EDGE Connect

Customized shape cutting control

 EDGE Connect ®

Customized shape cutting control

This is the next generation of Hypertherm’s industry leading
automated control systems. It includes Hypertherm’s embedded
cutting expertise combined with cutting machine OEM customizability.
EDGE Connect offers many new software features, enhanced
hardware, and field based system configuration capabilities.

Benefits
• Superior cutting performance and
embedded expertise (Hypertherm®
Phoenix® and SureCut™ technology)
• Convenient operator programming with
SureCut outcomes via ProNest® CNC
• Greater reliability through improved
industrial system hardware
• Optimized machine setup using
EtherCAT communications
• Reduced costs and customization via
a Soft Operator’s Console (Soft OpCon)
and PLC Connect
• Modular, simple and upgradable CNC
ordering and point-of-use configuration
design

Product benefits 2
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SureCut
SureCut™ allows customers to maximize performance through
embedded expertise. It is brought to you via various delivery
mechanisms that include Hypertherm® CAM software, CNCs,
and cutting systems.

Benefits
• Quality
• Productivity
• Operating cost
• Easy setup
• Optimized process parameters
• Easy troubleshooting

Outcomes/Techniques Setup/Diagnosis
True Hole® Easy setup
True Bevel™ Optimized process parameters
Rapid Part™ Easy troubleshooting
Optimized consumable life

SureCut 3
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Phoenix
Embedded expertise with Hypertherm’s® proprietary Phoenix®
CNC software delivers unsurpassed ease of use and consistent
performance for cutting applications. This software is designed
specifically for the X-Y and bevel cutting market and is available
in over fifteen languages for easy operation.

Benefits
• Integrated cut charts, automatic process
parameters and communications to cutting
tool and height control systems for automated
control of the cutting process
• Wizards and diagnostic support tools
that enable easy setup, use and rapid
troubleshooting
• Built-in cutting optimization tips for improving Phoenix 10
cutting machine performance and process
outcomes at the touch of a button
• Advanced process support for pipe, tube,
and bevel
• Consistent operator interface for existing
EDGE family customers
• Phoenix CNC software improves cut quality
and productivity by delivering our expertise
directly to your factory, making it as if you
have your best operator on every shift

Phoenix 4
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ProNest CNC
ProNest® CNC software enables end users to get optimal cut
quality for part programs created using the EDGE Connect CNC.
Through the touch screen interface machine operators can create
part programs quickly and easily without special training. There are
two nesting options available with the EDGE Connect platform.
ProNest CNC for automatic pattern array
nesting of a single shape comes standard,
and customers have the option to upgrade
to True Shape nesting for nesting for multiple
shapes with an advanced algorithm. ProNest
CNC complements offline ProNest and is
ideal for rush programming by the operator
when optimal cut quality is required.

Benefits
ProNest CNC User Interface
• ProNest based embedded cutting expertise
is included in every part program created on
the CNC, including parts from the standard
shape library.
• Simple and intuitive touch screen interface
requires minimal operator training.
• Operators can easily nest short-notice jobs
with optimal outcomes.

Standard

True Shape™
ProNest CNC 5
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Reliability
The EDGE Connect line of CNCs significantly
enhances overall system reliability.

Reliability
• Improved industrial hardware using a small
and highly flexible embedded CNC chassis
that requires no active cooling (no fans)
• Single cable, EtherCAT connectivity
• Projected Capacitive Touch Screen (PCAP)
technology available in the T and TC models
• Solid state hard drive
• Robust design for the harsh cutting
environment (heat, dust, electrical noise)
• Remote Help™ utility

Benefits
• Embedded CNC chassis offers the most
flexibility for cutting machine integration.
It only weighs 1.2 kg (2.7 lb.) and it is our
smallest control product
• All of the system components have been
integrated to minimize overall part count,
improve thermal performance – no cooling
fans required
• The system’s solid state hard drive has greater
long term reliability by removing moving parts
• The PCAP touch screen (available on some
models) is resistant to water droplets and The EDGE Connect only weighs 1.2 kg (2.7 lb.)
spray present in the cutting environment
• Remote Help reduces downtime and allows for
quick resolution should any problems arise

Reliability 6
EDGE Connect ®

Performance
The solid state drive eliminates read-write Operating vibration
errors and reliability issues due to vibration.

EDGE Pro EDGE Connect

Weight is reduced by >65%. Weight

EDGE Pro EDGE Connect

The low-power processor reduces power

CNC internal temperature vs. ambient
consumption by >70% and eliminates the
need for cooling fans. 16C
14C
12C
10C
8C
6C
4C
2C
0
EDGE Pro EDGE Connect

Power consumption

EDGE Pro EDGE Connect

Performance 7
 EDGE Connect ®

PLC Connect
PLC Connect is an internal PLC, integrated with Phoenix® in
real‑time. PLC Connect allows machine customization without
the need for additional external hardware.
Internal PLC for cutting machine customization PLC programming environment
EDGE Connect offers an internal PLC for • Cutting machine OEMs have the ability to
cutting machine customization allowing OEMs add their own programs, such as:
to integrate unique features into the machine
– Drill station with various operations
application. Basic functionality is included
with the EDGE Connect, and the system is – Control of oxyfuel torches with
upgradable to include greater functionality. programmable timers for preheat,
Programs are created in two different versions programmable gas flow control, and
of MULTIPROG, which are available from automatic igniters
Hypertherm to integrate with Phoenix.
– Plate markers using pneumatic punch,
zinc powder or ink jet technology
Benefits
• All programs are developed within
• Cutting machine manufacturers can MULTIPROG Express and MULTIPROG
add custom system functionality without
requiring changes by Hypertherm®.
• PLC Connect may replace costly
external PLCs used by cutting machine
manufacturers today
• Various logic frameworks available
(IEC 61131 compliant)
• Seamlessly integrated with Hypertherm
Real‑Time Operating System (RTOS)
PLC Connect

PLC Connect 8
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Customizable configuration
Each EDGE Connect system configuration can be customized
to specific applications based upon your needs.

Customizable configuration Benefits

Cutting machine manufacturers purchase their
EDGE Connect system hardware. After the
hardware arrives, software is ordered through
a web interface (Xnet). Software upgrades are
available and purchased anytime after the initial
installation through the same tool.
• CNCs can be configured to a specific cutting
machine configuration at the manufacturer’s site
rather than weeks before the machine is built.
• Field based upgrades can take place at any
time, allowing the flexibility of not returning
equipment back to Hypertherm®.
• All EDGE Connect hardware models can
support all of the processes.
• Hardware lead times and carrying costs
are reduced significantly with region-based
stocking.

Xnet order

Intermediate plasma/oxyfuel Advanced plasma/oxyfuel Advanced waterjet

Process Standard features Optional features

ProNest® CNC: single part, pattern array nesting ProNest CNC: multi-part, True Shape nesting
All PLC Connect LT PLC Connect
Soft Operator’s Console for 1-8 stations
Intermediate plasma (Powermax®, MAXPRO200® and others) support
Intermediate plasma/oxyfuel Sensor ™ THC height control (single torch only)
Basic oxyfuel support
Advanced plasma (HPRXD® and others) support Sensor THC height control (1–4 torches)
Advanced plasma/oxyfuel Intermediate plasma support Plasma bevel, pipe/tube and dual transverse
Basic oxyfuel support Oxyfuel bevel
Advanced waterjet Advanced waterjet cutting (HyPrecision™) support Sensor WHC height control

Customizable configuration 9
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Soft Operator’s Console (Soft OpCon)

The Soft OpCon provides users access to torch controls, station
select and manual motion without the need for costly external
hardware. Additionally, screen captures and camera support are
available. Hypertherm® also provides an API that allows cutting
machine builders to make their own customized Soft OpCon.

Benefits
• Soft OpCon works seamlessly with hardware
operator’s console
• Replaces the need for expensive hardware
switches and buttons, reducing cutting
machine costs
• Can be adapted to up to 8 cutting stations
without writing any software
• API is designed for the popular .NET Soft OpCon screen capture video
programming environment and consists of
a set of ready to use functions to simplify
cutting machine builder programming

Soft OpCon 10
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Core configurations
Specifications by models (core configuration)
EDGE Connect EDGE Connect TC
Size with antenna 43.1 mm (1.70 in.) H x 133.8 mm (5.27 in.) W 411.0 mm (16.18 in.) H x 560.3 mm (22.06 in.) W
x 94.2 mm (3.71 in.) D x 131.4 mm (5.17 in.) D
Weight 1.2 kg (2.7 lb.) 10.7 kg (23.6 lb.)
Display OEM supplied (1366 x 768) 495 mm (19.5 in) (1366 x 768)
Ports HDMI, 4-USB, Lan/Wireless, ECAT 2-USB, Lan/Wireless, ECAT
Front Panel OEM Supplied USB, power, start, stop,
program and manual speed adjustments
raise/lower torch and joystick.
Mount Side bracket or DIN rail Flush mount bracket, 100 mm VESA rear or 4 screw bottom

Benefits
• Smaller, thinner, lighter – significant physical
size and weight reductions over previous
Hypertherm® CNCs
• Integrated projective capacitive touch screen not
sensitive to water droplets
• Meets or exceeds previous generation testing: EDGE Connect

– Dust
– Shock
– Vibration
– Temperature

EDGE Connect TC

Core configurations 11
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Connectivity
Connectivity from the EDGE Connect to the cutting tool,
drives, and motors is achieved through EtherCAT.

Benefits
• Single cable connectivity between the CNC
and the drive cabinet
• All custom I/O, arc voltage and communications
cabling to the HyPerformance® Plasma
HPRXD® is replaced by a single, off-the-shelf
EtherCAT cable
• All drive wiring from the CNC (40–50,
individually wired connections) is replaced
by a single EtherCAT cable
• All EDGE Connect CNCs support the simplest
2-axis systems up to the most complex 10+
axis dual-bevel plasma systems

HDMI USB 3.0 USB 2.0 DVI EtherCAT

ANT USB 2.0 LAN ANT DC-IN

Connectivity 12
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Sensor THC lifter

Hypertherm provides lifter mechanics and an optional
magnetic breakaway to pair with the Sensor™ THC
software on Hypertherm CNCs.

Lifter
Hypertherm® provides lifter mechanics and
an optional magnetic breakaway to pair with
the Sensor THC software on Hypertherm
CNCs. This lifter mechanism, based on
the proven ArcGlide® design, provides
exceptional performance in the harsh plasma
cutting environment. The slide pairs with
both digital and analog drives and motors,
which are supplied by the cutting machine
manufacturer and connect to one of two
motor coupling options.
Sensor THC
Benefits
• Robust mechanics for the harsh cutting
environment
• Ability to be used on plasma systems up
to 800 amps
• Side shields protect the slide from debris
for multi-torch systems
• Magnetic breakaway protects the torch from
damage during collisions, and allows for quick,
repeatable recovery should a collision occur
• The integrated laser pointer allows for easy
plate alignment

Sensor torch height control is an integrated

torch positioning system to provide optimized
plasma cut performance using Hypertherm’s
embedded process expertise.

As a software feature built into EDGE Connect

CNC, this allows for use of Hypertherm
supplied lifter mechanics or custom lifter Shields
mechanics for special applications.

Magnetic breakaway

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 EDGE Connect ®

Additional accessories
Additional accessories available to optimize your system

In addition to the hardware CNCs and torch Benefits

height control accessories, Hypertherm®
also offers: • Hypertherm has everything that you need to
get your system up and running. We have
• EtherCAT cables
tested and confirmed the accessory items
• HyPerformance® HPR® EtherCAT interface that we provide.
boards
• Cabling is certified for performance for
• Mounting brackets EtherCAT in electrically noisy and harsh
environments ensuring optimal performance.

EDGE Connect DIN rail bracket EDGE Connect wall bracket EtherCAT cable

HyPerformance HPR interface kit EDGE Connect TC panel mount bracket

Additional accessories 14
 PLASMA | LASER | WATERJET | AUTOMATION | SOFTWARE | CONSUMABLES

Visit us on the web at:

www.hypertherm.com/EDGEConnect

 ypertherm, EDGE, Phoenix, SureCut, ProNest, True Hole, True Bevel, Rapid Part, Remote Help,
H
Powermax, MAX, HPR, HyPrecision, Sensor, HyPerformance, and ArcGlide are trademarks of
Hypertherm Inc. and may be registered in the United States and/or other countries.
 nvironmental stewardship is one of Hypertherm’s core values, and it is critical to our success
E
and our customers’ success. We are striving to reduce the environmental impact of everything
™
we do. For more information: www.hypertherm.com/environment.
© 1/2018 Hypertherm Inc. Revision 1
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