sub Connector

Name Pair ~ Pin #s (wire color) Signal Type

Cycle Start Pos 11 (RED) ~ Neg 23 (BLU) Isolator Input

Auto Disable / Corner
Pos 10 (RED) ~ Neg 22 (GRN) Isolator Input
Hold
IHS Sync Pos 9 (RED) ~ Neg 21 (WHT) Isolator Input

IHS Complete Pos 18 (BLK) ~ Neg 5 (YEL) Isolator Output

Motion Pos 17 (BLK) ~ Neg 4 (BLU) Isolator Output

Retract Complete Pos 16 (BLK) ~ Neg 3 (GRN) Isolator Output

Error Pos 15 (BLK) ~ Neg 2 (WHT) Isolator Output

Isolator & Relay
Interlock Pos 14 (BLK) ~ Neg 1 (RED)
coil
12 (RED) ~ 24 (YEL) Field Power
Field +12V
13 (YEL) ~ 25(BRN) Output
6 (BRN) ~ 19 (BLK), Field Power
Field Common
8 (BLK) ~ 20 (ORG) Common
Note: All required signals are shown in bold. All other signals are optional for multiple torch
operation, improved performance, or reduction in cycle times.

WARNING:
Observe optoisolator signal polarities or control unit damage may result.

CNC Signal Descriptions

Use a customer supplied mating 25 Pin “D” connector or cut off the unused connector and wire
directly to the appropriate signals.

Cycle Start
This signal is an output from the CNC and an input to the PHC. The CNC should activate this signal
to begin the Initial Height Sensing and start a plasma cut.

Auto Disable / Corner Hold

This output from the CNC should be activated to turn off the automatic voltage control and freeze the
position of the torch. This signal is usually issued to prevent diving in corners. The use of this signal
is optional and will improve performance if used. This signal is required if the PHC Pierce Delay has
been disabled and the CNC will be controlling the “Pierce Delay Time”. In this case, the “Auto
Disable” should be asserted during the “Pierce Delay Time” as well as the subsequent “Accel Delay”
to allow machine motion to reach steady-state cutting speed.

L-25
IHS Sync
This optional CNC output is used to synchronize torches in a multiple torch installation. For single
torch installations, this signal is not required and can be left unconnected. The CNC should issue
this signal to delay plasma torch ignition until all torches in a multiple torch configuration have
completed their IHS sequence and are in position and ready to fire. When the CNC releases (de-
activates) this signal, the torch will ignite and the plasma torch will begin piercing.

IHS Complete
This optional signal is an output from the PHC and an input to the CNC. This signal is used to
indicate that the Initial Height Sensing is complete and that a torch is in position and ready to fire.
For multiple torch installations, the CNC should wait for all active torches to indicate IHS COMPLETE
before simultaneously releasing all IHS SYNC signals to all allow the torches to ignite. For single
torch installations, this signal is not required.

Motion
This signal is an output from the PHC and an input to the CNC. The signal is issued after plasma
ignition and the PHC set Pierce Delay Time. It indicates to the CNC that the pierce delay is complete
and the cut motion should begin. If the CNC will perform all pierce delay timing, then the
EXT_PIERCE_DELAY - DIP switch on the PHC should be turned ON. This will force the PHC
pierce delay to be zero and disable the front panel Pierce Delay control. If the CNC is controlling the
pierce delay then it is the CNC’s responsibility to use the AUTO_DISABLE / HOLD signal to hold off
the arc voltage control until the Pierce and Accel Times have elapsed.

Retract Complete
This signal is an output from the PHC that is active when a cut has been completed and the torch
has been retracted to the selected retract height. The CNC can use this signal to delay rapid transit
to the next cut until the torch has been raised and will safely clear any tip-ups. The use of this signal
is optional.

Error
This signal is output by the PHC for any errors. The actual error number will be displayed on the
PHC front panel LED display.

Interlock
This is a normally closed contact closure provided by the CNC to allow PHC motion. If this contact is
opened, the PHC motor drive will be de-energized. JUMPER IF NOT USED

L-26
 CNC I/O Sensor PHC I/O
11 + 3300
OPTO

Start Input
23
RELAY
Start Output

17 + OPTO

Motion Input Motion Output

4

OPTO
+
+24V

+12V
14 +
jumper if Interlock
not used 1

RELAY
Interlock Output RELAY

25 Pin D Sub
Note: If required +12Vdc at 100mA is available on Sensor PHC connector pins 12, 13, 24, 25.
The +12V common is on pins 6, 8, 19, 20.

Figure 15: Basic CNC Interface

L-27
Plasma Interface Signals
These signals can be directly connected to Powermax® G3 plasma supplies equipped with an
internal voltage divider using the standard PHC to G3 cable. Alternately, these signals can be
connected using the Sensor™ PHC Plasma Interface. The Plasma Interface (ASSY-0215) includes
the arc voltage divider and provides terminal connections for all signals including the negative
Electrode arc voltage sense and the positive Work / chassis ground connection. See Figure 16.

Plasma Interface Signals

15-pin-D-Sub
Name Plasma Interface Signal Type
Connector Pin #s
Plasma Start 2, 10 J1-1, J1-2 (dry contact) Relay Contact Output

Hold Ignition Pos 3 Neg 11 J1-4 (+), J1-5 (-) Isolator Output

Transfer Pos 4 Neg 12 J3-1 (+), J3-2 (-) Isolator Input

Arc Voltage Pos 8 Neg 15 Gnd Stud (+), Term (-) Attenuated Filtered Analog

Field +12V 1, 9 J1-3 Field Power Output

Field Common 5, 6, 7, 13, 14 J3-3 Field Power Common

Start-

Start + PowerMax
G3 Series
1 1
15 D-Sub 2 2
3 3
4 4 J19
J1 J3 5 5 WHT
6 6 1
1 5 7 7 RED
PowerMax rear panel 2
2 4 8 8 YEL
Machine Interface Connection 9 9 3
3 3 Xfer- 10 10
4 2 11 11 4
Xfer+ 12 12 5 +24Vdc
5 1 13 13 BLK
14 14 6 Com

Note: re-wire XFER to source +24V.

Positive Ground Move BLK wire from pin-4 to pin-6
and add jumper wire as shown.
Arc Voltage Access
Strain Relief Work (pos GND)
J15
Arc Volts (neg)

Sensor PHC Electrode (neg)

Plasma Interface J16

Figure 16: PowerMax Connections using Plasma Interface Unit

L-28
Start Output +12V Output Hold Output +
(contact closure) 50mA Max Hold Output -
Common for
12V Output

Signals
Enter Here

High Voltage
Enter Here

-Transfer Input

+Transfer Input

Work Connection
(positive ground)

Connect Negative
Electrode Voltage
Here.

Figure 17: Plasma Interface

WARNING! For safety and proper operation this unit must be connected to positive ground.

L-29
 Sensor PHC Plasma External Plasma Supply
Interface I/O (using External +24V)
+24V External
PLASMA START (+24V)
RELAY
J1 HOLD
1
IGNITION
STR
2 STR
+12V Field 3
4 HLD+ DIODE RELAY 24V coil
5 HLD-
OPTO GND_External

J3
1 XFR+
2 XFR-
OPTO 3300 3 TRANSFER
4
5 RELAY
GND_External

1 Electrode (Neg) Electrode (Neg)

2

Work
Positive Ground

Figure 18: Plasma Interface Connections

WARNING:
Observe signal polarities when connecting to optocouplers. Do not exceed 24Vdc on any signal
lines. Do not exceed 30mA current from any input or output. Do not exceed 50mA total current
drawn from Sensor™ internal +12V field supply. Failure to observe these warnings could damage
the unit.

Plasma Start
This signal is a relay contact output from the PHC and an input the Plasma Power Supply. The PHC
will activate this signal by closing the contact to start the plasma power supply.

Hold Ignition
This output from the PHC and input to the Plasma Power Supply should be activated to delay the
high frequency ignition of mechanized torches. This signal is usually issued to synchronize the
ignition of multiple plasma torches. This signal can also be used to save cycle time by performing
Preflow during IHS. The use of this signal is optional and will improve performance on capable
plasma systems if used. This signal is not used for Contact Start torches installed on Powermax®
Plasma units.

Transfer
This signal is an output from the Plasma Power Supply and an input the PHC. The Plasma Power
Supply will activate this output to signal that arc transfer has occurred.

L-30
Lifter Interface Signals
These signals can be directly connected to a Sensor™ PHC standard lifter using the supplied cable.

Lifter Interface Signals 9 pin D-Sub Connector

Name Pin #s Signal Type

Lower Limit Switch 6 - Switch to Common Isolator Input

Upper Limit Switch 2 - Switch to Common Isolator Input

Torch Breakaway Switch 7 - Switch to Common Isolator Input

Torch Tip Touch Sense 4, 5, 9 Attenuated Filtered Analog

Field +12V 1 Field Power Output

Field Common 3, 8 Field Power Common

Lower Limit Switch

This signal is an output from the lifter and an input to the PHC. The lifter can activate this signal to
indicate that the lifter has reached the upper range of motion. The normally open/closed sense of
this signal can be changed through setup DIP Switch #14. The use of a limit switch is optional. The
PHC standard lifter does not include limit switches and the PHC detects the hard stop limits by
monitoring motor speed.

Upper Limit Switch

This signal is an output from the lifter and an input to the PHC. The lifter can activate this signal to
indicate that the lifter has reached the lower range of motion. The normally open/closed sense of this
signal can be changed through setup DIP Switch #14. The use of a limit switch is optional. The PHC
standard lifter does not include limit switches and the PHC detects the hard stop limits by monitoring
motor speed.

Breakaway Switch
This signal is an output from the lifter and an input to the PHC. The lifter can activate this signal to
indicate that the mechanical torch breakaway has tripped. The normally open/closed sense of this
signal can be changed through setup DIP Switch #15. The use of a torch breakaway switch is
optional.

L-31
Lifter Power Connections
These connections can be made directly to a Sensor™ PHC standard lifter using the supplied cable.

Lifter Power Connections 7 pin Circular Connector

Name Pin #s Signal Type

Motor Power – Up Direction Positive 1 Negative 2 PWM H Bridge Output

Lifter Brake Positive 4 Negative 5 +24Vdc Output

Chassis Ground 6

Motor Power
This signal is an output from the PHC. It is output from a PWM controlled “H” bridge motor drive.
The maximum current level can be set using DIP switches #1 and #2. This output is intended to
drive a 24Vdc permanent magnet motor.

Lifter Brake
This output from the PHC is a 24Vdc signal to an electromagnetic brake. When this signal is
energized, the brake is released to allow lifter motion.

L-32
 DIP Switch Setup

SW1 SW8

Arc Voltage
Calibrate

SW ON
Auto Kerf
Detect Level
SW OFF

Stall Force
Level

Figure 19: Setup DIP Switches

SW16
SW9

Switch Settings
Switch settings for control module operation and setup outlined below. Note*: Default switch
settings (as shipped) are indicated in BOLD text.

As shown in the figure above, the Setup DIP Switches are divided into two groups of eight switches.
The top set of switches is numbered SW1 through SW8 and the bottom set of switches is numbered
SW9 through SW16.

SW1 SW2 Maximum Motor Current / Power

on on Max Current = 2 Amps, 50 Watts
on off Max Current = 3 Amps, 75 Watts *
off on Max Current = 4 Amps, 100 Watts
off off Max Current = 6 Amps, 150 Watts

Set DIP switches SW1 and SW2 to the rated current of the lifter motor. This is the maximum current
that will be applied and is directly related to the motor power rating. This setting is also used to
determine the minimum applied current for stall sensing and to calculate the motor speed based on
the measured motor voltage.

NOTE: For optimum performance it is important that these switches are set correctly. For the
standard lifter, these switches should be set for 3 Amps

L-33
SW3 SW4 Voltage Control Response / Gain
on on Gain = Low = +/- 4V In Position Range
on off Gain = Med Low = +/- 2V In Position Range *
off on Gain = Med High = +/- 1V In Position Range
off off Gain = High = +/- 0.5V In Position Range

Set DIP switches SW3 and SW4 to select the closed loop voltage control response. The DIP
switches should be set for the highest gain possible that yields an acceptable control response. An
acceptable response should be stable and should have a minimum overshoot. These settings will be
a function of the lifter and motor combination. For faster lifters use a lower gain setting. Faster
settings may require the use of the “Corner Hold” signal from the CNC to prevent diving in the
corners. The control accuracy will be affected by this setting.

SW5 IHS Slow Approach / Retract Speed

off Speed = High = 30% of Max Speed
on Speed = Low = 15% of Max Speed *

The setting of SW5 will affect the speed that is used when the torch is approaching the plate during
an IHS cycle. This set speed will also be used during retract from plate contact to the pierce height
and during the first seconds of low speed manual motion. This setting is a compromise between
positioning accuracy and cycle time. Set a speed that is as fast as possible and still provides the
required IHS range and fine manual motion accuracy.

SW6 Spare – Not Used

SW7 Auto Voltage Control Acceleration Delay

off High – Enable Voltage Control 1.0 Second after Pierce delay
on Low – Enable Voltage Control 0.5 Second after Pierce delay *

The SW7 delay setting is used to allow the cutting machine to accelerate to steady state speed
before starting the closed loop voltage control of torch height. The shorter delay should be used for
most machines. For very large cutting machines, it may be necessary to use the longer delay to
avoid diving into the plate during machine acceleration.

SW8 External Pierce Delay

off Normal – Internal Pierce Delay *
on CNC will control – Front panel Pierce delay disabled

SW8 should be turned ON if the CNC will be used to time the pierce delay. When this switch is ON,
the front panel control for pierce time is disabled and the PHC will use a pierce time of zero. It is now
the responsibility of the CNC to assert the AUTO / CORNER HOLD and wait for the MOTION signal
and then begin timing the Pierce Delay Time. Once the Pierce Time has elapsed, the CNC should
begin the actual cutting machine motion and start to time the Acceleration Delay. Once the
Acceleration Delay time has elapsed, the CNC should remove the AUTO / CORNER HOLD and
allow the PHC to control the torch height.

L-34
SW9 SW10 End of Cut Retract Time
on on Retract = Low = 0.25 Sec @ Max Speed (0.8” std lifter)
on off Retract = Med Low = 0.5 Sec @ Max Speed (1.6” std lifter)*
off on Retract = Med High = 1.0 Sec @ Max Speed (3.3” std lifter)
off off Retract = High = 1.5 Sec @ Max Speed (5.0” std lifter)

SW9 and SW10 control the end of cut retract. This setting should be set as low as possible to
achieve optimum cycle times and still clear worst case tip-ups. The end of cut retract moves at the
maximum lifter speed.

SW11 Automatic Kerf Detect

off Automatic Kerf Detection is disabled *
on Normal – PHC will detect Kerf crossings and auto HOLD

For the Automatic Kerf Detection to operate properly, the Kerf Threshold Pot must be adjusted to the
correct level. The correct level is low enough to trip the Kerf Detection when crossing a Kerf, but
high enough that nuisance trips are avoided during normal cutting. This pot should be adjusted by
viewing the Yellow “Corner / Kerf Hold LED” during a test cut.

SW12 Preflow During IHS

off Normal – Plasma Start and Preflow after IHS – Contact Start Torch *
on Plasma Start and Preflow during IHS with capable plasma systems

Note: This function must be disabled for Powermax® contact start torches.

This function is only used with high frequency start mechanized torches. With mechanized torches,
this function can save cycle time by performing IHS and torch preflow during the same period of time.
When “Preflow During IHS” is active, the “Start” and “Ignition Hold” output signals are applied to the
plasma system during the IHS process. This allows the plasma system to begin the gas preflow
requirement during the same period of time when the PHC lifter is positioning the torch at the correct
Pierce Height. Once the PHC lifter has been positioned at the correct “Pierce Height”, the “Ignition
Hold” output is removed allowing the torch to start and the cutting process to begin.

SW13 Spare – Not Used

SW14 Lifter Limit Switches

off (Sw NO) Close on Limit – or switches not used, lifter hard stops *
on (Sw NC) Open on Limit – Use normally closed lifter inputs

For the standard lifter, limit switches are not used. The PHC senses the lifter upper and lower limits
by sensing when the lifter hard stops at the travel limits.

L-35
SW15 Torch Breakaway Switch
off (Sw NC) Close on Breakaway – or switch not used
on (Sw NO) Open on Breakaway – Use normally open switch input *

For the standard lifter, the torch breakaway uses a normally open proximity switch. When the
breakaway is installed the switch will close and when the breakaway is tripped the switch will open.

SW16 Arc Voltage Calibration Mode

off Normal – Display set arc voltage during Idle state *
on Display Actual Arc Voltage during Idle state for Calibration

For normal operation, this switch should be set to OFF.

This switch is used to display the actual arc voltage on the PHC display. This allows the arc voltage
to be calibrated by adjusting the Arc Voltage adjustment pot. When the calibration mode is active,
the PHC will display “X.X.X.” with the X’s indicating the measured arc voltage and all the decimal
points on to indicate calibration mode.

When calibration mode is active the display can be temporarily overridden by adjusting either the
Kerf Detect Level or the Stall Force. Adjusting either the Kerf Detect or Stall Force will result in a 0 to
10 reference level being temporarily displayed. After one second of inactivity the display will revert
back to the measured arc voltage.

NOTE: The arc voltage calibration procedure should be performed on all new
installations as the actual measured arc voltage accuracy is a combination of the individual
plasma interface and control units.

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Calibration Pot Setup

ARC - Arc Voltage Calibration

This trim pot is used to calibrate the Actual Arc Voltage used for arc voltage control feedback. To
calibrate the arc voltage, place the PHC into the Arc Voltage Calibration Mode by turning ON DIP
switch #16. This will cause the actual arc voltage to display on the 3 digit LED display. The user
can either perform a test cut with a meter connected to the plasma supply output or connect a known
voltage (250 Vdc max.) to the Plasma Interface Arc Voltage terminals (Negative Electrode and
Positive Ground). Adjust the Arc Voltage Pot until the display is equal to the applied voltage on the
meter.

NOTE: For accurate operation, this procedure should be done for all new installations since
the measured arc voltage accuracy is combination of the specific plasma interface and control units.

KERF - Auto Kerf Detection Level

This adjustment pot will set the Auto Kerf Detection level. The Auto Kerf function must be enabled by
turning ON the Automatic Kerf Detect DIP switch #11. When this pot is adjusted with the PHC in
calibration mode, the display will temporarily show a 0 to 10 reference level display. The Auto Kerf
Detection works by looking for a rapid change in the arc voltage. When the pot is adjusted toward
the lower settings, the PHC looks for smaller voltage changes and the Kerf detection is more
sensitive. At higher settings, the Kerf detection is less sensitive. The pot should be set sensitive
enough to reliably detect Kerf crossings but not so sensitive that false nuisance trips occur and
degrade the height control performance. The operation of Auto Kerf Detect can be checked by
monitoring the yellow Hold LED on the PHC front panel during a plasma cut. If the threshold is
properly set, the yellow Hold LED will light whenever a Kerf is crossed. Note that this LED will also
light when an active Auto/Corner input is present on the CNC Interface or when the unit is set for
Manual operation.

STALL - IHS Stall Sensing Level

This adjustment is used to set the Stall force sensing level during Initial Height Sense (IHS). When
this pot is adjusted with the PHC in calibration mode, the display will temporarily show a 0 to 10
reference level display. The stall force is always used as a backup to the ohmic contact sensing.
When it is set to the lower settings, the maximum applied force is lower during IHS. Higher settings
will increase the maximum applied force and if set too high could cause damage to the torch and
consumables or result in the deflection of the work piece or tripping the torch breakaway. This
adjustment should be set as low as possible but high enough so that false stalled plate detects do
not occur in mid air. The adjustment can be checked by executing an IHS Test with the nozzle ohmic
wire disconnected.

L-37
Section 3: Operation
Automated Torch Height Control (THC) Systems used in Mechanized Plasma Cutting are used to
provide the optimum height for the desired metal cutting process. The appropriate cut height is
crucial to the Plasma Process to provide the ability to transfer the Arc to the work piece for piercing /
cutting and for optimum cut quality (bevel angle, etc).

With the Plasma Process there is a direct relationship between the cut voltage and the torch height
(gap between the metal work surface and the torch electrode). By using the automated control to
monitor the working Arc (cut) Voltage, it can then control the Torch Height Control to maintain a
specific voltage set point.

L-38
Automatic Operation
Automatic voltage control operation is selected by placing the lower center toggle switch in the upper
Auto position. In this mode the unit will automatically IHS to the set Pierce Height, Ignite the plasma
torch, wait for the torch to pierce the plate, and begin the cutting machine motion. The basic
Sensor™ PHC auto operation setup consists of three steps. The first step is to adjust the correct Arc
Voltage Set point. The second step is to set and test the correct IHS Retract Height or Pierce Height.
The final step is to set the Pierce Time Delay.

Set up guidelines are outlined below.

Set Arc Voltage

Using the larger multi-turn adjustment, set the desired arc voltage on the display. The starting point
for this voltage should be included in the cut charts supplied with your plasma system. It is important
to remember that this voltage is just a starting point since the actual arc voltage will depend on
consumable wear, torch lead lengths, gas flow rates, and machine motion. For optimal cut quality
you may need to make small adjustments around the nominal arc voltage that is specified in the cut
charts. The important item to control is the torch-tip to work height during a cut. The arc voltage is
just an indirect method to control this height.

Set IHS Retract or Pierce Height

Using the lower left rotary control, set the desired IHS Retract Height. As this control is adjusted the
display will be temporarily overridden with a 0 to 10 reference level. This represents the desired
pierce height. The actual height should be available in the cut charts supplied with the plasma
system. This setting is approximate because it will depend on whether the unit can sense the plate
using ohmic contact or must rely on the backup limited force stall sensing. This setting should be
checked by performing an IHS Test and checking for the correct pierce height. Each time the lower
left IHS Test Switch is pressed, the torch should alternate between the set IHS Height and the end of
cut Retract Height. Continue testing and fine tuning this adjustment until the desired IHS Height is
achieved. If the IHS speed (DIP SW #5) has been set to the normal low speed setting, then the IHS
retract adjustment range should be between about 50 thousandths and 1/2 inch. If the IHS speed
was set to the high speed setting, then the IHS retract adjustment range should be between about
1/10th inch and 1 inch.

Set Pierce Delay Time

Using the lower right rotary control, set the desired pierce time delay. As this control is adjusted the
display will be temporarily overridden with a 0 to 4.0 second delay time. This is the time delay
between igniting the torch and beginning the cut motion. The Pierce Delay is the time required for
the plasma torch to initially cut through the plate. This time delay should be included in the cut charts
provided with your plasma system. To provide more accuracy for the short delay settings, this rotary
control is divided into two ranges. The first range covers the first ½ rotation of the control and will
provide a linear delay between 0 and 1 second. The second ½ rotation provides a linear delay of
between 1 and 4 seconds.

L-39
Manual Operation
Manual lifter operation is selected by placing the lower center toggle switch in the lower Manual
position. In this mode the unit will manually jog or slew slow or fast in the desired direction. If a cut
is started while in the Manual Mode, the torch will move only in response to the front panel manual
move commands. The IHS, Voltage Control, and End-of-Cut Retract functions are all disabled during
Manual Mode.

The three types of manual motion, jog, slow and fast are detailed below.

Manual Jog
When the lower right manual motion switch is momentarily switched into either the Up or Down
position the torch will jog approximately 20 thousandths in the desired direction. Repeated
momentary depression of the switch Up or Down will cause a series of discrete jog motions in the
desired direction. This is useful for fine tuning the torch height in manual mode.

Slow Manual Motion

Continuing to hold the manual motion switch for about ½ second after the jog has completed will
result in slow manual motion in the desired direction. This motion should be at the IHS speed as
determined by DIP SW #5.

Fast Manual Motion

Continuing to hold the manual motion switch for about one second after the start of slow manual
motion will result in fast manual motion. The fast manual motion will continue for as long as the
manual motion switch is depressed.

L-40
Section 4: Troubleshooting
Error Indications

Error Code
Displayed Here

Red Error
LED

Figure 20: Error Indications

The red ERROR LED indicates abnormal conditions. The error code is displayed in the PHC 3 digit
LED display as E.XX where XX represents the error number. The meanings are listed below. Most
errors are cleared by either removing the abnormal condition or with the application of the next
“Cycle Start” from the CNC.

E.01 CYCLE_START at power up Error

This error indicates that the CNC CYCLE_START input was active when the PHC was powered up.
This protects against unintentionally starting the plasma at power up. Deactivate the
CYCLE_START input on the CNC interface to clear the error.

E.02 Plate Contact at Home Error

The error indicates that ohmic contact sensed the work piece when the torch was at the maximum
retract position. This generally indicates that there is a short circuit in either the nozzle connection
wire or the torch consumables. It could also be the result of a coolant leak on a liquid cooled torch.
This error will be cleared on the next CYCLE_START.

L-41
E.03 Lifter Timeout Error
Indicates that lifter motion was commanded but the lifter destination was not sensed within the
timeout period. This error can occur when moving to the HOME position and it is not sensed within
10 seconds or when moving to or from contact with the work piece and it is not sensed within 10
seconds. This error could occur when there is some mechanical problem in the lifter such as the
motor coupling to the lifter mechanics has loosened. Another possible problem could be that the
torch lead set is binding and limiting the lifter motion. This error could also indicate a problem with
the motor wiring, motor drive, or with the motor itself. The error will be reset on the next
CYCLE_START.

E.04 Limit Reached during Auto Operation

This error is caused when the lifter reaches a travel limit during arc voltage controlled operation. It
could indicate that the lifter does not have the range of travel to accommodate the thickness of the
material being cut. If this is the case, the lifter or torch mounting must be adjusted to make more
effective use of the lifter travel range. Another reason for this error could be the mis-operation of
either the limit switches or the limit switch wiring. This error is reset on the next CYCLE_START.

E.05 IHS SYNC Timeout

This error occurs when the torch reaches the IHS pierce position and is waiting for the IHS_SYNC
input from the CNC to be released. If this input is not released within 5 seconds, then this timeout
error will occur. Check the wiring of the IHS_SYNC input and check the CNC programming for this
signal. This error will be reset on the next CYCLE_START. The IHS_SYNC signal is usually used
for multiple torch installations only.

E.06 Transfer Timeout Error

This error indicates that the Plasma torch was fired but that the TRANSFER signal was not received
within 5 seconds. This error could be the result of an actual failure to transfer due to bad
consumables or improper plasma gas settings or bad work piece grounding. It could also be caused
by a faulty IHS sequence that resulted in an improperly high pierce height. Another possibility is that
the TRANSFER signal on the power supply interface is missing or improperly connected to the PHC
Plasma Interface. The next CYCLE_START will reset this error.

E.07 Lost Plasma Arc Error

During operation the plasma torch lost transfer before CYCLE_START was removed. This could be
caused by cutting off the edge of the plate or the result of bad consumables or improper height
control settings. Repeated occurrences of this error can result in excessive consumable wear for
mechanized long-life torches. This excessive wear occurs since the arc is extinguished before the
plasma system can perform a controlled ramp down of the arc. The next CYCLE_START will reset
this error.

E.08 Torch Breakaway Error

This error indicates that the torch breakaway has tripped. It is probably the result of the torch
crashing into the work piece due to tip-ups or improper height control setup. If the torch breakaway
has not tripped, then check the connections from the lifter back to the PHC. If the torch breakaway is
not installed, then turn OFF setup DIP SW #15 to ignore this input. To clear this error reset the torch
breakaway.

L-42
E.09 Low Input Power Error
This error occurs when the PHC input power is 20% below the nominal voltage. This will occur for
115Vac power below 92Vac and for 230Vac power below 184Vac. To reset this error, increase the
input voltage to within the nominal operating range.

E.10 High Input Voltage Error

This error occurs when the PHC input power is 15% above the nominal voltage. This will occur for
115Vac power above 132Vac and for 230Vac power above 264Vac. To reset this error, decrease
the input voltage to within the nominal operating range.

E.11 Over Temperature Error

This error indicates that the motor drive circuitry has experienced an over temperature shutdown.
This may occur if the unit is being operated near the maximum output power for an extended period
of time in high ambient temperature (> 50 deg C) conditions. During normal operation with a
properly, functioning unit this error should not occur. To reset this error allow the unit to cool down.

E.12 Interlock Tripped Error

This error occurs when the External Interlock has been tripped. When this interlock is tripped, the
PHC motor drive is disabled and no lifter motion is possible. To reset this error, ensure that there is
a contact closure across the External Interlock input on the CNC Interface connector.

E.13 Excess Plate Contact Error

During a cut when Ohmic Contact is sensed the lifter will automatically retract until the contact is
broken and arc voltage control resumes. This will cause an error when the torch tip makes excess
contact with the plate during a short period of time. This error could indicate that the voltage set
point is too low or that the consumables have worn requiring an increase in the voltage set point.
The next CYCLE_START will reset this error.

E.99 Internal Software Error

This error indicates that an abnormal, unexpected condition occurred in the software. It occurs
when the software erroneously tries to enter some undefined state or when an internal parameter is
out of range. It is probably the result of either a noise glitch or a software bug. During normal
operation this error should never occur. Please try to record exactly what happened prior to this error
so that it can be reproduced and debugged. This error can only be cleared with a power up reset of
the PHC.

L-43
Troubleshooting Guide

Problem Solution
The Error LED and Error  Note the Error code number and refer to the detailed list of
code are displayed. error indications.

No response to  Check Power Switch on PHC

CYCLE START Input  Check Power Connections
 Check Fuse in Power Entry Module
 Check Cycle Start Connection

Torch Ignites before IHS is  Check that preflow during IHS is disabled – DIP SW #12 Off
complete  If used check plasma Corner Hold Input

No IHS motion  Check that PHC is in Auto Mode

 Check that torch lead set is not binding
 Check that the stall force is not set too low – increase stall
force setup adjustment
Inaccurate IHS using ohmic  Check that PHC is in Auto Mode
contact  Check that Ohmic Contact Wire is connected
 Check that the torch retaining cap is tight
 Check for water on plate. If present disconnect the Ohmic
wire and use stall force only.
 Check for oil or paint coating on plate. If present use stall
force only.
 Check nozzle / shield, clean or replace
 Check work plate connection
Inaccurate IHS using stall  To disable ohmic sensing disconnect the wire from the torch
force tip
 Check that the stall force is set correctly
 Check for excessive plate deflection. Check plate support
 Increase the IHS setting to compensate for plate deflection
Torch fails to ignite  Check that plasma is powered and operational
 Check for proper IHS height
 Check that the IHS SYNC input from the CNC is not active
 Check the torch consumables
Torch fails to Transfer  Check that the Pierce Height is not too high
 Check the work plate connection
 Check the torch consumables
 Check the preflow gas flow rate

L-44
 Problem Solution
Arc extinguishes after  Check that the pierce delay is not too long
Transfer with large pierce  Check that the Machine Motion Output is active and
hole connected to the CNC
 Check that the CNC is active and the set machine speed is
appropriate
Torch begins cutting before  Check that the Pierce Delay is not set too short.
the pierce is complete

Torch dives toward plate  Increase Set Arc Voltage

immediately after voltage  Increase Machine Accel Delay – DIP SW#7 Off
control begins  Check Arc Voltage calibration

Torch retracts from plate  Decrease Set Arc Voltage

immediately after voltage  Increase Set Pierce Height
control begins  Check Arc Voltage calibration
Erratic voltage control  Check all system ground connections
 Check torch for cooling water leaks

Failure to retract at end of  Check End of Cut Retract settings – DIP SW #9 & #10
cut  Check for torch and lead set binding or obstruction

L-45
 Printed in the
USA

L-46