Hypertherm ArcGlide THC Reference manual

Field Service Bulletin
806560 Revision 3 November 2013
ArcGlide
®
THC
Replacement Parts

Hypertherm, Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
[email protected] (Main Office Email)
800-643-9878 Tel (Technical Service)
[email protected] (Technical Service Email)
800-737-2978 Tel (Customer Service)
[e-mail] (Customer Service Email)
866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization)
[email protected] (RMA email)
Hypertherm Plasmatechnik GmbH
Technologiepark Hanau
Rodenbacher Chaussee 6
D-63457 Hanau-Wolfgang, Deutschland
49 6181 58 2100 Tel
49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm (S) Pte Ltd.
82 Genting Lane
Media Centre
Annexe Block #A01-01
Singapore 349567, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
65 6841 2489 (Technical Service)
Hypertherm (Shanghai) Trading Co., Ltd.
Unit 301, South Building
495 ShangZhong Road
Shanghai, 200231
PR China
86-21-60740003 Tel
86-21-60740393 Fax
Hypertherm Europe B.V.
Vaartveld 9
4704 SE
Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
Hypertherm Japan Ltd.
Level 9, Edobori Center Building
2-1-1 Edobori, Nishi-ku
Osaka 550-0002 Japan
81 6 6225 1183 Tel
81 6 6225 1184 Fax
Hypertherm Brasil Ltda.
Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP - Brasil
CEP 07115-030
55 11 2409 2636 Tel
55 11 2408 0462 Fax
Hypertherm México, S.A. de C.V.
Avenida Toluca No. 444, Anexo 1,
Colonia Olivar de los Padres
Delegación Álvaro Obregón
México, D.F. C.P. 01780
52 55 5681 8109 Tel
52 55 5683 2127 Fax
Hypertherm Korea Branch
#3904 Centum Leaders Mark B/D,
1514 Woo-dong, Haeundae-gu, Busan
Korea, 612-889
82 51 747 0358 Tel
82 51 701 0358 Fax
© 2013 Hypertherm, Inc. All rights reserved.
ArcGlide and Hypertherm are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries. All other trademarks
are the property of their respective holders.

ArcGlide THC Replacement Parts Field Service Bulletin 806560 3
Contents
1 Parts ................................................................................................................................................. 5
Introduction ....................................................................................................................................................................................... 5
Tools ........................................................................................................................................................................................... 5
Lifter parts .................................................................................................................................................................................. 6
THC controller parts ............................................................................................................................................................... 8
HMI parts ................................................................................................................................................................................... 9
Plasma interface board ........................................................................................................................................................ 10
2 Replacing ArcGlide parts ......................................................................................................... 11
Accessing ArcGlide parts ........................................................................................................................................................... 12
Accessing lifter parts ........................................................................................................................................................... 12
Accessing control module parts ........................................................................................................................................ 12
Accessing HMI parts ............................................................................................................................................................ 12
Replacement procedures ........................................................................................................................................................... 13
228576 – Plasma interface board .................................................................................................................................... 13
228577 – THC control interface board .......................................................................................................................... 14
228578 – THC processor board ..................................................................................................................................... 15
228579 – 230 V surge board ........................................................................................................................................... 16
228580 – Lifter interface board ........................................................................................................................................ 17
228581 – HMI processor board ....................................................................................................................................... 18
228582 – HMI 7-segment display board ....................................................................................................................... 19
228583 – Momentary pushbutton switch ...................................................................................................................... 20
228584 – Torch up/down switch ..................................................................................................................................... 21
228585 – Enable/disable switch ...................................................................................................................................... 22
228586 – Lifter lower limit proximity switch .................................................................................................................. 23
228587 – Lifter upper limit proximity switch .................................................................................................................. 25
228588 – Station Enable 5 V LED .................................................................................................................................. 26
228589 – LCD display ....................................................................................................................................................... 27

4ArcGlide THC Replacement Parts Field Service Bulletin 806560
Contents
228590 – 120 VAC, 5 V, 5 amp, 25 W power source ............................................................................................... 28
228591 – Lifter slide ........................................................................................................................................................... 29
228592 – Laser pointer diode .......................................................................................................................................... 29
228593 – 11.34 kg (25 lb) Magnetic breakaway ........................................................................................................ 30
228607 – 4.54 kg (10 lb) Magnetic breakaway ........................................................................................................... 30
228595 – Lifter motor brushes ......................................................................................................................................... 31
228597 – Pneumatic breakaway ...................................................................................................................................... 31
228608 – Breakaway cable ............................................................................................................................................... 32
228938 – 20 kf (45 lbf) Replacement magnets ........................................................................................................... 35
228939 – 35.7 kf (78.7 lbf) Replacement magnets .................................................................................................... 35
228940 – Breakaway retaining tether ............................................................................................................................. 36
428081 – Servo amplifier module .................................................................................................................................... 36
428241 – Lifter side shield ................................................................................................................................................ 38
428242 – Ohmic wire ......................................................................................................................................................... 38
428245 – Sealing band ...................................................................................................................................................... 40
428302 – Lifter motor ......................................................................................................................................................... 40

ArcGlide THC Replacement Parts Field Service Bulletin 806560 5
Section 1
Parts
Introduction
This Field Service Bulletin provides information on replacement parts for the ArcGlide THC and how to replace them.
Tools
The following tools and materials are used in the replacement procedures in this FSB:
WARNING!
ELECTRIC SHOCK CAN KILL
Disconnect electrical power before performing any maintenance.
See the Safety section of the ArcGlide THC Instruction Manual for more
safety precautions.
9/16-inch wrench 3/16-inch blade screwdriver
1/4-inch socket wrench and extension Number 1 and 2 Phillips screwdrivers
14 mm, 21 mm wrenches Needle-nose pliers
Hex wrenches (inches): 3/32, 7/64, 9/64, 5/32, 3/16, 0.05 Thread sealant (
Locktite® 242 or equivalent )
Hex wrenches (metric): 3 mm, 4 mm Level
Adjustable wrench

6ArcGlide THC Replacement Parts Field Service Bulletin 806560
1 – Parts
Lifter parts
Item Kit number Description Quantity
1228588 Station Enable 5 V LED 1
2228585 Enable/disable switch 1
3228584 Torch up/down switch 1
4228592 Laser pointer diode 1
5228608 Breakaway cable 1
6228593 11.34 kg (25 lb) magnetic breakaway 1
7228607 4.54 kg (10 lb) magnetic breakaway 1
8228597 Pneumatic breakaway 1
9228939 35.7 kf (78.7 lbf) replacement magnets 4
104473 35.7 kf (78.7 lbf) replacement magnet 1
10 228938 20 kf (45 lbf) replacement magnets 5
104513 20 kf (45 lbf) replacement magnet 1
11 228940 Breakaway retaining tether 1
1
2
3
45
67
11 8
10
9
11

ArcGlide THC Replacement Parts Field Service Bulletin 806560 7
1 – Parts
Item Kit number Description Quantity
1228595 Lifter motor brushes 2
2228580 Lifter interface board 1
3428302 Lifter motor 1
4428259 Grease gun 1
5228591 Lifter slide 1
6428245 Sealing band 1
7228587 Lifter upper limit proximity switch 1
8228586 Lifter lower limit proximity switch 1
9428242 Ohmic wire 1
10 428241 Lifter side shields 2
1
2
4
5
3
6
7
9
8
10

8ArcGlide THC Replacement Parts Field Service Bulletin 806560
1 – Parts
THC controller parts
Item Kit number Description Quantity
1228589 LCD display 1
2228578 THC processor board 1
3428081 Servo amplifier module 1
4228577 THC control interface board 1
5228579 230 V surge board 1
6228590 120 VAC, 5 V, 5 amp, 25 W power source 1
1
2
4
3
5
6

ArcGlide THC Replacement Parts Field Service Bulletin 806560 9
1 – Parts
HMI parts
Item Kit number Description Quantity
1228589 LCD display 1
2228583 Momentary pushbutton switch 1
3228582 HMI 7-segment display board 1
4228579 230 V surge board 1
5228590 120 VAC, 5 V, 5 amp, 25 W power source 1
6228581 HMI processor board 1
1
2
3
4
5
6

10 ArcGlide THC Replacement Parts Field Service Bulletin 806560
1 – Parts
Plasma interface board
Item Kit number Description Quantity
1228576 Discrete plasma interface board 1
141162 Hypernet plasma interface board 1
228604 Hypernet upgrade kit for HPR400XD and HPR800XD 1
228611 Hypernet upgrade kit for HPR130XD and HPR260XD 1
1

ArcGlide THC Replacement Parts Field Service Bulletin 806560 11
Section 2
Replacing ArcGlide parts
Use the instructions in the following sections to replace parts in the ArcGlide THC.

Replacement procedures are listed in order by the kit number for the part you are
replacing. Before you begin a procedure, verify that you are using the procedure for the
correct part.
WARNING!
ELECTRIC SHOCK CAN KILL
Disconnect electrical power before performing any maintenance.
See the Safety section in the ArcGlide THC Instruction Manual for more
safety precautions.
CAUTION!
Static electricity can damage circuit boards. Use proper precautions when handling
printed circuit boards.
Store PC boards in anti-static containers.
Wear a grounded wrist strap when handling PC boards.

12 ArcGlide THC Replacement Parts Field Service Bulletin 806560
2 – Replacing ArcGlide parts
Accessing ArcGlide parts
The following procedures provide the initial steps for replacing parts in each of the ArcGlide modules:
Accessing lifter parts
1. Turn OFF power to the lifter and disconnect the power cable.
2. Remove the lifter from the gantry.
3. Remove the front of the lifter motor enclosure:
a. Remove the 4 screws on the front of the enclosure and set them aside.
b. Remove the 3 connectors for the switches and LED from the front cover on the lifter interface board.
Accessing control module parts
1. Turn OFF power to the control module and disconnect the power cable and other cables connected to the front
panel.
2. Remove the control module from the cutting table.
3. Remove the 6 screws from the rear panel and set them aside.
4. Fold the rear panel down from the enclosure and lay it flat.
Accessing HMI parts
1. Turn OFF power to the HMI and disconnect the power and HMI cables.
2. Remove the 6 screws from the rear panel and set them aside.
3. Fold the rear panel down from the enclosure and lay it flat.

ArcGlide THC Replacement Parts Field Service Bulletin 806560 13
2 – Replacing ArcGlide parts
Replacement procedures
228576 – Plasma interface board
To remove the plasma interface board:
1. Turn OFF power to the plasma system.
2. Inside the plasma system, remove the 4 screws from the
front of the plasma interface enclosure.
3. Label the wiring at terminal blocks J2 (inputs) and J3
(outputs) to insure that you can rewire them accurately.
4. Disconnect all wires from terminal blocks J2 and J3, the
work and electrode wires from J4, and the ground wire
connector.
5. Remove the 2 standoffs next to each of the two D-sub
connectors on the front and bottom of the enclosure.
6. Remove the 4 screws from the standoffs at the corners of
the plasma interface board.
To replace the plasma interface board:
1. Place the new plasma interface board over the 4 standoffs and fasten the screws. Tighten the screws to 1.12 N·m
(10 lb·in.).
2. Fasten the screws to the standoffs next to each of the two D-sub connectors. Tighten the screws to 0.67 N·m
(6 lb·in.).
3. Fasten the ground wire to the grounding connector. Tighten the connector to 1.12 N·m (10 lb·in.).
4. Replace the work and electrode leads to the work and electrode terminal block (J4).
5. Using your labels, replace the input and output wires to the appropriate connectors on terminal blocks J2 and J3.
6. Replace the front of the enclosure and fasten the 4 screws. Tighten the screws to 1.12 N·m (10 lb·in.).
7. Restore power to the plasma system.
J2
J3
J4

14 ArcGlide THC Replacement Parts Field Service Bulletin 806560
2 – Replacing ArcGlide parts
228577 – THC control interface board
Follow the steps in Accessing control module parts on page 12 to
open the rear panel of the control module. Set aside all screws
and other hardware for reuse.
To access the THC control interface board, you must use the
following procedures to remove additional parts:
428081 – Servo amplifier module on page 36
228578 – THC processor board on page 15
To remove the THC control interface board:
1. On the outside of the front panel, remove the screws from
around each black circular connector.
2. Remove the screw from the center bottom of the board.
3. Snap the board off the upper standoffs.
4. Lift the board off the standoffs and let the cables slip through the cutout in the board.
To replace the THC control interface board:
1. Thread the ribbon cables through the cutout.
2. Align the circular connectors through the front of the front panel.
3. Snap the board onto the standoffs.
4. Fasten the screw through the standoff in the center bottom of the board. Tighten the screw to 1.13 N·m (10 lb·in.).
5. Fasten the screws around the circular connectors on the front panel. Tighten the screws to 0.67 N·m (6 lb·in.).
Use the following procedures to replace additional parts:
228578 – THC processor board on page 15
428081 – Servo amplifier module on page 36
THC control interface
board

ArcGlide THC Replacement Parts Field Service Bulletin 806560 15
2 – Replacing ArcGlide parts
228578 – THC processor board
Follow the steps in Accessing control module parts on
page 12 to open the rear panel. Set aside all screws and
other hardware for reuse.
To access the THC processor board, you must use the
following procedure to remove additional parts:
428081 – Servo amplifier module on page 36
To remove the THC processor board:
1. Remove the two screws that attach the THC
processor board to the top of the enclosure.
2. Use a 1/4-inch socket wrench with an extension to
remove the 6 standoffs from the inside of the front of
the enclosure.
3. Remove the enclosure from the front panel assembly.
4. Disconnect the Ethernet cable from J8, the ribbon
cables from J2 and J5, and the LCD cable from J4.
5. Remove the 2 screws that secure the board to the top of the enclosure.
6. Ease the board from the 100-pin connector on the THC control board.
To replace the THC processor board:
1. Carefully align J3 on the THC processor board with J1 on the THC control board. Gently press the connectors
together to avoid bending the pins.
2. Fasten the two screws that secure the board to the top of the enclosure. Tighten the screws to 1.13 N·m (10 lb·in.).
3. Connect the Ethernet cable into J8, the ribbon cables into J2 and J5, and the LCD cable into J4.
4. Replace the enclosure on the front panel assembly, with the opening for the heatsink on the left, and the tabs that
hold the control board on top.
5. Replace the 6 standoffs inside the front of the enclosure. Tighten the standoffs to 0.90 N·m (8 lb·in.).
Use the following procedures to replace additional parts:
428081 – Servo amplifier module on page 36
J8
J5 J2
J4
J3

16 ArcGlide THC Replacement Parts Field Service Bulletin 806560
2 – Replacing ArcGlide parts
228579 – 230 V surge board
Follow the steps in Accessing control module parts or
Accessing HMI parts on page 12 to open the rear panel. Set
aside all screws and other hardware for reuse.
To remove the surge board:
1. Remove the cables from J1 and J2.
2. Remove the screws at either end of the board.
3. Remove the board from the standoffs.
To replace the surge board:
1. Place the new board over the standoffs and snap it into
place.
2. Fasten the 2 screws at either end of the board. Tighten the
screws to 1.13 N·m (10 lb·in.).
3. Replace the cable from the transformer (in the control
module) or line filter (in the HMI) into J1.
4. Replace the cable from the power supply into J2.
5. Replace the rear panel of the enclosure and fasten the screws. Tighten the screws to 1.13 N·m (10 lb·in.).
J1 J2
Surge board

ArcGlide THC Replacement Parts Field Service Bulletin 806560 17
2 – Replacing ArcGlide parts
228580 – Lifter interface board
Follow the steps in Accessing lifter parts on page 12 to open
the front cover of the motor enclosure. Set aside all screws and
other hardware for reuse.
To remove the lifter interface board:
1. Remove the top of the motor enclosure by unfastening the
3 screws on the top of the enclosure and setting them
aside.
2. Remove all cable connectors from the lifter interface board,
except for the connector for the ohmic contact wire in J5.
3. Remove the bottom panel of the board assembly. This
panel has Danger High-Voltage printed on the bottom side.
Use needle-nose pliers to depress the tabs on the
standoffs.
4. Remove the ohmic wire connector from J5.
5. Remove the 4 screws around the circular, lifter cable
connector.
6. Remove the 2 screws from the standoffs.
7. Pull the board from the standoffs.
To replace the lifter interface board:
1. Fit the new board over the standoffs and fasten the 2
screws into the standoffs. Tighten the screws to 1.13 N·m
(10 lb·in.).
2. Fasten the 4 screws around the circular connector. Tighten
the screws to 0.67 N·m (6 lb·in.).
3. Install the ohmic wire in terminal block J5 on the underside
of the lifter interface board.
4. Snap the bottom panel of the board assembly onto the plastic standoffs.
5. Replace the top cover of the motor enclosure and fasten the 3 screws. Tighten the screws to 1.13 N·m (10 lb·in.).
J5
J1
J2
J3
J4
J6
J7
J8J9
Lifter
interface
board
Lifter
cable
connector
Bottom panel

18 ArcGlide THC Replacement Parts Field Service Bulletin 806560
2 – Replacing ArcGlide parts
6. Install cable connectors in the following connectors on the lifter interface board:
7. Install the connectors from the switches and LED on the front cover to the lifter interface board:
8. Replace the front cover of the motor enclosure and fasten the 4 screws. Tighten the screws to 1.13 N·m (10 lb·in.).
228581 – HMI processor board
Follow the steps in Accessing HMI parts on
page 12 to open the rear panel. Set aside all
screws and other hardware for reuse.
To remove the HMI processor board:
1. Remove the Ethernet cable connector from
J7 and the red and black wires to the
power source from J12.
2. Remove the 3 toggle switch boots on the
front of the enclosure.
3. Remove 6 standoffs around the processor
board.
4. Push gently on the board to remove it and
the front panel from the enclosure.
5. Remove cables from connectors J3, J4, J8, J9, J10, J11.
6. Remove the screws from the standoffs at the upper corners and the lower center of the board.
7. Remove the board from the front panel.
8. On the front of the board, remove the hex nuts and round washers from the toggle switches. Save the washers for
reuse.
J1 Upper limit switch
J3 Lower limit switch
J4 Breakaway
J6 Motor brake encoder
J7 Laser pointer
J2 LED
J8 Enable/disable switch
J9 Up/down switch
J7
J12
J3
J4
J8
J9 J10 J11

ArcGlide THC Replacement Parts Field Service Bulletin 806560 19
2 – Replacing ArcGlide parts
To replace the HMI processor board:
1. Remove the 9/16-inch hex nuts from the toggle switches on the front of the new board, install the washers, and
finger-tighten the hex nuts plus a 1/4 turn.
2. Place the new board over the standoffs on the front panel.
3. Fasten the screws in the standoffs. Tighten the screws to 1.13 N·m (10 lb·in.).
4. Replace the cable connectors in J3, J4, J8, J9, J10, J11.
5. Replace the new board and front panel in the enclosure with the station switch aligned with the rubber gasket and
hole in the side of the enclosure.
6. Replace the 6 standoffs around the processor board. Tighten the standoff to 0.90 N·m (8 lb·in.).
7. Reconnect the Ethernet cable to J7 and red and black wires to J12.
8. Fit the back cover on the enclosure and fasten the 6 screws. Tighten the screws to 1.13 N·m (10 lb·in.).
9. Replace the hex boots around the toggle switches on the front panel of the enclosure and finger-tighten them.
228582 – HMI 7-segment display board
Follow the steps in Accessing HMI parts on page 12 to open the rear
panel of the HMI enclosure. Set aside all screws and other hardware for
reuse.
To access the HMI 7-segment display board, you must use the
following procedure to remove additional parts:
228581 – HMI processor board on page 18
To remove the display board:
1. Remove the wide ribbon cable from the display board.
2. Remove the threaded standoff and washer and save them for
reuse.
3. Remove the 3 screws from the remaining standoffs.
4. Lift the LED board from the standoffs.

20 ArcGlide THC Replacement Parts Field Service Bulletin 806560
2 – Replacing ArcGlide parts
To replace the display board:
1. Fit the new LED board over the standoffs with the 34-pin connector at the top.
2. Replace the threaded standoff and washer in the upper left corner of the board. Tighten the standoff to 0.90 N·m
(8 lb·in.).
3. Replace the 3 screws in the remaining standoffs. Tighten the screws to 1.13 N·m (10 lb·in.).
4. Insert the connector for the ribbon cable in the 34-pin connector on the board.
Use the following procedure to replace additional parts:
228581 – HMI processor board on page 18
228583 – Momentary pushbutton switch
Follow the steps in Accessing HMI parts on page 12 to open the rear panel of
the HMI enclosure. Set aside all screws and other hardware for reuse.
To access the momentary pushbutton switch, you must use the following
procedure to remove additional parts:
228581 – HMI processor board on page 18
To remove the momentary pushbutton switch:
1. Remove the 14-mm hex nut from the back of the switch on the inside of the front panel.
2. Remove the switch from the front of the front panel.
To replace the momentary pushbutton switch:
1. Thread the cable for the replacement switch through the switch opening in the front panel.
2. Replace the hex nut around the base of the switch and tighten it to 1.35 N·m (12 lb·in.).
Use the following procedures to remove and replace additional parts:
228581 – HMI processor board on page 18