Hypertherm Automation Family Instruction Manual (IM)

Phoenix™ Software Version 9 Series

Programmer Reference

806420 | Revision 9 | English

ArcGlide, COMMAND, EDGE Pro, EDGE Pro Ti, HPR, HSD, HyIntensity Fiber Laser, Hypernest, Hypernet, Hypertherm, HyPrecision, MAXPRO, MicroEDGE Pro, Phoenix, Powermax, and Sensor are trademarks of Hypertherm, Inc. and may be registered in the United States and other countries.

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Other trademarks are the property of their respective owners.

Phoenix Software® Version 9 Series

Programmer Reference

806420

Revision 9

English

December 2014

Hypertherm Inc.

Hanover, NH 03755 USA

Hypertherm Inc.

Etna Road, P.O. Box 5010 Hanover, NH 03755 USA 603-643-3441 Tel (Main Office) 603-643-5352 Fax (All Departments) info@hypertherm.com (Main Office Email)

800-643-9878 Tel (Technical Service)

technical.service@hypertherm.com (Technical Service Email)

800-737-2978 Tel (Customer Service)

customer.service@hypertherm.com (Customer Service Email)

866-643-7711 Tel (Return Materials Authorization) 877-371-2876 Fax (Return Materials Authorization)

return.materials@hypertherm.com (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

Safety ....................................................................................................................................... SC-11

Recognize safety information ...............................................................................................................................................SC-11

Follow safety instructions ......................................................................................................................................................SC-11

Electrical hazards ....................................................................................................................................................................SC-11

Electric shock can kill ............................................................................................................................................................SC-12

Cutting can cause fire or explosion ....................................................................................................................................SC-13

Fire prevention .................................................................................................................................................................SC-13

Explosion prevention ......................................................................................................................................................SC-13

Toxic fumes can cause injury or death ...............................................................................................................................SC-14

Grounding safety ....................................................................................................................................................................SC-15

Static electricity can damage circuit boards ....................................................................................................................SC-15

A plasma arc can cause injury and burns .........................................................................................................................SC-16

Compressed gas equipment safety ...................................................................................................................................SC-16

Gas cylinders can explode if damaged .............................................................................................................................SC-16

Arc rays can burn eyes and skin .........................................................................................................................................SC-17

Pacemaker and hearing aid operation ...............................................................................................................................SC-18

Noise can damage hearing ...................................................................................................................................................SC-18

A plasma arc can damage frozen pipes ............................................................................................................................SC-18

Dry dust collection information ............................................................................................................................................SC-19

Laser radiation .........................................................................................................................................................................SC-20

Additional safety information ................................................................................................................................................SC-20

Warning labels ........................................................................................................................................................................SC-21

Symbols and marks ................................................................................................................................................................SC-23

Phoenix 9.76.0 Programmer’s Reference 806420 5

Contents

Product Stewardship ...........................................................................................................SC-25

Introduction ..............................................................................................................................................................................SC-25

National and local safety regulations .................................................................................................................................SC-25

Certification test marks .........................................................................................................................................................SC-25

Differences in national standards .......................................................................................................................................SC-25

Safe installation and use of shape cutting equipment ...................................................................................................SC-26

Procedures for periodic inspection and testing ..............................................................................................................SC-26

Qualification of test personnel .............................................................................................................................................SC-26

Residual current devices (RCDs) .......................................................................................................................................SC-26

Higher-level systems ..............................................................................................................................................................SC-27

Environmental Stewardship .............................................................................................. SC-29

Introduction ..............................................................................................................................................................................SC-29

National and local environmental regulations ...................................................................................................................SC-29

The RoHS directive ................................................................................................................................................................SC-29

Proper disposal of Hypertherm products ..........................................................................................................................SC-29

The WEEE directive ...............................................................................................................................................................SC-29

The REACH regulation ..........................................................................................................................................................SC-30

Proper handling and safe use of chemicals .....................................................................................................................SC-30

Fumes emission and air quality ...........................................................................................................................................SC-30

Shrink-wrap License Agreement ...................................................................................... SC-31

1 Shape Library ................................................................................................................................ 33

Text Editor ........................................................................................................................................................................................34

Shape Wizard ..................................................................................................................................................................................35

Teach Trace .....................................................................................................................................................................................36

Remnant Trace Mode ............................................................................................................................................................37

Teach Trace Mode .................................................................................................................................................................38

2 ASCII Codes .................................................................................................................................. 41

Control Codes .................................................................................................................................................................................42

All Codes ..........................................................................................................................................................................................44

3 EIA RS-274D Program Support ............................................................................................... 47

Directly Supported EIA Codes ....................................................................................................................................................48

Mapped EIA Codes .......................................................................................................................................................................54

Unsupported EIA Codes ...............................................................................................................................................................57

EIA Comments ................................................................................................................................................................................58

6 Phoenix 9.76.0 Programmer’s Reference 806420

Contents

4 ESSI Code Support ..................................................................................................................... 59

Mapped ESSI Codes .................................................................................................................................................................... 60

Unsupported ESSI Codes ........................................................................................................................................................... 64

ESSI Comments ............................................................................................................................................................................ 65

5 Advanced Feature Codes .......................................................................................................... 67

Kerf Table Codes ........................................................................................................................................................................... 67

Special Kerf and G59 Code Settings ...................................................................................................................................... 67

Kerf Override ........................................................................................................................................................................... 67

G59 Code Override .............................................................................................................................................................. 67

Parallel Kerf Enable for Hole Center Piercing ................................................................................................................. 67

Tilt / Rotator Part Codes .............................................................................................................................................................. 68

Station Select Codes ................................................................................................................................................................... 68

Process Select Codes ................................................................................................................................................................. 69

Automatic Plate Alignment Codes ..................................................................................................................................... 69

Automatic Torch Spacing ............................................................................................................................................................ 69

Automatic Torch Spacing Program Codes ..................................................................................................................... 71

Automatic Torch Spacing I/O ............................................................................................................................................. 72

Example Part Program .................................................................................................................................................................. 72

Dual Transverse without Beveling .............................................................................................................................................. 73

Beveling ........................................................................................................................................................................................... 73

Contour Bevel Head for Oxyfuel Cutting (CBH) ............................................................................................................ 73

Tilt Rotator Plasma Bevel ..................................................................................................................................................... 73

Dual Tilt Rotator Plasma Bevel ........................................................................................................................................... 74

Bevel Angle Change on the Fly (BACF) .......................................................................................................................... 75

M and G Codes Used for Beveling ................................................................................................................................... 75

Kerf Table Commands to Change Kerf During Multi-pass, Multi-bevel Cuts .................................................. 75

Tilt/Rotator Commands ................................................................................................................................................ 75

Dual Tilt/Rotator Commands Used with Dual Plasma Bevel Systems .............................................................. 76

Tube cutting with bevel command ............................................................................................................................. 76

Drilling and Tapping using a PLC .............................................................................................................................................. 76

Operation ................................................................................................................................................................................. 77

Sample code and description ............................................................................................................................................. 77

Ladder Logic Diagram of Drill Cycle ................................................................................................................................. 79

RACF – Rotate Angle Change on the Fly ............................................................................................................................... 79

All Possible Axis Assignments .................................................................................................................................................... 80

Special Passwords ........................................................................................................................................................................ 80

NRT – No Rotate Tilt ............................................................................................................................................................. 80

RT – Rotate Tilt ...................................................................................................................................................................... 80

NSA – No SERCOS Axes ................................................................................................................................................... 80

Phoenix 9.76.0 Programmer’s Reference 806420 7

Contents

6 Subparts ......................................................................................................................................... 81

7 Marker Font Generator .............................................................................................................. 85

Internal Fonts ...................................................................................................................................................................................87

External Fonts ..................................................................................................................................................................................87

Custom Fonts ..................................................................................................................................................................................87

8 G59 Process Variables ............................................................................................................... 89

Variable Types .................................................................................................................................................................................90

Part program format .......................................................................................................................................................................92

V5xx Variables .................................................................................................................................................................................94

Torch type ...............................................................................................................................................................................95

Material type .............................................................................................................................................................................96

Plasma current .........................................................................................................................................................................96

Plasma/shield gas or Laser assist gas ...............................................................................................................................97

Cutting surface ........................................................................................................................................................................98

Material Thickness ..................................................................................................................................................................98

Water Muffler ........................................................................................................................................................................ 106

Laser power setting .............................................................................................................................................................106

Laser focal length ................................................................................................................................................................107

Laser nozzle size .................................................................................................................................................................. 107

Waterjet nozzle size ............................................................................................................................................................107

Waterjet orifice size ............................................................................................................................................................. 107

Waterjet cut pressure ......................................................................................................................................................... 108

Fuel gas for Oxyfuel ............................................................................................................................................................108

Oxyfuel tip size .....................................................................................................................................................................108

V6xx plasma variables ................................................................................................................................................................. 109

V8xx laser variables ..................................................................................................................................................................... 113

V8xx waterjet variables ............................................................................................................................................................... 114

9 Serial Messaging ....................................................................................................................... 117

Overview ........................................................................................................................................................................................117

Options ..........................................................................................................................................................................................117

Programming Code ..................................................................................................................................................................... 119

Message Information ...........................................................................................................................................................119

Message Command Type .......................................................................................................................................................... 120

Optional Format Value ................................................................................................................................................................ 120

Specialty Characters Supported ..................................................................................................................................... 121

Optional Format Character Assignments ...................................................................................................................... 122

Optional Delay Time/Time Out Value ..................................................................................................................................... 122

Optional Port ................................................................................................................................................................................ 123

8 Phoenix 9.76.0 Programmer’s Reference 806420

Contents

Message Text Content ...............................................................................................................................................................123

Non-Printing Characters ............................................................................................................................................................123

Character Options ...............................................................................................................................................................123

Exceptions / Additions ........................................................................................................................................................123

Non-Printing Character Table ...................................................................................................................................................124

ASCII Codes Less Than Hexadecimal 20 ..................................................................................................................... 124

8 bit Character Codes Greater Than Hexadecimal 80 ............................................................................................... 124

10 Importing Prepared DXF Files ...............................................................................................127

Drawing Format ............................................................................................................................................................................127

Text Commands ...........................................................................................................................................................................127

Directional Commands ............................................................................................................................................................... 128

Phoenix 9.76.0 Programmer’s Reference 806420 9

Contents

10 Phoenix 9.76.0 Programmer’s Reference 806420

Safety

RECOGNIZE SAFETY INFORMATION

The symbols shown in this section are used to identify potential hazards. When you see a safety symbol in this manual or on your machine, understand the potential for personal injury, and follow the related instructions to avoid the hazard.

FOLLOW SAFETY INSTRUCTIONS

Read carefully all safety messages in this manual and safety labels on your machine.

• Keep the safety labels on your machine in good condition. Replace missing or damaged labels immediately.

• Learn how to operate the machine and how to use the controls properly. Do not let anyone operate it without instruction.

• Keep your machine in proper working condition. Unauthorized modifications to the machine may affect safety and machine service life.

DANGER WARNING CAUTION

Hypertherm uses American National Standards Institute guidelines for safety signal words and symbols. A signal word DANGER or WARNING is used with a safety symbol. DANGER identifies the most serious hazards.

• DANGER and WARNING safety labels are located on your machine near specific hazards.

• DANGER safety messages precede related instructions in the manual that will result in serious injury or death if not followed correctly.

• WARNING safety messages precede related instructions in this manual that may result in injury or death if not followed correctly.

• CAUTION safety messages precede related instructions in this manual that may result in minor injury or damage to equipment if not followed correctly.

ELECTRICAL HAZARDS

• Only trained and authorized personnel may open this equipment.

• If the equipment is permanently connected, turn it off, and lock out/tag out power before the enclosure is opened.

• If power is supplied to the equipment with a cord, unplug the unit before the enclosure is opened.

• Lockable disconnects or lockable plug covers must be provided by others.

• Wait 5 minutes after removal of power before entering the enclosure to allow stored energy to discharge.

Safety and Compliance SC-11

• If the equipment must have power when the enclosure is open for servicing, arc flash explosion hazards may exist. Follow ALL local requirements (NFPA 70E in the USA) for safe work practices and for Personal Protective Equipment when servicing energized equipment.

• The enclosure shall be closed and the proper earth ground continuity to the enclosure verified prior to operating the equipment after moving, opening, or servicing.

• Always follow these instructions for disconnecting power before inspecting or changing torch consumable parts.

Safety

Touching live electrical parts can cause a fatal shock or severe burn.

• Operating the plasma system completes an electrical circuit between the torch and the workpiece. The workpiece and anything touching the workpiece are part of the electrical circuit.

• Never touch the torch body, workpiece or the water in a water table when the plasma system is operating.

Electric shock prevention

All Hypertherm plasma systems use high voltage in the cutting process (200 to 400 VDC are common). Take the following precautions when operating this system:

• Wear insulated gloves and boots, and keep your body and clothing dry.

• Do not stand, sit or lie on – or touch – any wet surface when using the plasma system.

• Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. If you must work in or near a damp area, use extreme caution.

• Provide a disconnect switch close to the power supply with properly sized fuses. This switch allows the operator to turn off the power supply quickly in an emergency situation.

• When using a water table, be sure that it is correctly connected to earth ground.

• Install and ground this equipment according to the instruction manual and in accordance with national and local codes.

• Inspect the input power cord frequently for damage or cracking of the cover. Replace a damaged power cord immediately. Bare wiring can kill.

• Inspect and replace any worn or damaged torch leads.

• Do not pick up the workpiece, including the waste cutoff, while you cut. Leave the workpiece in place or on the workbench with the work cable attached during the cutting process.

• Before checking, cleaning or changing torch parts, disconnect the main power or unplug the power supply.

• Never bypass or shortcut the safety interlocks.

• Before removing any power supply or system enclosure cover, disconnect electrical input power. Wait 5 minutes after disconnecting the main power to allow capacitors to discharge.

• Never operate the plasma system unless the power supply covers are in place. Exposed power supply connections present a severe electrical hazard.

• When making input connections, attach proper grounding conductor first.

• Each Hypertherm plasma system is designed to be used only with specific Hypertherm torches. Do not substitute other torches which could overheat and present a safety hazard.

ELECTRIC SHOCK CAN KILL

SC-12 Safety and Compliance

CUTTING CAN CAUSE FIRE OR EXPLOSION

Safety

Fire prevention

• Be sure the area is safe before doing any cutting. Keep a fire extinguisher nearby.

• Remove all flammables within 35 feet (10 m) of the cutting area.

• Quench hot metal or allow it to cool before handling or before letting it touch combustible materials.

• Never cut containers with potentially flammable materials inside – they must be emptied and properly cleaned first.

• Ventilate potentially flammable atmospheres before cutting.

• When cutting with oxygen as the plasma gas, an exhaust ventilation system is required.

Explosion prevention

• Do not use the plasma system if explosive dust or vapors may be present.

• Do not cut pressurized cylinders, pipes, or any closed container.

• Do not cut containers that have held combustible materials.

WAR N ING

Explosion Hazard

Argon-Hydrogen and Methane

Hydrogen and methane are flammable gases that present an explosion hazard. Keep flames away from cylinders and hoses that contain methane or hydrogen mixtures. Keep flames and sparks away from the torch when using methane or argon-hydrogen plasma.

WAR N ING

Hydrogen Detonation with

Aluminum Cutting

• Do not cut aluminum underwater or with water touching the underside of the aluminum.

• Cutting aluminum underwater or with the water touching the underside of the aluminum can result in an explosive condition that can detonate during plasma cutting operations.

WAR N ING

Explosion Hazard

Underwater Cutting with Fuel Gases

• Do not cut under water with fuel gases containing hydrogen.

• Cutting under water with fuel gases containing hydrogen can result in an explosive condition that can detonate during plasma cutting operations.

Safety and Compliance SC-13

Safety

TOXIC FUMES CAN CAUSE INJURY OR DEATH

The plasma arc by itself is the heat source used for cutting. Accordingly, although the plasma arc has not been identified as a source of toxic fumes, the material being cut can be a source of toxic fumes or gases that deplete oxygen.

Fumes produced vary depending on the metal that is cut. Metals that may release toxic fumes include, but are not limited to, stainless steel, carbon steel, zinc (galvanized), and copper.

In some cases, the metal may be coated with a substance that could release toxic fumes. Toxic coatings include, but are not limited to, lead (in some paints), cadmium (in some paints and fillers), and beryllium.

Gases produced by plasma cutting vary based on the material to be cut and the method of cutting, but may include ozone, oxides of nitrogen, hexavalent chromium, hydrogen, and other substances if such are contained in or released by the material being cut.

Caution should be taken to minimize exposure to fumes produced by any industrial process. Depending upon the chemical composition and concentration of the fumes (as well as other factors, such as ventilation), there may be a risk of physical illness, such as birth defects or cancer.

It is the responsibility of the equipment and site owner to test the air quality in the area where the equipment is used and to ensure that the air quality in the workplace meets all local and national standards and regulations.

The air quality level in any relevant workplace depends on site-specific variables such as:

• Table design (wet, dry, underwater).

• Material composition, surface finish, and composition of coatings.

• Volume of material removed.

• Duration of cutting or gouging.

• Size, air volume, ventilation and filtration of the work area.

• Personal protective equipment.

• Number of welding and cutting systems in operation.

• Other site processes that may produce fumes.

If the workplace must conform to national or local regulations, only monitoring or testing done at the site can determine whether the site is above or below allowable levels.

To reduce the risk of exposure to fumes:

• Remove all coatings and solvents from the metal before cutting.

• Use local exhaust ventilation to remove fumes from the air.

• Do not inhale fumes. Wear an air-supplied respirator when cutting any metal coated with, containing, or suspected to contain toxic elements.

• Assure that those using welding or cutting equipment, as well as air-supplied respiration devices, are qualified and trained in the proper use of such equipment.

• Never cut containers with potentially toxic materials inside. Empty and properly clean the container first.

• Monitor or test the air quality at the site as needed.

• Consult with a local expert to implement a site plan to ensure safe air quality.

SC-14 Safety and Compliance

GROUNDING SAFETY

Safety

Work cable Attach the work cable securely to the

workpiece or the work table with good metal-to-metal contact. Do not connect it to the piece that will fall away when the cut is complete.

Work table Connect the work table to an earth ground, in accordance with appropriate national and local electrical codes.

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.

Input power

• Be sure to connect the power cord ground wire to the ground in the disconnect box.

• If installation of the plasma system involves connecting the power cord to the power supply, be sure to connect the power cord ground wire properly.

• Place the power cord’s ground wire on the stud first, then place any other ground wires on top of the power cord ground. Fasten the retaining nut tightly.

• Tighten all electrical connections to avoid excessive heating.

Safety and Compliance SC-15

Safety

COMPRESSED GAS EQUIPMENT SAFETY

• Never lubricate cylinder valves or regulators with oil or grease.

• Use only correct gas cylinders, regulators, hoses and fittings designed for the specific application.

• Maintain all compressed gas equipment and associated parts in good condition.

• Label and color-code all gas hoses to identify the type of gas in each hose. Consult applicable national and local codes.

GAS CYLINDERS CAN EXPLODE IF DAMAGED

Gas cylinders contain gas under high pressure. If damaged, a cylinder can explode.

• Handle and use compressed gas cylinders in accordance with applicable national and local codes.

• Never use a cylinder that is not upright and secured in place.

• Keep the protective cap in place over valve except when the cylinder is in use or connected for use.

• Never allow electrical contact between the plasma arc and a cylinder.

• Never expose cylinders to excessive heat, sparks, slag or open flame.

• Never use a hammer, wrench or other tool to open a stuck cylinder valve.

A PLASMA ARC CAN CAUSE INJURY AND BURNS

Instant-on torches

Plasma arc comes on immediately when the torch switch is activated.

The plasma arc will cut quickly through gloves and skin.

• Keep away from the torch tip.

• Do not hold metal near the cutting path.

• Never point the torch toward yourself or others.

SC-16 Safety and Compliance

ARC RAYS CAN BURN EYES AND SKIN

Eye protection Plasma arc rays produce intense

visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

• Use eye protection in accordance with applicable national and local codes.

• Wear eye protection (safety glasses or goggles with side shields, and a welding helmet) with appropriate lens shading to protect your eyes from the arc’s ultraviolet and infrared rays.

Skin protection Wear protective clothing to protect against burns caused by ultraviolet light, sparks, and hot metal.

• Gauntlet gloves, safety shoes and hat.

• Flame-retardant clothing to cover all exposed areas.

• Cuffless trousers to prevent entry of sparks and slag.

• Remove any combustibles, such as a butane lighter or matches, from your pockets before cutting.

Cutting area Prepare the cutting area to reduce reflection and transmission of ultraviolet light:

• Paint walls and other surfaces with dark colors to reduce reflection.

• Use protective screens or barriers to protect others from flash and glare.

• Warn others not to watch the arc. Use placards or signs.

Safety

Minimum

Arc current

(amps)

protective shade

number

(ANSIZ49.1:2005)

Less than 40 A

41 to 60 A

61 to 80 A

81 to 125 A

126 to 150 A

151 to 175 A

176 to 250 A

251 to 300 A

301 to 400 A

401 to 800 A

5589 6689 8889 8989 89810 89811 89812 89813 912913

10 14 10 N /A

Safety and Compliance SC-17

Suggested shade

number for

comfort

OSHA 29CFR

1910.133(a)(5)

EN168:2002

(ANSI Z49.1:2005)

Europe

Safety

PACEMAKER AND HEARING AID OPERATION

Pacemaker and hearing aid operation can be affected by magnetic fields from high currents.

Pacemaker and hearing aid wearers should consult a doctor before going near any plasma arc cutting and gouging operations.

NOISE CAN DAMAGE HEARING

Cutting with a plasma arc can exceed acceptable noise levels as defined by local codes in many applications. Prolonged exposure to excessive noise can damage hearing. Always wear proper ear protection when cutting or gouging, unless sound pressure level measurements taken at the installed site have verified personal hearing protection is not necessary per relevant international, regional, and local codes.

Significant noise reduction can be obtained by adding simple engineering controls to cutting tables such as barriers or curtains positioned between the plasma arc and the workstation; and/or locating the workstation away from the plasma arc. Implement administrative controls in the workplace to restrict access, limit operator exposure time, screen off noisy working areas and/or take measures to reduce reverberation in working areas by putting up noise absorbers.

To reduce magnetic field hazards:

• Keep both the work cable and the torch lead to one side, away from your body.

• Route the torch leads as close as possible to the work cable.

• Do not wrap or drape the torch lead or work cable around your body.

• Keep as far away from the power supply as possible.

Use ear protectors if the noise is disruptive or if there is a risk of hearing damage after all other engineering and administrative controls have been implemented. If hearing protection is required, wear only approved personal protective devices such as ear muffs or ear plugs with a noise reduction rating appropriate for the situation. Warn others in the area of possible noise hazards. In addition, ear protection can prevent hot splatter from entering the ear.

A PLASMA ARC CAN DAMAGE FROZEN PIPES

Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch.

SC-18 Safety and Compliance

DRY DUST COLLECTION INFORMATION

Safety

At some sites, dry dust can represent a potential explosion hazard.

The U.S. National Fire Protection Association’s 2007 edition of NFPA standard 68, “Explosion Protection by Deflagration Venting,” provides requirements for the design, location, installation, maintenance, and use of devices and systems to vent combustion gases and pressures after any deflagration event. Consult with the manufacturer or installer of any dry dust collection system for applicable requirements before you install a new dry dust collection system or make significant changes in the process or materials used with an existing dry dust collection system.

Consult your local “Authority Having Jurisdiction” (AHJ) to determine whether any edition of NFPA 68 has been “adopted by reference” in your local building codes.

Refer to NFPA68 for definitions and explanations of regulatory terms such as deflagration, AHJ, adopted by reference, the Kst value, deflagration index, and other terms.

Note 1 – Hypertherm’s interpretation of these new requirements is that unless a site-specific evaluation has been completed to determine that all dust generated is not combustible, the 2007 edition of NFPA 68 requires the use of explosion vents designed to the worst-case Kst value (see annex F) that could be generated from dust so that the explosion vent size and type can be designed. NFPA 68 does not specifically identify plasma cutting or other thermal cutting processes as requiring deflagration venting systems, but it does apply these new requirements to all dry dust collection systems.

Note 2 – Users of Hypertherm manuals should consult and comply with all applicable federal, state, and local laws and regulations. Hypertherm does not, by the publication of any Hypertherm manual, intend to urge action that is not in compliance with all applicable regulations and standards, and this manual may never be construed as doing so.

Safety and Compliance SC-19

Safety

LASER RADIATION

Exposure to the laser output can result in serious eye injury. Avoid direct eye exposure.

For your convenience and safety, on Hypertherm products that use a laser, one of the following laser radiation labels has been applied on the product near where the laser beam exits the enclosure. The maximum output (mV), wavelength emitted (nM) and, if appropriate, the pulse duration is also provided.

Additional laser safety instructions:

• Consult with an expert on local laser regulations. Laser safety training may be required.

• Do not allow untrained persons to operate the laser. Lasers can be dangerous in the hands of untrained users.

• Do not look into the laser aperture or beam at any time.

• Position the laser as instructed to avoid unintentional eye contact.

• Do not use the laser on reflective workpieces.

• Do not use optical tools to view or reflect the laser beam.

• Do not disassemble or remove the laser or aperture cover.

ADDITIONAL SAFETY INFORMATION

1. ANSI Standard Z49.1, Safety in Welding and Cutting, American Welding Society, 550 LeJeune Road P.O. Box 351020, Miami, FL 33135

2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and Welding Processes, American National Standards Institute 1430 Broadway, New York, NY 10018

3. ANSI Standard Z87.1, Safe Practices for Occupation and Educational Eye and Face Protection, American National Standards Institute, 1430 Broadway, New York, NY 10018

4. AWS F4.1, Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances, American Welding Society 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135

5. AWS F5.2, Recommended Safe Practices for Plasma Arc Cutting, American Welding Society 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135

• Modifying the laser or product in any way can increase the risk of laser radiation.

• Use of adjustments or performance of procedures other than those specified in this manual may result in hazardous laser radiation exposure.

• Do not operate in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust.

• Use only laser parts and accessories that are recommended or provided by the manufacturer for your model.

• Repairs and servicing MUST be performed by qualified personnel.

• Do not remove or deface the laser safety label.

6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in Cylinders, Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202

7. CSA Standard W117.2, Code for Safety in Welding and Cutting, Canadian Standards Association Standard Sales 178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada

8. NFPA Standard 51B, Cutting and Welding Processes, National Fire Protection Association 470 Atlantic Avenue, Boston, MA 02210

9. NFPA Standard 70–1978, National Electrical Code, National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210

10. OSHA, Safety and Health Standards, 29FR 1910 U.S. Government Printing Office, Washington, D.C. 20402

11. AWS Safety and Health Fact Sheets, American Welding Society 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135 www.aws.org/technical/facts/

SC-20 Safety and Compliance

WARNING LABELS

Read and follow these instructions, employer safety practices, and material safety data sheets. Refer to ANS Z49.1, “Safety in Welding, Cutting and Allied Processes” from American Welding Society (http://www.aws.org) and OSHA Safety and Health Standards, 29 CFR 1910 (http://www.osha.gov).

WARNING

1. Cutting sparks can cause explosion or ﬁre.

1.1 Do not cut near ﬂammables.

1.2 Have a ﬁre extinguisher nearby and ready to use.

1.3 Do not use a drum or other closed container as a cutting table.

2. Plasma arc can injure and burn; point the nozzle away from yourself. Arc starts instantly when triggered.

2.1 Turn off power before disassembling torch.

2.2 Do not grip the workpiece near the cutting path.

2.3 Wear complete body protection.

3. Hazardous voltage. Risk of electric shock or burn.

3.1 Wear insulating gloves. Replace gloves when wet or damaged.

3.2 Protect from shock by insulating yourself from work and ground.

3.3 Disconnect power before servicing. Do not touch live parts.

4. Plasma fumes can be hazardous.

4.1 Do not inhale fumes.

4.2 Use forced ventilation or local exhaust to remove the fumes.

4.3 Do not operate in closed spaces. Remove fumes with ventilation.

6. Become trained.

Only qualiﬁed personnel should operate this

equipment. Use torches speciﬁed in the manual. Keep non-qualiﬁed personnel and children away.

5. Arc rays can burn eyes and injure skin.

5.1 Wear correct and appropriate protective equipment to protect head, eyes, ears, hands, and body. Button shirt collar. Protect ears from noise. Use welding helmet with the correct shade of ﬁlter.

7. Do not remove, destroy, or cover this label.

Replace if it is missing, damaged, or worn (PN 110584 Rev C).

Plasma cutting can be injurious to operator and persons in the work area. Consult manual before operating. Failure to follow all these safety instructions can result in death.

AVERTISSEMENT

Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le non respect des ces instructions de sécurité peut entraîner la mort.

1. Les étincelles de coupage peuvent provoquer une explosion ou un incendie.

1.1 Ne pas couper près des matières inﬂammables.

1.2 Un extincteur doit être à proximité et prêt à être utilisé.

1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.

2. L’arc plasma peut blesser et brûler; éloigner la buse de soi. Il s’allume instantanément quand on l’amorce;

2.1 Couper l’alimentation avant de démonter la torche.

2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.

2.3 Se protéger entièrement le corps.

3. Tension dangereuse. Risque de choc électrique ou de brûlure.

3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou endommagés.

3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.

3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.

4. Les fumées plasma peuvent être dangereuses.

4.1 Ne pas inhaler les fumées

4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.

4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.

5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.

5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles contre le bruit. Utiliser un masque de soudeur avec un ﬁltre de nuance appropriée.

6. Suivre une formation. Seul le personnel qualiﬁé a le droit de faire

fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le manual. Le personnel non qualiﬁé et les enfants doivent se tenir à l’écart.

7. Ne pas enlever, détruire ni couvrir cette étiquette.

La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C).

This warning label is affixed to some power supplies. It is important that the operator and maintenance technician understand the intent of these warning symbols as described.

Safety

Safety and Compliance SC-21

Safety

Warning labels

This warning label is affixed to some power supplies. It is important that the operator and maintenance technician understand the intent of these warning symbols as described. The numbered text corresponds to the numbered boxes on the label.

1. Cutting sparks can cause explosion or fire.

1.1 Do not cut near flammables.

1.2 Have a fire extinguisher nearby and ready to use.

1.3 Do not use a drum or other closed container as a cutting table.

2. Plasma arc can injure and burn; point the nozzle away from yourself. Arc starts instantly when triggered.

2.1 Turn off power before disassembling torch.

2.2 Do not grip the workpiece near the cutting path.

2.3 Wear complete body protection.

3. Hazardous voltage. Risk of electric shock or burn.

3.1 Wear insulating gloves. Replace gloves when wet or damaged.

3.2 Protect from shock by insulating yourself from work and ground.

3.3 Disconnect power before servicing. Do not touch live parts.

4. Plasma fumes can be hazardous.

4.1 Do not inhale fumes.

4.2 Use forced ventilation or local exhaust to remove the fumes.

4.3 Do not operate in closed spaces. Remove fumes with ventilation.

5. Arc rays can burn eyes and injure skin.

5.1 Wear correct and appropriate protective equipment to protect head, eyes, ears, hands, and body. Button shirt collar. Protect ears from noise. Use welding helmet with the correct shade of filter.

6. Become trained. Only qualified personnel should operate this equipment. Use torches specified in the manual. Keep non-qualified personnel and children away.

7. Do not remove, destroy, or cover this label. Replace if it is missing, damaged, or worn.

SC-22 Safety and Compliance

Safety

Symbols and marks

Your product may have one or more of the following markings on or near the data plate. Due to differences and conflicts in national regulations, not all marks are applied to every version of a product.

S mark

The S mark indicates that the power supply and torch are suitable for operations carried out in environments with increased hazard of electrical shock according to IEC 60974-1.

CSA mark

Products with a CSA mark meet the United States and Canadian regulations for product safety. The products were evaluated, tested, and certified by CSA-International. Alternatively, the product may have a mark by one of the other Nationally Recognized Testing Laboratories (NRTL) accredited in both the United States and Canada, such as UL or TÜV.

CE mark

The CE marking signifies the manufacturer’s declaration of conformity to applicable European directives and standards. Only those versions of products with a CE marking located on or near the data plate have been tested for compliance with the European Low Voltage Directive and the European Electromagnetic Compatibility (EMC) Directive. EMC filters needed to comply with the European EMC Directive are incorporated within versions of the product with a CE marking.

Eurasian Customs Union (CU) mark

CE versions of products that include an EAC mark of conformity meet the product safety and EMC requirements for export to Russia, Belarus, and Kazakhstan.

GOST-TR mark

CE versions of products that include a GOST-TR mark of conformity meet the product safety and EMC requirements for export to the Russian Federation.

C-Tick mark

CE versions of products with a C-Tick mark comply with the EMC regulations required for sale in Australia and New Zealand.

CCC mark

The China Compulsory Certification (CCC) mark indicates that the product has been tested and found compliant with product safety regulations required for sale in China.

UkrSEPRO mark

The CE versions of products that include a UkrSEPRO mark of conformity meet the product safety and EMC requirements for export to the Ukraine.

Serbian AAA mark

CE versions of products that include a AAA Serbian mark meet the product safety and EMC requirements for export to Serbia.

Safety and Compliance SC-23

Safety

SC-24 Safety and Compliance

Product Stewardship

Introduction

Hypertherm maintains a global Regulatory Management System to ensure that products comply with regulatory and environmental requirements.

National and local safety regulations

National and Local safety regulations shall take precedence over any instructions provided with the product. The product shall be imported, installed, operated and disposed of in accordance with national and local regulations applicable to the installed site.

Certification test marks

Certified products are identified by one or more certification test marks from accredited testing laboratories. The certification test marks are located on or near the data plate.

Each certification test mark means that the product and its safety-critical components conform to the relevant national safety standards as reviewed and determined by that testing laboratory. Hypertherm places a certification test mark on its products only after that product is manufactured with safety-critical components that have been authorized by the accredited testing laboratory.

Once the product has left the Hypertherm factory, the certification test marks are invalidated if any of the following occurs:

Voltage Directive and the European EMC Directive. EMC filters needed to comply with the European EMC Directive are incorporated within versions of the power supply with a CE Marking.

Certificates of compliance for Hypertherm products are available from the Downloads Library on the Hypertherm web site at https://www.hypertherm.com.

Differences in national standards

Nations may apply different performance, safety or other standards. National differences in standards include, but are not limited to:

•Voltages

• Plug and cord ratings

• Language requirements

• Electromagnetic compatibility requirements

These differences in national or other standards may make it impossible or impractical for all certification test marks to be placed on the same version of a product. For example, the CSA versions of Hypertherm’s products do not comply with European EMC requirements, and therefore do not have a CE marking on the data plate.

Countries that require CE marking or have compulsory EMC regulations must use CE versions of Hypertherm products with the CE marking on the data plate. These include, but are not limited to:

• The product is modified in a manner that creates a hazard or non-conformance with the applicable standards.

• Safety-critical components are replaced with unauthorized spare parts.

• Any unauthorized assembly, or accessory that uses or generates a hazardous voltage is added.

• There is any tampering with a safety circuit or other feature that is designed into the product as part of the certification, or otherwise.

CE marking constitutes a manufacturer’s declaration of conformity to applicable European directives and standards. Only those versions of Hypertherm products with a CE Marking located on or near the data plate have been tested for compliance with the European Low

• Australia

• New Zealand

• Countries in the European Union

•Russia

It is important that the product and its certification test mark be suitable for the end-use installation site. When Hypertherm products are shipped to one country for export to another country; the product must be configured and certified properly for the end-use site.

Safety and Compliance SC-25

Product Stewardship

Safe installation and use of shape cutting equipment

IEC 60974-9, titled Arc Welding Equipment – Installation and use, provides guidance in the safe installation and use of shape cutting equipment and the safe performance of cutting operations. The requirements of national and local regulations shall be taken into consideration during installation, including, but not limited to, grounding or protective earth connections, fuses, supply disconnecting device, and type of supply circuit. Read these instructions before installing the equipment. The first and most important step is the safety assessment of the installation.

The safety assessment must be performed by an expert, and determines what steps are necessary to create a safe environment, and what precautions should be adopted during the actual installation and operation.

Procedures for periodic inspection and testing

Where required by local national regulations, IEC 60974-4 specifies test procedures for periodic inspection and after repair or maintenance, to ensure electrical safety for plasma cutting power sources built in conformity with IEC 60974-1. Hypertherm performs the continuity of the protective circuit and insulation resistance tests in the factory as non-operating tests. The tests are performed with the power and ground connections removed.

Hypertherm also removes some protective devices that would cause false test results. Where required by local national regulations, a label shall be attached to the equipment to indicate that it has passed the tests prescribed by IEC 60974-4. The repair report shall indicate the results of all tests unless an indication is made that a particular test has not been performed.

Qualification of test personnel

Electrical safety tests for shape cutting equipment can be hazardous and shall be carried out by an expert in the field of electrical repair, preferably someone also familiar with welding, cutting, and allied processes. The safety risks to personnel and equipment, when unqualified personnel are performing these tests, may be much greater than the benefit of periodic inspection and testing.

Residual current devices (RCDs)

In Australia and some other countries, local codes may require the use of a Residual Current Devices (RCD) when portable electrical equipment is used in the workplace or at construction sites to protect operators from electrical faults in the equipment. RCDs are designed to safely disconnect the mains electrical supply when an imbalance is detected between the supply and return current (there is a leakage current to earth). RCDs are available with both fixed and adjustable trip currents between 6 to 40 milliamperes and a range of trip times up to 300 milliseconds selected for the equipment installation, application and intended use. Where RCDs are used, the trip current and trip time on RCDs should be selected or adjusted high enough to avoid nuisance tripping during normal operation of the plasma cutting equipment and low enough in the extremely unlikely event of an electrical fault in the equipment to disconnect the supply before the leakage current under a fault condition can pose a life threatening electrical hazard to operators.

To verify that the RCDs continue to function properly over time, both the trip current and the trip time should be tested periodically. Portable electrical equipment and RCDs used in commercial and industrial areas in Australia and New Zealand are tested to the Australian standard AS/NZS 3760. When you test the insulation of plasma cutting equipment to AS/NZS 3760, measure the insulation resistance according to Appendix B of the standard, at 250 VDC with the power switch in the ON position to verify proper testing and to avoid the false failure of the leakage current test. False failures are possible because the metal oxide varistors (MOVs) and electromagnetic compatibility (EMC) filters, used to reduce emissions and protect the equipment from power surges, may conduct up to 10 milliamperes leakage current to earth under normal conditions.

If you have any questions regarding the application or interpretation of any IEC standards described here, you are required to consult with an appropriate legal or other advisor familiar with the International Electrotechnical standards, and shall not rely on Hypertherm in any respect regarding the interpretation or application of such standards.

Hypertherm recommends that only visual inspection be performed unless the electrical safety tests are specifically required by local national regulations in the country where the equipment is installed.

SC-26 Safety and Compliance

Higher-level systems

When a system integrator adds additional equipment; such as cutting tables, motor drives, motion controllers or robots; to a Hypertherm plasma cutting system, the combined system may be considered a higher-level system. A higher-level system with hazardous moving parts may constitute industrial machinery or robotic equipment, in which case the OEM or end-use customer may be subject to additional regulations and standards than those relevant to the plasma cutting system as manufactured by Hypertherm.

It is the responsibility of the end-use customer and the OEM to perform a risk assessment for the higher-level system, and to provide protection against hazardous moving parts. Unless the higher-level system is certified when the OEM incorporates Hypertherm products into it, the installation also may be subject to approval by local authorities. Seek advice from legal counsel and local regulatory experts if you are uncertain about compliance.

Product Stewardship

External interconnecting cables between component parts of the higher level system must be suitable for contaminants and movement as required by the final end use installation site. When the external interconnecting cables are subject to oil, dust, water, or other contaminants, hard usage ratings may be required.

When external interconnecting cables are subject to continuous movement, constant flexing ratings may be required. It is the responsibility of the end-use customer or the OEM to ensure the cables are suitable for the application. Since there are differences in the ratings and costs that can be required by local regulations for higher level systems, it is necessary to verify that any external interconnecting cables are suitable for the end-use installation site.

Safety and Compliance SC-27

Product Stewardship

SC-28 Safety and Compliance

Environmental Stewardship

Introduction

The Hypertherm Environmental Specification requires RoHS, WEEE and REACH substance information to be provided by Hypertherm’s suppliers.

Product environmental compliance does not address the indoor air quality or environmental release of fumes by the end user. Any materials that are cut by the end user are not provided by Hypertherm with the product. The end user is responsible for the materials being cut as well as for safety and air quality in the workplace. The end user must be aware of the potential health risks of the fumes released from the materials being cut and comply with all local regulations.

National and local environmental regulations

National and local environmental regulations shall take precedence over any instructions contained in this manual.

The product shall be imported, installed, operated and disposed of in accordance with all national and local environmental regulations applicable to the installed site.

The European Environmental regulations are discussed later in The WEEE Directive.

“CE Marking” on the data plate of CE versions of Powermax series units shipped since 2006. Parts used in CSA versions of Powermax and other products manufactured by Hypertherm that are either out of scope or exempt from RoHS are continuously being converted to RoHS compliance in anticipation of future requirements.

Proper disposal of Hypertherm products

Hypertherm plasma cutting systems, like all electronic products, may contain materials or components, such as printed circuit boards, that cannot be discarded with ordinary waste. It is your responsibility to dispose of any Hypertherm product or component part in an environmentally acceptable manner according to national and local codes.

• In the United States, check all federal, state, and local laws.

• In the European Union, check the EU directives, national, and local laws. For more information, visit www.hypertherm.com/weee.

• In other countries, check national and local laws.

• Consult with legal or other compliance experts when appropriate.

The WEEE directive

The RoHS directive

Hypertherm is committed to complying with all applicable laws and regulations, including the European Union Restriction of Hazardous Substances (RoHS) Directive that restricts the use of hazardous materials in electronics products. Hypertherm exceeds RoHS Directive compliance obligations on a global basis.

Hypertherm continues to work toward the reduction of RoHS materials in our products, which are subject to the RoHS Directive, except where it is widely recognized that there is no feasible alternative.

Declarations of RoHS Conformity have been prepared for the current CE versions of Powermax plasma cutting systems manufactured by Hypertherm. There is also a “RoHS mark” on the Powermax CE versions below the

On January 27, 2003, the European Parliament and the Council of the European Union authorized Directive 2002/96/EC or WEEE (Waste Electrical and Electronic Equipment).

As required by the legislation, any Hypertherm product covered by the directive and sold in the EU after August 13, 2005 is marked with the WEEE symbol. This directive encourages and sets specific criteria for the collection, handling, and recycling of EEE waste. Consumer and business-to-business wastes are treated differently (all Hypertherm products are considered business-to-business). Disposal instructions for the CE versions of Powermax plasma systems can be found at www.hypertherm.com/weee.

Safety and Compliance SC-29

Environmental Stewardship

The URL is printed on the symbol-only warning label for each of these CE version Powermax series units shipped since 2006. The CSA versions of Powermax and other products manufactured by Hypertherm are either out of scope or exempt from WEEE.

The REACH regulation

The REACH regulation (1907/2006), in force since June1, 2007, has an impact on chemicals available to the European market. The REACH regulation requirements for component manufacturers states that the component shall not contain more than 0.1% by weight of the Substances of Very High Concern (SVHC).

Component manufacturers and other downstream users, such as Hypertherm, are obligated to obtain assurances from its suppliers that all chemicals used in or on Hypertherm products will have a European Chemical Agency (ECHA) registration number. To provide chemical information as required by the REACH regulation, Hypertherm requires suppliers to provide REACH declarations and identify any known use of REACH SVHC. Any use of SVHC in amounts exceeding

0.1% w/w of the parts has been eliminated. The MSDS contains a full disclosure of all substances in the chemical and can be used to verify REACH SVHC compliance.

The lubricants, sealants, coolants, adhesives, solvents, coatings and other preparations or mixtures used by Hypertherm in, on, for, or with its shape cutting equipment are used in very small quantities (except the coolant) and are commercially available with multiple sources that can and will be replaced in the event of a supplier problem associated with REACH Registration or REACH Authorization (SVHCs).

Proper handling and safe use of chemicals

Chemical Regulations in the USA, Europe, and other locations require that Material Safety Data Sheets (MSDS) be made available for all chemicals. The list of chemicals is provided by Hypertherm. The MSDS are for chemicals provided with the product and other chemicals used in or on the product. MSDS can be downloaded from the Downloads Library on the Hypertherm web site at https://www.hypertherm.com. On the Search screen, insert MSDS in the document title and click on Search.

Hypertherm does not manufacture or provide the materials that are cut and has no knowledge whether the fumes released from materials that are cut will pose a physical hazard or health risk. Please consult with your supplier or other technical advisor if you need guidance concerning the properties of the material you will cut using a Hypertherm product.

Fumes emission and air quality

Note: The following information on air quality is intended for general information only and should not be used as a substitute for reviewing and implementing applicable government regulations or legal standards in the country where the cutting equipment will be installed and operated.

In the USA, the National Institute for Occupational Safety and Health (NIOSH) Manual of Analytical Methods (NMAM) is a collection of methods for sampling and analyzing contaminants in workplace air. Methods published by others, such as OSHA, MSHA, EPA, ASTM, ISO or commercial suppliers of sampling and analytical equipment, may have advantages over NIOSH methods.

For example, ASTM Practice D 4185 is a standard practice for the collection, dissolution, and determination of trace metals in workplace atmospheres. The sensitivity, detection limit, and optimum working concentrations for 23 metals are listed in ASTM D 4185. An industrial hygienist should be used to determine the optimum sampling protocol, considering analytical accuracy, cost, and optimum sample number. Hypertherm uses a third party industrial hygienist to perform and interpret air quality testing results taken by air sampling equipment positioned at operator stations in Hypertherm buildings where plasma cutting tables are installed and operated.

Where applicable, Hypertherm also uses a third party industrial hygienist to obtain air and water permits.

If you are not fully aware and up to date on all applicable government regulations and legal standards for the installation site, you should consult a local expert prior to purchasing, installing, and operating the equipment.

In the USA, OSHA does not require Material Safety Data Sheets for articles such as electrodes, swirl rings, retaining caps, nozzles, shields, deflectors and other solid parts of the torch.

SC-30 Safety and Compliance

Shrink-wrap License Agreement

ENTERING INTO THE LICENSE AGREEMENT SET FORTH BELOW (THE “LICENSE AGREEMENT”) GIVES YOU THE RIGHT TO USE THE HYPERTHERM TECHNOLOGY AND RELATED SOFTWARE AND EMBODIED THEREIN WITH HYPERTHERM HPR XD PLASMA SYSTEMS.

PLEASE READ THE LICENSE AGREEMENT CAREFULLY BEFORE USING THE SOFTWARE.

YOUR RIGHT TO USE THE HYPERTHERM TECHNOLOGY AND RELATED SOFTWARE EMBODIED THEREIN IS SUBJECT TO YOUR AGREEMENT TO BE BOUND BY THE TERMS AND CONDITIONS OF THE LICENSE AGREEMENT. BY ACTIVATING YOUR CONTROL PLATFORM AND/OR RELATED SOFTWARE PLATFORM, YOU ACKNOWLEDGE YOUR ACCEPTANCE OF THE LICENSE AGREEMENT AND REPRESENT THAT YOU ARE AUTHORIZED TO ENTER INTO THE LICENSE AGREEMENT ON BEHALF OF LICENSEE. IF YOU DO NOT AGREE TO THESE TERMS AND CONDITIONS, HYPERTHERM DOES NOT GRANT YOU THE RIGHT TO USE THE HYPERTHERM TECHNOLOGY OR RELATED SOFTWARE.

1. Certain definitions: “Designated Hypertherm Patents 12/466,786, and 12/557,920, including foreign equivalents, and any patents issuing therefrom; “Hypertherm Plasma Systems” shall mean Hypertherm HPR XD plasma systems, including 130, 260 and 400 amp systems; “Hypertherm Technology” shall mean Hypertherm’s proprietary hole cutting technology, including know-how, specifications, inventions, methods, procedures, algorithms, software, programs, works of authorship and other information, documentation and materials for use in programming and operating an automated high temperature thermal cutting system; “Controller Platform supplied with this license; and “End User Customer(s) Technology for such entity’s own internal business purposes and not for distribution to others.

2. The End User Customer shall be granted a non-exclusive, non-transferable, personal license, without the right to sublicense, to use the Hypertherm Technology, for internal business purposes only, solely as incorporated within the Controller Platform and solely for use in conjunction with Hypertherm Plasma Systems.

3. The End User Customer shall be granted a non-exclusive, non-transferable, personal, royalty-free license, without the right to sublicense, under the Designated Hypertherm Patents solely to the extent necessary to enable the End User Customer to exercise the rights granted under Paragraph 2, above. The License Agreement shall provide that, except for the rights expressly granted to the End User Customer in the License Agreement, the license under the Designated Hypertherm Patents shall not be deemed to grant any license or immunity for combining the Hypertherm Technology with other items or for the use of such combination.

4. The licenses granted to the End User Customer under Paragraphs 2 and 3, above, shall expressly be made subject to the following limitations and restrictions, and the End User Customer’s agrees that it shall not (and shall not permit any third party to): (a) use or permit the use of the Hypertherm Technology in conjunction with any high temperature thermal cutting systems other than Hypertherm Plasma Systems; (b) remove, alter or obscure any copyright, trademark or other proprietary or restrictive notice or legend on or within the Hypertherm Technology; (c) disclose, sublicense, distribute or otherwise make available the Hypertherm Technology to any third party or permit others to use it; (d) provide timesharing, service bureau, data processing or other services to a third party whereby such third party would obtain the benefits of the Hypertherm Technology for its own end-user purposes through the End User Customer; (e) decompile, disassemble, or otherwise reverse engineer or attempt to deconstruct or discover any source code or underlying ideas or algorithms of the Hypertherm Technology by any means whatsoever; (f) assign, rent, lease, sell or otherwise transfer the Hypertherm Technology; or (g) modify or alter the Hypertherm Technology in any manner whatsoever or create derivative works thereof.

5. The License Agreement shall provide that nothing therein shall be construed as granting the End User Customer any right or license under any intellectual property right of Hypertherm or any of its licensors or suppliers by implication, estoppel or otherwise, except as expressly set forth in the License Agreement.

” shall mean Hypertherm computer numerical controller and/or MTC software platform

” shall mean United States Patent Application Nos. 12/341,731,

” shall mean an entity licensed to use the Hypertherm

Safety and Compliance SC-31

Shrink-wrap License Agreement

6. The License Agreement shall provide that Hypertherm shall retain sole and exclusive ownership of the Hypertherm Technology and that the End User Customer shall obtain no rights in the Hypertherm Technology, except for those expressly set forth in the sublicense agreement.

7. The License Agreement shall give Hypertherm the right to terminate the agreement effective immediately upon written notice if the End User Customer breaches any provision of the License Agreement and fails to cure such breach within five (5) days after receiving written notice thereof from Hypertherm.

8. HYPERTHERM, ITS LICENSORS AND SUPPLIERS MAKE NO REPRESENTATIONS OR WARRANTIES, EXPRESS OR IMPLIED, WITH RESPECT TO THE HYPERTHERM TECHNOLOGY OR RELATED SOFTWARE EMBODIED THEREIN, AND DISCLAIM ALL IMPLIED WARRANTIES, INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. WITHOUT LIMITING THE FOREGOING, NEITHER HYPERTHERM NOR ANY OF ITS LICENSORS OR SUPPLIERS MAKES ANY REPRESENTATION OR WARRANTY REGARDING THE FUNCTIONALITY, RELIABILITY OR PERFORMANCE OF THE HYPERTHERM TECHNOLOGY OR RELATED SOFTWARE EMBODIED THEREIN, OR THE RESULTS TO BE OBTAINED THROUGH THE USE OF THE HYPERTHERM TECHNOLOGY OR RELATED SOFTWARE, OR THAT THE OPERATION OF SUCH HYPERTHERM TECHNOLOGY OR RELATED SOFTWARE WILL BE UNINTERRUPTED OR ERROR-FREE.

9. TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW, IN NO EVENT SHALL HYPERTHERM, ITS LICENSORS OR SUPPLIERS BE LIABLE FOR ANY INDIRECT, EXEMPLARY, PUNITIVE, CONSEQUENTIAL, INCIDENTAL OR SPECIAL DAMAGES, INCLUDING LOST PROFITS, ARISING OUT OF OR IN CONNECTION WITH THE USE OF THE HYPERTHERM TECHNOLOGY OR RELATED SOFTWARE EMBODIED THEREIN, EVEN IF SUCH PARTY HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. THE LIMITATION STATED IN THIS SECTION SHALL APPLY REGARDLESS OF THE FORM OF ACTION, WHETHER THE ASSERTED LIABILITY OR DAMAGES ARE BASED ON CONTRACT (INCLUDING, BUT NOT LIMITED TO, BREACH OF WARRANTY), TORT (INCLUDING, BUT NOT LIMITED TO, NEGLIGENCE), STATUTE, OR ANY OTHER LEGAL OR EQUITABLE THEORY.

SC-32 Safety and Compliance

Section 1

Shape Library

The CNC contains a built-in Shape Library with more than 68 commonly used shapes. These shapes are parametric. Parametric shapes are shapes whose size or geometry you can edit. The shapes in the library are color-coded from easy (green) to difficult (black).

Phoenix 9.76.0 Programmer’s Reference 806420 33

1 – Shape Library

To select a simple shape:

1. On the Main screen, press Shape Manager.

2. Choose a shape, then OK.

The shape is displayed with the default parameters or the parameters from the last time this shape was edited. For more information on the available shapes, see Loading a part from the Shape Library in the Phoenix 9.72.0 Operator’s Manual.

Text Editor

The text editor screen allows you to write or edit a part program in either ESSI or EIA format. The current part that is in memory is displayed when this screen opens.

To edit code:

1. Choose a line of code. On the CNC, the alphanumeric keypad displays.

2. Enter changes to existing lines of code or add new lines.

3. Press OK to save your changes. If you want to save the changes to the hard drive, select Files > Save to Disk.

The text editor screen contains the following soft keys:

Show Original Text:

Allows you to view and edit the part program in its original format.

34 Phoenix 9.76.0 Programmer’s Reference 806420

1 – Shape Library

Delete Part: Deletes the current part from the Text Editor so that a new part can be constructed.

Shape Wizard

ShapeWizard® is a proprietary graphical part editor that provides a user-friendly, graphical interface for editing part programs.

You can view the segment that you edit and other changes that you make, as well.

There are a number of features on the Shape Wizard screen to facilitate editing part programs:

 The shape you select is displayed in the Preview Window and the corresponding code is displayed in the EIA Text

window.

 As you edit lines of code, the changes are visible in the Preview Window.

 You can add or modify EIA RS-274D codes in a part program in the EIA Text window.

 If you don’t know EIA RS-274D codes, you can edit or create segments by making entries and selections in the

Segment Data fields below the EIA Text window.

 Zoom keys decrease or increase the size of the part in the Preview Window.

To edit a part program in the EIA Text window:

1. Choose on a line of code to highlight it.

Phoenix 9.76.0 Programmer’s Reference 806420 35

1 – Shape Library

2. Choose Manual Line Edit. The alphanumeric keypad is displayed for line edits.

3. Type over a line to replace the text.

The ASCII text that you enter must be a valid EIA RS-274D code or an error message will display.

4. To view data about the segment of the part that you have highlighted, select the View Segment Data Below check box.

5. You can use the Segment Type field and related fields to change the highlighted segment type and add it to the program.

6. While a line is highlighted in blue, use soft keys to add or replace a segment:

Replace Segment: Replaces the segment highlighted in gray in the Text Editor window with the segment selected from the Segment Type window.

Insert Before Segment: Inserts the segment selected from the Segment Type window to be inserted before the segment highlighted in. gray in the Text Editor window.

Insert After Segment: Inserts the segment selected from the Segment Type window after the segment highlighted in gray in the Text Editor window.

Remove Segment: Deletes the segment that is highlighted in gray or blue in the EIA Text window from the part program.

7. As you edit a line of code, the picture of the part in the Preview window is updated. The corresponding segment is highlighted in red if it is a cut segment or in blue if it is a traverse.

Teach Trace

The Teach Trace function of the CNC allows parts and remnants to be traced rather than programmed. The position information from the traced part remains as a part program that can be saved to disk.

The Teach Trace algorithms in the CNC can recognize both arcs and lines. This reduces the overall memory required to store these parts and improves the smoothness of the cut.

The traced part in memory is in EIA format and can be cut, saved or edited using any of the part options.

Teach Trace has two modes, Remnant Trace and Teach Trace. The screen opens in Remnant Trace mode. Press the Select Teach Trace Mode soft key to use Teach Trace.

36 Phoenix 9.76.0 Programmer’s Reference 806420

1 – Shape Library

Remnant Trace Mode

In Remnant Trace mode, you can trace the outline of a plate remnant and save it as a file so that it can be used later and nests of parts can be cut from the remnant.

To trace a remnant:

1. On the TeachTrace screen, press the Select Remnant Mode soft key.

2. Jog to the point on the Remnant window where you want the trace to begin. Use the joystick or jog keys to move the

torch over the plate.

3. Choose First Point.

4. Jog to the next point and choose Next Point. Repeat this step until you have traced all but the final point.

5. When the pointer is over the last point you need to trace, choose Last Point. Trace Remnant draws a line between

this point and the first point to close the remnant.

6. Choose OK to let TeachTrace create the remnant. TeachTrace connects the last point to the first point automatically and returns to the Preview Window.

7. Choose Files > Save to Disk.

Phoenix 9.76.0 Programmer’s Reference 806420 37

1 – Shape Library

8. Select a folder for the new remnant file from the Save to drop-down list. It is helpful to have a folder named Remnant to hold your remnant files.

9. Enter a file name in the File Name field.

10. Choose OK.

Teach Trace Mo de

The Teach Trace function must be used with an optional stand-alone optical tracing system.

To trace a part:

1. Press Select Auto Mode to trace the part automatically.

2. Press Select Manual Mode to trace the part manually. This also enables the Change Move Speed button so you can

change the speed at which the sensor moves.

3. Select traverse or pierce. You can switch between traverse and pierce during the tracing procedure.

4. Position the optical sensor near the part drawing.

5. Press Start. Use the sensor positioning controls to direct the sensor towards the part.

6. After the sensor has located the part, the tracing system will follow the part outline until completion.

38 Phoenix 9.76.0 Programmer’s Reference 806420

1 – Shape Library

7. If you are using manual mode, you can press the Change Move Speed button repeatedly to select a speed for the optical sensor.

8. When the tracing system is finished tracing, press OK. You can cut, save or edit the part.

The Teach Trace function contains the following parameters:

Start Corner: Allows you to select where the part you trace will begin for proper viewing on the screen.

Tracing Pitch: Determines how precisely to learn a part. The Tracing Pitch can be adjusted to favor the resolution or size

of the taught part. This value does not affect the actual position resolution of the part.

A good starting point for most tracing systems is 0.01".

Arc Radial Error: Specifies the arc error tolerance to be used when checking the current segment for dimensional

accuracy. All ESSI or EIA programs are comprised of lines, arcs, and circles. Arc Radial Error is used to ensure that the starting and ending radial vectors are within tolerance to describe a valid geometry.

Auto Closure Detect: Allows the CNC to detect that it has returned to the starting point. With this feature on, the CNC

stops the motion of the tracer when the part is complete and programs a lead-out.

Closure Over/Under Lap: By specifying a positive value for this parameter, the CNC does not stop the tracer until it

has gone past the start point by the value of this parameter.

Specify a negative value to stop the tracer as soon as the tracing head position is within this parameter’s distance of the starting point. This is only available if the Auto Closure Detect is On.

Kerf Direction: Selects the kerf for cut segments.

Traverse/Pierce: Switches between the traverse and cut segments of the part as it is taught.

Select Auto/Manual Mode: Use this button to change trace modes.

If you select manual mode, you can also use the Change Move Speed button to change the trace speed.

Change Move Speed: Press this button to change the trace speed in manual mode.

Select Remnant Mode: Press this button to use remnant mode to create remnants.

Phoenix 9.76.0 Programmer’s Reference 806420 39

1 – Shape Library

40 Phoenix 9.76.0 Programmer’s Reference 806420

Section 2

ASCII Codes

This section provides the 128 ASCII codes (American Standard Code for Information Interchange) as defined by ANSI (American National Standards Institute) Standard X3.4-1977.

Phoenix 9.76.0 Programmer’s Reference 806420 41

2 – ASCII Codes

Control Codes

Hex Dec Character Name Description

00 0 ^ @ NUL Null

01 1 ^A SOH Start of Header

02 2 ^B STX Start of Text

03 3 ^C ETX End of Text

04 4 ^D EOT End of Transmission

05 5 ^E ENQ Enquiry

06 6 ^F ACK Acknowledge

07 7 ^G BE L Bell

08 8 ^H BS Backspace

09 9 ^I HT Horizontal Tab

0A 10 ^J LF Line Feed

0B 11 ^K VT Vertical Tab

0C 12 ^L FF Form Feed

0D 13 ^M CR Carriage Return

0E 14 ^N SO Shift Out

0F 15 ^O SI Shift In

10 16 ^P DLE Data Link Escape

11 17 ^Q DCI Device Control 1

12 18 ^R DC2 Device Control 2

13 19 ^S DC3 Device Control 3

14 20 ^T DC4 Device Control 4

15 21 ^U NAK Negative Acknowledge

16 22 ^V SYN Synchronous Idle

17 23 ^W ETB End Transmission Block

18 24 ^X CAN Cancel

19 25 ^Y EM End of Medium

42 Phoenix 9.76.0 Programmer’s Reference 806420

Hex Dec Character Name Description

1A 26 ^Z Sub Substitute

1B 27 ^[ ESC Escape

1C 28 ^\ FS File Separator

1D 29 ^] GS Group Separator

1E 30 ^^ RS Record Separator

1F 31 ^_ US Unit Separator

20 32 SP Space

2 – ASCII Codes

Phoenix 9.76.0 Programmer’s Reference 806420 43

2 – ASCII Codes

All Codes

Hex Dec Symbol Hex Dec Symbol Hex Dec Symbol

00 0 ^ @ 2B 43 + 56 86 V

01 1 ^A 2C 44 , 57 87 W

02 2 ^B 2D 45 - 58 88 X

03 3 ^C 2E 46 . 59 89 Y

04 4 ^D 2F 47 / 5A 90 Z

05 5 ^E 30 48 0 5B 91 [

06 6 ^F 31 49 1 5C 92 \

07 7 ^G 32 50 2 5D 93 ]

08 8 ^H 33 51 3 5E 94 ^

09 9 ^I 34 52 4 5F 95 _

0A 10 ^J 35 53 5 60 96 `

0B 11 ^K 36 54 6 61 97 a

0C 12 ^L 37 55 7 62 98 b

0D 13 ^M 38 56 8 63 99 c

0E 14 ^N 39 57 9 64 100 d

0F 15 ^O 3A 58 : 65 101 e

10 16 ^P 3B 59 ; 66 102 f

11 17 ^Q 3C 60 < 67 103 g

12 18 ^R 3D 61 = 68 104 h

13 19 ^S 3E 62 > 69 105 i

14 20 ^T 3F 63 ? 6A 106 j

15 21 ^U 40 64 @ 6B 107 k

16 22 ^V 41 65 A 6C 108 l

17 23 ^W 42 66 B 6D 109 m

18 24 ^X 43 67 C 6E 110 n

19 25 ^Y 44 68 D 6D 111 o

44 Phoenix 9.76.0 Programmer’s Reference 806420

2 – ASCII Codes

Hex Dec Symbol Hex Dec Symbol Hex Dec Symbol

1A 26 ^Z 45 69 E 70 112 p

1B 27 ^[ 46 70 F 71 113 q

1C 28 ^\ 47 71 G 72 114 r

1D 29 ^] 48 72 H 73 115 s

1E 30 ^^ 49 73 I 74 116 t

1F 31 ^_ 4A 74 J 75 117 u

20 32 4B 75 K 76 118 v

21 33 ! 4C 76 L 77 119 w

22 34 “ 4D 77 M 78 120 x

23 35 # 4E 78 N 79 121 y

24 36 $ 4F 79 O 7A 122 z

25 37 % 50 80 P 7B 123 {

26 38 & 51 81 Q 7C 124 |

27 39 ‘ 52 82 R 7D 125 }

28 40 ( 53 83 S 7E 126 ~

29 41 ) 54 84 T 7F 127 ¬

2A42‘ 5585U

Phoenix 9.76.0 Programmer’s Reference 806420 45

2 – ASCII Codes

46 Phoenix 9.76.0 Programmer’s Reference 806420

Section 3

EIA RS-274D Program Support

1BThe CNC supports EIA RS-274D part programs. An EIA RS-274D program lists the codes that are used to create a part.

The Phoenix software provides the ShapeWizard

The following list defines the EIA codes that are directly supported, mapped, or currently unsupported by the CNC. Mapped EIA codes are automatically converted into directly supported EIA codes when the program is loaded. Unsupported EIA codes are ignored. All other EIA codes generate an error.

graphical programming environment to help you edit your programs.

Phoenix 9.76.0 Programmer’s Reference 806420 47

3 – EIA RS-274D Program Support

Directly Supported EIA Codes

EIA Code Description

Fx Machine Speed (if Speed Override enabled)

Nx Line Number

(text) Comments

Xxx X Axis Endpoint or other Data

Yxx Y Axis Endpoint or other Data

Ixx I Axis Integrand or Part Option Data

Jxx J Axis Integrand or Part Option Data

Oxx Sxx Output (1-64), State (0-Off or 1-On)

Wxx Sxx Wait for Input (1-64), State (0-Off or 1-On)

G00 Xx Yx Rapid traverse (linear interpolation)

G00 Ax Sets Tilt angle – A is the angle value in degrees

G00 XYxx Axx Performs Linear Interpolation of Tilt angle along line segment.

G00 Xx Yx Traverse command where x = value to move the desired axes a distance.

G00 Zx.xx Tx Index THC height Z distance for torch T. Manual mode only.

G00 Cxx Move to rotate “C” position

G00 C180- Rotate Axis offset 180 degrees will continue to rotate in the proper direction

G00 C-180- Rotate Axis offset -180 degrees will continue to rotate in the proper direction

G00 Px Tx Sx Rx Rapid traverse: Rotate Transverse 2 axis for square or rectangular tube positioning.

P = +/- 180 degrees

T = Top measurement of tube

S = Side measurement of tube

R = Corner radius, +/- 90 degrees

X or Y = Optional: Rail axis position

G01 Xx Yx Linear interpolation (cut) at program cut speed

G01 Ax Fx Sets Tilt angle, A-axis position in degrees with a speed command (F) in RPM. F is

required.

G01 Cx Fx Sets Rotate angle, C-axis position in degrees with a speed command (F) in RPM. F is

required.

G01 C180- Fx Rotate Axis offset 180 degrees with speed command in RPM. F is required.

G01 C-180- Fx Rotate Axis offset -180 degrees with speed command in RPM. F is required.

48 Phoenix 9.76.0 Programmer’s Reference 806420

3 – EIA RS-274D Program Support

EIA Code Description

G01 Px Fx Tx Sx Rx Rotate Transverse 2 axis for square or rectangular tube cutting.

P = +/- 180 degrees

F = Optional: Rotational speed in RPM

T = Top measurement of tube

S = Side measurement of tube

R = Corner radius, +/- 90 degrees

X or Y = Optional: Rail axis position

G02 Xx Yx Ix Jx Clockwise Circle or Arc

Xx Yx = Arc end point

Ix Jx = Arc center point (radius value)

G03 Xx Yx Ix Jx Counterclockwise Circle or Arc

Xx Yx = Arc end point

Ix Jx = Arc center point (radius value)

G04 Preset Dwell (uses Setup Dwell Time)

G04 xx Program Dwell in Seconds

G08 X x Repeat Subroutine X Times

G20 Select English Units (inches)

G21 Select Metric Units (mm)

G40 Disable Kerf Compensation

G41 Enable Left Kerf Compensation

G42 Enable Right Kerf Compensation

G43 Xx Kerf Value

G41 D1-200 Enables Left Kerf using a Kerf Table variable

G42 D1-200 Enables Right Kerf using a Kerf Table variable

G43 D1-200 Sets the current Kerf value via the Kerf Table using prior set Left / Right Kerf

G59 D1-200Xx Sets Kerf table variable from 1-200

G59 Vxx Fxx Changes Hypertherm CNC parameters from within the part programs. This use of the

G59 code is unique to Hypertherm part programs that run on a Hypertherm CNC. See G59 Process Variables on page 89 for more information.

G66 Dx Bx Cx Auto Align 3 Point Method with Long Offset Distance, Fast Speed, Slow Speed values

respectively

G82 Oxyfuel Cut Mode

G83 Oxyfuel Cut Mode Contour Bevel Head

G84 Plasma Cut Mode

G85 Plasma Cut Mode Contour Bevel Head

Phoenix 9.76.0 Programmer’s Reference 806420 49

3 – EIA RS-274D Program Support

EIA Code Description

G90 Absolute Programming Mode

G91 Incremental Programming Mode

G92 Set Axis Presets

G93 Xx.xxx Bevel consumable correction. Adds or subtracts a value from the Bevel Pivot Length

parameter used only with ABXYZ bevel heads. The Bevel Pivot Length baseline value uses 130A O code at the beginning of the part program (after setting the part program units) to change the Bevel Pivot Length.

For example, G93 X0.035 adds 0.035 inches (0.89 mm) to the Bevel Pivot Length to correct for HPR260XD consumables.

80 A O 130 A O 200 A O 260 A O 400 A O

Bevel Pivot Length.)

/Air consumables. When using a different consumable set, issue the G93

/Air = 0.000 inches or mm

/Air = 0.011 inches or 0.28 mm

/Air = 0.035 inches or 0.89 mm

/Air = -0.019 inches or -0.48 mm (The 400 A values are subtracted from the

G96 X xx Sets the rotational speed of a rotating Transverse 2 axis used in pipe cutting (use Y if Y is

the Transverse axis). The xx value equals the diameter of the pipe.

G97 Program Repeat Pointer

G97 Tx Program Repeat Pointer. Executes the repeat T times

G98 Repeat at G97, or start of program if no G97

G99 Part Options

M00 Program Stop

M01 Optional Program Stop (uses Setup Parameter)

M02 End of Program

M07 Cut On

M07 HS Forces an IHS for cutting, regardless of the distance between cuts or any previous M08

command.

M08 RF Retracts to Full Retract height. Works only with Sensor THC.

M08 RT –x.xx Retracts to the Transfer Height and skips IHS, if the skip IHS distance is >0, instead of

the Retract Height at the end of a cut. The –x.xx variable represents the amount of time before the end of a cut that the Cut Off command is issued.

M08 Txx.xx Cut Off

T = Temporary Optional Time Delay from –1 to 99.99 seconds

M09 Enable Marker 1

M09 HS Forces an IHS for marking, regardless of the distance between marks or any previous

M10 RT command.

M10 Disable Marker 1

50 Phoenix 9.76.0 Programmer’s Reference 806420

3 – EIA RS-274D Program Support

EIA Code Description

M10 RF Retracts to Retract Height. Works only with Sensor THC.

M10 RT Retracts to the Transfer Height and skips IHS, if the skip IHS distance is >0, instead of

the Retract Height at the end of a mark.

M11 Marker Offset 1 On

M12 Marker Offset 1 Off

M13 Enable Marker 2

M14 Disable Marker 2

M14 RF Retracts to Retract Height. Works only with Sensor THC.

M15 Cut On

M16 Cut Off

M17 Oxy Gas On

M18 Oxy Gas Off

M19 Cancel All Stations

M26 Station Select On

M27 Station Select Off

M28 Follower Disabled / CBH rotator disable or disable automatic control of C axis

M29 Follower Enable / CBH rotator disable/ enable automatic control of C axis.

M30 End of Program (same as M02)

M31 Reset Functions (Cut Off, Marker Off, Kerf Off)

M32 Unclamp / Unlock All Stations

M32 Txx Unclamp / Unlock T Station, where T = 1 through 19

M33 Unclamp / Lock All Stations

M34 Clamp / Unlock All Stations

M34 Txx Clamp / Unlock T Station, where T = 1 through 19

M35 Clamp / Unlock All Stations Mirror

M35 Txx Clamp / Unlock Mirror T Station, where T = 1 through 19

M36 Tx Process Select T where x selects the process

1 = Plasma 1 2 = Plasma 2 3 = Marker 1 4 = Marker 2 5 = Laser 6 = Waterjet

M37 Txx (1-20) Select Station T where T = 1 through 20

M38 Txx (1-20) Deselect Station T where T = 1 through 20

Phoenix 9.76.0 Programmer’s Reference 806420 51

3 – EIA RS-274D Program Support

EIA Code Description

M40 Start of Subroutine

M40 x Start of Subroutine. Executes the repeat X times

M41 End of Subroutine

M48 Speed Override Enable

M49 Speed Override Disable

M50 Disable torch height control

M51 Txx.xx Enable torch height control (Optional Time Delay in seconds before enable)

M52 Disable Sensor THC and raise torch (for oxyfuel parts only)

M53 Enable Sensor THC and lower torch (for oxyfuel parts only)

M63 User Defined 1 On

M64 User Defined 1 Off

M54 User Defined 2 On

M55 User Defined 2 Off

M56 User Defined 3 On

M57 User Defined 3 Off

M58 User Defined 4 On

M59 User Defined 4 Off

M65 End of Program (same as M02) or Auto Reload

M72 Marker Offset 2 Off

M73 Marker Offset 2 On

M75 A Axis/Tilt Go to Home Command - Rapid Index

M76 C Axis/Rotate Go to Home Command - Rapid Index

M77 Go to Home position Y Axis

M78 Go to Home position X Axis

M79 Tx (1-4) Go To Home Position (1-4)

M84 Disable Mirror Head 2

M85 Enable Mirror Head 2

M86 Unpark Head 1

M87 Park Head 1

M88 Unpark Head 2

M89 Park Head 2

M90 Aligns CBH / Rotator to Tangent angle of next cut segment

M90- Align rotator negative, when not using shortest path motion

52 Phoenix 9.76.0 Programmer’s Reference 806420

3 – EIA RS-274D Program Support

EIA Code Description

M91 Space Head 2. Includes a spacingvalue that is an absolute position on the specified axis.

M92 Space Head 1. Includes a spacingvalue that is an absolute position on the specified axis.

M93 Drill Cycle output

M94 Peck Drill Cycle output

M95 Tap Cycle output

M96 Tool Change output

M274 Marker Offset 3 Off

M275 Marker Offset 3 On

M276 Marker Offset 4 Off

M277 Marker Offset 4 On

M278 Marker Offset 5 Off

M279 Marker Offset 5 On

M280 Marker Offset 6 Off

M281 Marker Offset 6 On

M282 Marker Offset 7 Off

M283 Marker Offset 7 On

M284 Marker Offset 8 Off

M285 Marker Offset 8 On

M286 Marker Offset 9 Off

M287 Marker Offset 9 On

M288 Marker Offset 10 Off

M289 Marker Offset 10 On

M290 Marker Offset 11 Off

M291 Marker Offset 11 On

M292 Marker Offset 12 On

M293 Marker Offset 12 On

M301 Assigns the current X/Y position to Home Position 1

M302 Assigns the current X/Y position to Home Position 2

M303 Assigns the current X/Y position to Home Position 3

M304 Assigns the current X/Y position to Home Position 4

M305 Assigns the current X/Y position to Home Position 5

M306 Assigns the current X/Y position to Home Position 6

M307 Assigns the current X/Y position to Home Position 7

Phoenix 9.76.0 Programmer’s Reference 806420 53

3 – EIA RS-274D Program Support

EIA Code Description

M308 Assigns the current X/Y position to Home Position 8

M309 Assigns the current X/Y position to Home Position 9

M310 Assigns the current X/Y position to Home Position 10

M311 Assigns the current X/Y position to Home Position 11

M312 Assigns the current X/Y position to Home Position 12

Mapped EIA Codes

Phoenix supports part programs that contain mapped EIA codes. However, all of the EIA codes in the program must be mapped. Phoenix supports code-mapping of the entire part program, but not a part program that has a mix of mapped and un-mapped codes.

EIA Code Description Mapped to

G04 Fx Program Dwell G04 x

G05 Set Axis Presets G92

G21 Linear Interpolation G01 (at cut speed)

G22 CW Circular Interpolation G02

G23 CCW Circular Interpolation G03

G41 Kx Left Kerf with value G41 with kerf value

G42 Kx Right Kerf with value G42 with kerf Value

G97 Tx Subroutine Loop G08 Xvalue and M40

G45 Lead In to Kerfed Part G01, G02, or G03

G70 Select English Units G20

G71 Select Metric Units G21

G98 End of Subroutine Loop M41

M03 Cutting Device On/Off M07 (Oxyfuel) or M08 as

appropriate

M04 Cutting Device On M07

M05 Cutting Device Off M08 (Oxyfuel)

M06 Cutting Device Off M08

M06 Enable Marker 2 M13

M07 Disable Marker 1 or 2 M10 or M14 as appropriate

M08 Enable Marker 1 M09

M09 Disable Marker 1 or 2 M10 or M14 as appropriate

M10 Enable Marker 2 M13

54 Phoenix 9.76.0 Programmer’s Reference 806420

3 – EIA RS-274D Program Support

EIA Code Description Mapped to

M14 Height Sensor Disable M50

M15 Height Sensor Enable M51

M20 Cutting Device On/Off M07 or M08 as appropriate

(Plasma)

M21 Cutting Device On/Off M07 or M08 as appropriate

(Plasma)

M20 Output 9 On O9 S1

M21 Output 9 Off O9 S0

M22 Output 12 On O12 S1

M23 Output 12 Off O12 S0

M24 Wait for Input 7 On W7 S1

M25 Wait for Input 8 On W8 S1

M25 CBH Enable M29

M26 Wait for Input 7 Off W7 S0

M26 CBH Disable M28

M27 Wait for Input 8 Off W8 S0

M67, M02 Kerf Left G41

M68, M03 Kerf Right G42

M69, M04 Kerf Off G40

M65, M70 Cutting Device On M07

M66, M71, M73 Cutting Device Off M08

M70 Marker Offset 1 Off M12

M71 Marker Offset 1 On M11

M70T01 Marker Offset 1 Off M12

M71T01 Marker Offset 1 On M11

M70T02 Marker Offset 2 Off M72

M71T02 Marker Offset 2 On M73

M70T03 Marker Offset 3 Off M274

M71T03 Marker Offset 3 On M275

M70T04 Marker Offset 4 Off M276

M71T04 Marker Offset 4 On M277

M70T05 Marker Offset 5 Off M278

M71T05 Marker Offset 5 On M279

M70T06 Marker Offset 6 Off M280

Phoenix 9.76.0 Programmer’s Reference 806420 55

3 – EIA RS-274D Program Support

EIA Code Description Mapped to

M71T06 Marker Offset 6 On M281

M70T07 Marker Offset 7 Off M282

M71T07 Marker Offset 7 On M283

M70T08 Marker Offset 8 Off M284

M71T08 Marker Offset 8 On M285

M98 End Comment )

M99 Start Comment (

M221 No Mirror, No Rotate G99 X1 Y0 I0 J0

M222 Mirror Y, No Rotate G99 X1 Y0 I0 J1

M223 Mirror X and Y G99 X1 Y0 I1 J1

M224 Mirror X, No Rotate G99 X1 Y0 I1 J0

M225 Mirror X/Y on -45 Deg G99 X1 Y270 I1 J0

M226 Rotate 90 Deg CCW G99 X1 Y90 I0 J0

M227 Mirror X/Y on +45 Deg G99 X1 Y270 I0 J1

M228 Rotate 90 Deg CW G99 X1 Y270 I0 J0

M245 Output 1 On O1 S1

M246 Output 1 Off O1 S0

M247 Output 2 On O2 S1

M248 Output 2 Off O2 S0

M249 Output 3 On O3 S1

M250 Output 3 Off O3 S0

M251 Output 4 On O4 S1

M252 Output 4 Off O4 S0

M253 Wait for Input 1 On W1 S1

M254 Wait for Input 1 Off W1 S0

M255 Wait for Input 2 On W2 S1

M256 Wait for Input 2 Off W2 S0

M257 Wait for Input 3 On W3 S1

M258 Wait for Input 3 Off W3 S0

M259 Wait for Input 4 On W4 S1

M260 Wait for Input 4 Off W4 S0

56 Phoenix 9.76.0 Programmer’s Reference 806420

Unsupported EIA Codes

EIA Code Description

G30 Mirror Off

G46 Table 0 Select

G94 Feed per minute

G95 Feed per rev

G99 Freestanding G99

G103 Qname Stop Current Program/ Load New Program

G201 Incremental Line In2

G202 Incremental CW Arc In2

G203 Incremental CCW Arc In2

G211 Incremental Line In3

G212 Incremental CW Arc In3

3 – EIA RS-274D Program Support

G213 Incremental CCW Arc In3

G221 Absolute Line In2

G222 Absolute CW Arc In2

G223 Absolute CCW Arc In2

G231 Absolute Line In3

G232 Absolute CW Arc In3

G233 Absolute CCW Arc In3

G240 Programmable Kerf

G247 Table 1 Select

G248 Table 2 Select

G249 Table 3 Select

G250 Table 4 Select

G276 Internal Variable Load

G277 External Variable Load

G278 X Axis Home

G279 Y Axis Home

G280 X Home Return

G281 Y Home Return

M66 PLC Control Code

M75 Ignored if not using CBH, Tilt Rotator(s)

M76 Ignored if not using CBH, Tilt Rotator(s)

Phoenix 9.76.0 Programmer’s Reference 806420 57

3 – EIA RS-274D Program Support

EIA Code Description

M210 X Sign Toggle

M211 Y Sign Toggle

M212 X and Y Swap and Toggle

M231 Aux. State Reset

M261 Aux. Torch Master On

M262 Aux. Torch Master Off

The unsupported EIA codes previously noted are ignored when read. Some of these codes may be supported in the future. Any EIA codes that are not listed above will result in a translator error upon loading the EIA program. Known EIA codes that will not be accepted include, but are not limited to:

 Pxx: Program number

 Dxx: Indexed Kerf operations

 Vxx: Internal variable load

EIA Comments

Comments may be placed into the part program to be displayed on screen and viewed by the operator. The comment line must first be preceded by a program stop command (EIA M00 code or ESSI 0 code). For example:

 M00 – Pauses Program

 (Comment) – Text to be displayed

58 Phoenix 9.76.0 Programmer’s Reference 806420

Section 4

ESSI Code Support

The CNC supports ESSI part programs as defined by the International Standards Organization in ISO 6582. An ESSI program lists the sequence of lines, arcs, speeds, kerf and I/O functions used to create a part. While the user is free to program in ESSI using a standard text editor, it is recommended that the ShapeWizard environment be used instead.

While the user is free to download ESSI programs to the control, it is important to note that all Part Programs will be internally converted to EIA for execution in the control. Following is a list of the ESSI codes that are mapped into the control, or currently unsupported by the control. Mapped ESSI codes are automatically converted upon program load into directly supported EIA codes. Unsupported ESSI codes are ignored. All other ESSI codes will generate an error.

Graphical Programming

Phoenix 9.76.0 Programmer’s Reference 806420 59

4 – ESSI Code Support

Mapped ESSI Codes

ESSI Code Description Mapped to EIA

% Start of Program Not Used-Automatic

+/-value… Line or Arc G00, G01, G02 or G03 as appropriate

0 End Program or Stop M02 or M00 (if 64 is End Program)

3 Start Comment (

4 End Comment )

5 Enable Rapid Traverse Not Used-Automatic

6 Disable Rapid Traverse Not Used-Automatic

7 Cutting Device On M07

8 Cutting Device Off M08

9 Enable Marker 1 M09

10 Disable Marker 1 M10

11 Marker Offset 1 On M11

12 Marker Offset 1 Off M12

11+1 Marker Offset 1 On M11

12+1 Marker Offset 1 Off M12

11+2 Marker Offset 2 On M73

12+2 Marker Offset 2 Off M72

11+3 Marker Offset 3 On M275

12+3 Marker Offset 3 Off M274

11+4 Marker Offset 4 On M277

12+4 Marker Offset 4 Off M276

11+5 Marker Offset 5 On M279

12+5 Marker Offset 5 Off M278

11+6 Marker Offset 6 On M281

12+6 Marker Offset 6 Off M280

11+7 Marker Offset 7 On M283

60 Phoenix 9.76.0 Programmer’s Reference 806420

ESSI Code Description Mapped to EIA

12+7 Marker Offset 7 Off M282

11+8 Marker Offset 8 On M285

12+8 Marker Offset 8 Off M284

13 Enable Marker 2 M13

14 Disable Marker 2 M14

15 Marker Offset 2 On M73

16 Marker Offset 2 Off M72

21 No Mirror, No Rotate G99 X1 Y0 I0 J0

22 Mirror Y, No Rotate G99 X1 Y0 I0 J1

23 Mirror X and Y G99 X1 Y0 I1 J1

4 – ESSI Code Support

24 Mirror X, No Rotate G99 X1 Y0 I1 J0

25 Mirror X/Y on -45 Deg G99 X1 Y270 I1 J0

26 Rotate 90 Deg CCW G99 X1 Y90 I0 J0

27 Mirror X/Y on +45 Deg G99 X1 Y270 I0 J1

28 Rotate 90 Deg CW G99 X1 Y270 I0 J0

29 Enable Left Kerf Comp G41

30 Enable Right Kerf Comp G42

38 Disable Kerf G40

39+value Machine Speed Fvalue

40+value Programmable Kerf G43 Xvalue

41 Preset Dwell G04

41+value Program Dwell in mSec G04 Xvalue

45 Ht Sensor Enable/Lower M53

46 Ht Sensor Disable/Raise M52

47 Ht Sensor Enable M51

48 Ht Sensor Disable M50

51 CBH Enable M29

Phoenix 9.76.0 Programmer’s Reference 806420 61

4 – ESSI Code Support

ESSI Code Description Mapped to EIA

52 CBH Disable M28

53 Cutting Device On M07

54 Cutting Device Off M08

63 Reset Functions M31

64 End Program M02

65 End of Program/ Reload M65

67 Ht Sensor Disable M50

68 Ht Sensor Enable M51

70 Select English Units (in) G20

71 Select Metric Units (mm) G21

79+1 Go To Home Position 1 M79 T1

79+2 Go To Home Position 2 M79 T2

79+3 Go To Home Position 3 M79 T3

79+4 Go To Home Position 4 M79 T4

81 Incremental Mode G91

82 Absolute Mode G90

83 Set Axis Presets G92

90 End of Program M02

97 Program Repeat Pointer G97

97+value Subroutine Loop M40 Xvalue

98 Repeat at 97, Subroutine loop G97, G98 or M41 as appropriate or start of

program if no 97

99 End of Program M02

245 Output 1 On O1 S1

246 Output 1 Off O1 S0

247 Output 2 On O2 S1

248 Output 2 Off O2 S0

62 Phoenix 9.76.0 Programmer’s Reference 806420

ESSI Code Description Mapped to EIA

249 Output 3 On O3 S1

250 Output 3 Off O3 S0

251 Output 4 On O4 S1

252 Output 4 Off O4 S0

253 Wait for Input 1 On W1 S1

254 Wait for Input 1 Off W1 S0

255 Wait for Input 2 On W2 S1

256 Wait for Input 2 Off W2 S0

257 Wait for Input 3 On W3 S1

258 Wait for Input 3 Off W3 S0

4 – ESSI Code Support

259 Wait for Input 4 On W4 S1

260 Wait for Input 4 Off W4 S0

282 Marker Offset 3 On M275

283 Marker Offset 3 Off M274

284 Marker Offset 4 On M277

285 Marker Offset 4 Off M276

286 Marker Offset 5 On M279

287 Marker Offset 5 Off M278

288 Marker Offset 6 On M281

289 Marker Offset 6 Off M280

290 Marker Offset 7 On M283

291 Marker Offset 7 Off M282

292 Marker Offset 8 On M285

293 Marker Offset 8 Off M284

Phoenix 9.76.0 Programmer’s Reference 806420 63

4 – ESSI Code Support

Unsupported ESSI Codes

ESSI Code Description

103+Name Stop Current Program/ Load New Program

237 X Sign Toggle

238 Y Sign Toggle

239 X and Y Swap and Toggle

266 Table 1 Select

267 Table 2 Select

268 Table 3 Select

269 Table 4 Select

276 Internal Variable Load

277 External Variable Load

278 X Axis Home

279 Y Axis Home

280 X Home Return

281 Y Home Return

The unsupported ESSI codes above are ignored when read. Some of these codes may be supported in the future. Any ESSI codes that are not listed above will result in a translator error upon loading the ESSI program.

64 Phoenix 9.76.0 Programmer’s Reference 806420

4 – ESSI Code Support

ESSI Comments

Comments may be placed in to the part program to be displayed on screen and viewed by the operator. The comment line must first be preceded by a program stop command (EIA M00 code or ESSI 0 code).

 ESSI example:

 0 – Pauses Program

 3 – Start Comment

 Comment – Text to be displayed

 4 – End Comment

Phoenix 9.76.0 Programmer’s Reference 806420 65

4 – ESSI Code Support

66 Phoenix 9.76.0 Programmer’s Reference 806420

Advanced Feature Codes

Kerf Table Codes

Code Description

G59 D1-200Xxx Sets kerf table variable from 1 – 200

G41 D1-200 Enables Left Kerf using a Kerf Table variable

G42 D1-200 Enables Right Kerf using a Kerf Table variable

G43 D1-200 Changes current kerf value via Kerf Table using previously set left or right kerf

Special Kerf and G59 Code Settings

Section 5

Kerf Override

By default, this option is enabled. If the parameter is disabled, all kerf value codes (G41 X, G42 X, G43 X, etc.) are ignored. The Load Kerf Table variable is also ignored. This parameter cannot be changed while the part program is paused.

G59 Code Override

By default, this option is enabled. If the parameter is disabled, all G59 codes are ignored. The parameter cannot be changed while the part program is paused.

Parallel Kerf Enable for Hole Center Piercing

This parameter allows the kerf to be enabled in parallel with the first segment of cut motion that follows the Enable Kerf command. Kerf location is interpolated in parallel with the first cut segment so that the kerf offset is reached by the end of the first cut segment. The overall effect on a radial lead-in is to turn it into a spiral lead-in. This parameter allows all current part programs and nests to take advantage of parallel kerf enable without being reposted by the host.

Phoenix 9.76.0 Programmer’s Reference 806420 67

5 – Advanced Feature Codes

Users of Hypertherm CNCs now have an option to enable or disable this feature in the Cut Setup screen.

Tilt / Rotator Part Codes

Code Description

G00 Avalue Sets tilt angle as a preparatory command – A is the angle value in degrees

G00 XYvalue Avalue Performs Linear Interpolation of Tilt angle along line segment.

G00 Avalue Fvalue Sets tilt angle – Angle value in degrees with a speed command in RPM

M28 Disables Follower

M29 Enables Follower

M90 Preparatory Cmd - Aligns Rotator to Tangent angle of next cut segment

M90- Align rotator when not using shortest path motion

M75 A axis/Tilt Goto Home Cmd - Rapid Index

G00 Cxx Move to rotate C position

G01 Cxx Fxx Move to rotate C position with Speed “F” command

G00 C180- Rotate Axis align 180 degrees will continue to rotate in the proper direction

G00 C-180- Rotate Axis align -180 degrees will continue to rotate in the proper direction

G01 C180- Fxx Rotate Axis align 180 degrees with speed

G01 C-180- Fxx Rotate Axis align -180 degrees with speed

Station Select Codes

Stations (Lifter / THCs) can be selected and de-selected using the following EIA-274D program codes.

Code Description

M19 Tvalue Cancel All Station Selections

M37 Tvalue Select Station 1-20 (Tvalue)

M38 Tvalue De-select Station 1-20 (Tvalue)

Additionally, these Station Select program codes can be overridden using the user selected THC inputs to the CNC. The feature to override the part program must be enabled at the Cutting Setup screen.

68 Phoenix 9.76.0 Programmer’s Reference 806420

5 – Advanced Feature Codes

Process Select Codes

Process selections can be made using a EIA-274D program code in the following format.

Example: M36 Tx

 M36 = Select Process

 Tx = Process name, where:

 T1 = Plasma Process 1

 T2 = Plasma Process 2

 T3 = Marker Process 1

 T4 = Marker Process 2

 T5 = Laser Process

 T6 = Waterjet

Automatic Plate Alignment Codes

Three point alignment distance and speeds can be defined with the following EIA format program code:

G66D100B300C30

Where:

 G66 = 3-point alignment command

 Dxx= Distance between two plate edge reference points

 Bxx = Rapid feed rate for distance (D) motion

 Cxx = Slow feed rate for the distance to the edge

Automatic Torch Spacing

The automatic torch spacing feature uses part program codes and CNC outputs to position cutting stations for multiple torch cutting processes.

To enable Automatic Torch Spacing:

1. Choose Setups > Password > Machine Setups and choose ON for Automatic Torch Spacing. Save the values.

2. In the Cutting screen, under Status and Program Code, set Auto Torch Spacing Override to Enabled.

In this process, the primary torch station has a fixed mount to the transverse axis and the other secondary torch stations have the ability to clamp to the mechanics of the transverse axis during use or lock to the gantry or beam when not in use.

For the example, in the following illustration, Torch 1 is the primary station and Torch 2-4 are the secondary stations.

Typical use is as follows:

1. Unclamp and unlock all stations (except the first which is fixed and slides the others).

Phoenix 9.76.0 Programmer’s Reference 806420 69

5 – Advanced Feature Codes

2. Go to Home Command on Transverse Axis (M77 or M78 depending on orientation).

3. Clamp and Unlock all carriages and G00 index inward on transverse (optional command - may used to space all

stations away from edge / OT switch of machine).

4. Lock and Unclamp all and G00 index to space first station (remember-first station has no clamping/locking on board).

70 Phoenix 9.76.0 Programmer’s Reference 806420

5. Unlock and Clamp next station and G00 index to space the next station.

5 – Advanced Feature Codes

6. Repeat Step 5 until as many stations as needed are spaced.

Homing also automatically includes the commands necessary to push the stations to the side and lock or clamp them



whenever the transverse is homed, if Auto Torch Spacing is enabled. Unclamp/ Clamp and Unlock / Lock commands execute a one second delay before moving.

Automatic Torch Spacing Program Codes

Code Description

M32 Unclamp / Unlock All Stations

M33 Unclamp / Lock All Stations

M34 Clamp / Unlock All Stations

M34Txx Clamp / Unlock T Station, where T = 1 through 19

M35 Clamp / Unlock All Stations Mirror

M35Txx Clamp / Unlock Mirror T Station, where T = 1 through 19

M77 Go to Home position Y Axis

M78 Go to Home position X Axis

G00 Xxx Yx Traverse command where x = value to move the desired axes a distance.

Phoenix 9.76.0 Programmer’s Reference 806420 71

5 – Advanced Feature Codes

Automatic Torch Spacing I/O

Station Lock 1-19: Locks the unused torch station to the gantry or beam when not in use.

Station Clamp 1-19: Clamps the selected torch station to the transverse axis for standard cutting.

Station Mirror 1-19: Clamps the selected torch station to the transverse axis for mirrored cutting.

Example Part Program

The transverse axis is configured as the X axis.

Three station cut of 20 inch vertical rip.

Code Description

G70 English Units

G91 Incremental Mode

G99 X1 Y0 I0 J0 Axes Preset zero Scaling

M32 Unclamp / Unlock All Stations

M78 Home X Axis (move all stations to Home position)

M34 Clamp All / Unlock All

G00X2Y0 Traverse X axis 2 inches (to move off edge/switch)

M33 Unclamp All / Lock All

G00X10Y0 Traverse X axis 10 inches (to set 10 inch space – station 1)

M34 T1 Clamp Station 1 / Unlock Station 1

G00X10Y0 Traverse X axis 10 inches (to set 10 inch space – station 2)

M34 T2 Clamp Station 2 / Unlock Station 2

G41 Left Kerf

M07 Cut On

G01 X0 Y20 Line segment (Y axis 20 inches)

M08 Cut Off

G40 Kerf Off

M02 End of Program

72 Phoenix 9.76.0 Programmer’s Reference 806420

5 – Advanced Feature Codes

Dual Transverse without Beveling

Hypertherm supports dual transverse without beveling for cutting machines that have only SERCOS drives.

To set up this type of table:

1. A CNC must be enabled with 10 axes.

2. SERCOS drives should be set up with the following addresses (on the physical drives):

 Address 1: Rail

 Address 2: Transverse

 Address 3: Dual Gantry

 Address 4: Sensor THC1

 Address 5: Dual Transverse

 Address 6: Sensor THC2 (if a second THC is used)

3. After these addresses are set, enable dual transverse. From the Main screen, select Setups > Password and enter the NRT password (no rotate and tilt).

The NRT password allows the use of dual transverse axis without dual bevel axes systems. The RT password reverses



this setup.

4. The measurement units (English or metric) that are used in the drives must match the units that are used in the CNC.

5. Park Dual Head 1 and Park Dual Head 2 are both required I/O points that must be assigned for either Park Dual

Head 1 or Park Dual Head 2 to function.

Beveling

Hypertherm supports several software beveling options. The following sections describe the software beveling options available. Hypertherm does not support the mechanical design of bevel heads.

Contour Bevel Head for Oxyfuel Cutting (CBH)

The CBH axis supports a rotational motion bevel for oxyfuel cutting process. There is no tilting axis with CBH. The CBH axis is either set up on Axis 3 or Axis 4, depending on whether dual gantry or Sensor THC axes are enabled and assigned to Axis 3. The beveling codes M28, M29, M90, and M76 (described in the M and G Codes Used for Beveling section), can be used with CBH. A CBH axis cannot be defined when tilt rotator or dual tilt rotator axes are defined on the Machine Setups screen.

The program code M90 is typically used at the beginning of a part program to align the rotational axis before cutting begins. The M76 code is used at the end of the part program to bring the CBH back to its rotational home position.

Tilt Rotator Plasma Bevel

The tilt rotator is assigned to Axes 5 and 6 and supports plasma beveling. The preferred tilt rotator settings include No Scaled Rotator, No Dual Tilting Rotator and No Transformation. These are the simplest settings and work well for bevel mechanical designs in which the torch center point is directly in line with the tilt and rotate axes.

Phoenix 9.76.0 Programmer’s Reference 806420 73

5 – Advanced Feature Codes

Some plasma bevel designs require that the rotator motion be scaled. The Scaled Rotator setting allows the rotational axis motion to be scaled directly by this parameter. It is the responsibility of the machine/bevel designer to determine the value for this setting, if it is required.

Some plasma bevel designs require dual tilting axes. Dual Tilting Mode 1 is used for most standard dual tilting systems where both tilt axes move through +/- 45 degrees to achieve the desired tilt and rotation motions. Mode 2 is a special form of dual tilting axis in which special equations control the motion. If Dual Tilting mode is needed, and special equations are needed, the machine/bevel designer must calculate and provide them. Hypertherm determines the amount of time that is required to add these equations to a new Dual Tilting mode for the customer.

Note that BACF, described in the Bevel Angle Change on the Fly (BACF) section, is not supported for dual tilting bevel designs. In addition, even though both axes are dual tilting, they are still referred to as rotate and tilt axes on all screens, as the effective motions are still rotation and tilt.

Some plasma bevel designs require a transformation of the rotate and tilt axes motion to achieve the proper motion. The transformation allows the torch to be at the correct bevel angle and orientation to the cut for the given bevel mechanical design. The machine/bevel designer must provide these equations if they are needed. Hypertherm determines the amount of time that is required to add these equations to a new Transformation mode for the customer. BACF, described in the Bevel Angle Change on the Fly (BACF) section, is supported for transformed bevel designs.

The beveling codes M28, M29, M90, M75, and M76, described in M and G Codes Used for Beveling, can be used with tilt rotator.

M90 is typically used at the beginning of the part to align the rotational axis before cutting begins. M75 and M76 are used at the end of the part to bring the tilt rotator back to its vertical home position.

Dual Tilt Rotator Plasma Bevel

The dual tilt rotator is assigned to Axes 8 and 9 and supports a second plasma beveling system. All of the settings described in the Tilt Rotator Plasma Bevel section also apply to the dual tilt rotator.

In addition, the dual tilt rotator can also have its own dual transverse axis assigned to Axis 7. When there is a dual transverse axis assigned, the two plasma bevel systems are homed to opposite sides of the machine. The dual transverse axis allows the two transverse axes to be independently parked and unparked, spaced, and mirrored to each other using the M84 through M92 commands described in M and G Codes Used for Beveling.

Include the following code sequences in your torch spacing part programs:

 M91Yxx – Moves Head 2 Yxx inches from Bevel Head 1

 M92Yxx – Moves Head 1 Yxx inches from Bevel Head 2

These spacing commands establish a relative spacing between the heads regardless of where the heads are actually located. Only one of these commands should be used at one time. If Head 1 needs to be at a specific position before head 2 is positioned in relation to Head 1, then the command sequence is:

 M89 – Park Head 2

 G01 Yxx – Move Head 1 to actual coordinate

 M88 – Unpark Head 2

 M91Yxx – Space Head 2 in relation to Head 1 by Yxx inches

 M02 – End Program – Used if this is a standalone Torch Spacing program

74 Phoenix 9.76.0 Programmer’s Reference 806420

5 – Advanced Feature Codes

Likewise, if Head 2 needs to be at a specific position before Head 1 is positioned in relation to Head 2, then the command sequence is:

 M87 – Park Head 1

 G01 Yxx – Move Head 2 to actual coordinate

 M86 – Unpark Head 1

 M92Yxx – Space Head 1 from Head 2 by Yxx inches

 M02 – End Program – if this is a standalone torch spacing program

Bevel Angle Change on the Fly (BACF)

BACF allows the tilt axis to change position in parallel with X and Y motion, instead of only in a preparatory G00 'Axx' command. 'G01,02,03 X Y I J Axx' is supported for true rotate and tilt bevel mechanical designs. BACF is not supported for dual tilting bevel mechanical designs.

The 'Axx' command (where xx = the bevel angle) executes in parallel with X and Y motion. The A angle is reached at the end of the segment.

All BACF motions are only performed if the maximum speed of the appropriate axis is not exceeded by excess X and Y speed, or by Max Tilt or Rotator Max speeds that are too low.

M and G Codes Used for Beveling

The following lists of the M and G codes can be used for beveling.

Kerf Table Commands to Change Kerf During Multi-pass, Multi-bevel Cuts

G59 D(1-200) Xvalue: Sets the kerf table variable from 1-200

G41 D(1-200): Enables the left kerf using a kerf table variable

G42 D(1-200): Enables the right kerf using a kerf table variable

G43 D(1-200): Changes the current kerf value via kerf table using previously set left or right kerf

Tilt/Rotator Commands

G00 Aangle in degrees: Sets Tilt angle as a preparatory command

G01 X Y Aangle in degrees: Performs Tilt BACF

M28: Disables follower

M29: Enables follower

M90: Aligns rotator to tangent angle of next cut segment

M75: A axis/tilt go to home command - rapid index

M76: C axis/rotate go to home command - rapid index

Phoenix 9.76.0 Programmer’s Reference 806420 75

5 – Advanced Feature Codes

Tool change cycle

CNC

PLC

(OEM

supplied)

Drilling/tapping

tools

(OEM supplied)

Drill cycle

Tool cycle active

Peck drill cycle

Tap cycle

Dual Tilt/Rotator Commands Used with Dual Plasma Bevel Systems

M84: Disable mirror Head 2

M85: Enable mirror Head 2

M86: Unpark Head 1

M87: Park Head 1

M88: Unpark Head 2

M89: Park Head 2

M91 Yxxxx: Space Head 2 xxxx millimeters

M92 Yxxxx: Space Head 1 xxxx millimeters

Tube cutting with bevel command

G00 or G01 Px Ax Tx Sx Rx Xx or Yx Rotate Transverse 2 axis for square or rectangular tube cutting.

P = +/- 180 degrees A = Tilt angle F = Rotational speed in RPM (optional only for G01. Not used for G00) T = Top measurement of tube S = Side measurement of tube R = Corner radius, +/- 90 degrees X or Y = Optional: Rail axis position

Drilling and Tapping using a PLC

Phoenix supports new program codes that turn on and off outputs to allow drilling and tapping with an external programmable logic control (PLC). The drill cycles can be included in a part program to be run on a multi-tool table.

76 Phoenix 9.76.0 Programmer’s Reference 806420

5 – Advanced Feature Codes

After wiring is complete between the CNC and the PLC, assign the outputs and input in the Machine Setups > I/O screen. When the CNC reads one of the following codes in a part program, it activates the corresponding output.

Code Output

M93 Drill cycle

M94 Peck drill cycle

M95 Tap cycle

M96 Tool change

Operation

 The CNC runs a part program and reads one of the tool cycle program codes.

 The CNC brings the gantry to a controlled stop and inhibits motion and then turns on the corresponding output.

 The PLC receives the input signal for one of the tool cycles and activates the Tool Cycle Active signal to the CNC.

 The CNC receives the Tool Cycle Active input from the PLC and waits.

 The PLC controls the operation of the drill during the tool cycle.

 The PLC turns off the Tool Cycle Active input when the tool cycle completes.

 The CNC turns off the tool cycle output and continues with the part program.

Notes:

 The CNC inhibits motion while the Tool Cycle Active input is on. When the input shuts off, motion immediately

starts. You can use the Program Inhibit input if a pause is required or if motion restarts too abruptly. Turn on the Program Inhibit input with the Tool Cycle Active input. Turn off the Program Inhibit input after a short time delay after shutting off the Tool Cycle Active input. Using the Program Inhibit input creates a smoother motion transition than relying on the Tool Cycle Active input alone.

 Pausing or stopping with Tool Cycle Active input on: When you press F10 to pause or stop the part

program, the Pause screen appears. The CNC turns off the drill or tool change cycle output. When the part program resumes, the CNC re-executes the drill cycle M code if the machine hasn’t been moved forward or backward on path. The CNC does not execute any X/Y motion until the drill cycle completes.

 Tool Cycle Active Input must be off to move the machine or resume part program motion.

 Drill and Tool Change cycles are not run in trial mode or when using Forward/Backup on Path on the Pause

screen.

 Serial messaging can be used can be used to issue tool change commands to a PLC before running the M

codes. See the Serial Messaging section of the Programmer’s Reference Manual for more information.

Sample code and description

The following sample code demonstrates the sequence of commands to drill a hole, then cut a 5 in (127 mm) square.

Phoenix 9.76.0 Programmer’s Reference 806420 77

5 – Advanced Feature Codes

Note: The Marker Offset XY position is set in the Cutting screen (Choose Setups from the Main Screen). Marker

Offset Off reverses the polarity of the position. For example, if Marker Offset is X+5 Y+5, then Marker Offset Off position would be X-5 Y-5.

Code Description

G20 English units

G91 Incremental mode

M11 Marker Offset On to reposition the torch and drill

M93 Drill Cycle

M12 Marker Offset Off to return torch and drill to original position.

G00 X-2.5 Y-2.5 Rapid Traverse to square

G41 Left kerf

M07 Cut control on

G01 X0 Y5 G01 X5 Y0 G01 X0 Y-5 G01 X-5 Y0

M08 Cut control off

G40 Kerf off

M02 End of part program

Cut out a square, 5 inches on each side

78 Phoenix 9.76.0 Programmer’s Reference 806420

Ladder Logic Diagram of Drill Cycle

Tool Cycle Input

Pause for Drill

M93

Tool Cycle Input

Tool Cycle Over

M93 Active

Drill Cycle Outpu t

Drill Cycle C omplete

Cycle Stop

Drill Cycle Outpu t Tool Cycle Active

Extertnal PLC Logic

Drill Cycle Outpu t

Program Inhibit Input (Optional)

Tool Cycle Active

Cycle Start

Ladder Logic Representation of the Drill Cycle

Drill Cycle Outpu t

EDGE Pro

Tool Cycle Input

M93 Active

Drill Cycle Output

Tool Cycle Active

5 – Advanced Feature Codes

RACF – Rotate Angle Change on the Fly

RACF allows rotate angle change on the fly interpolated along with X, Y motion so that cuts can be made on more than one side of a square tube when it is rotated during the cut. The THC must be able to respond to the arc voltage fast enough during the tube rotation.

'G01,02,03 X Y I J Cxx' is the command that is used.

The transverse backs up or moves ahead to account for the change in part location due to the CBH or rotary axis tube rotation.

Phoenix 9.76.0 Programmer’s Reference 806420 79

5 – Advanced Feature Codes

All Possible Axis Assignments

 Axis 1 – Transverse or Rail

 Axis 2 – Rail or Transverse

 Axis 3 – Dual Gantry, CBH or Sensor THC

 Axis 4 – CBH or Sensor THC

 Axis 5 – Rotate or Sensor THC

 Axis 6 – Tilt or Sensor THC

 Axis 7 – Dual Transverse or Sensor THC

 Axis 8 – Dual Rotate or Sensor THC

 Axis 9 – Dual Tilt or Sensor THC

 Axis 10 – Sensor THC

 Axis 11 – Sensor THC

 Axis 12 – Sensor THC

Special Passwords

NRT – No Rotate Tilt

The NRT password allows you to use a dual transverse axis without physically having the tilt rotator and dual tilt rotator drives and motors. The Tilt Rotator Axes screens are still visible, but are not used. They are typically used when non-bevel 2-torch servo spacing with vertical cutting is needed with a dual transverse. This password remains in effect after the CNC is powered off.

RT – Rotate Tilt

The RT password re-enables the use of the tilt rotator and dual tilt rotator drives and motors with a dual transverse system. This password is needed only if the NRT password has previously been used. This password remains in effect after the CNC is powered off.

NSA – No SERCOS Axes

The NSA password allows a SERCOS ring to be phased up but does not phase up any SERCOS axes that are configured. This allows SERCOS I/O nodes or modules, such as Hypertherm I/O, Beckhoff, or Reco I/O modules to be tested without requiring the SERCOS drives to phase up. The password is temporary until the power on the CNC is cycled.

80 Phoenix 9.76.0 Programmer’s Reference 806420

Section 6

Subparts

Subparts allow you to call and execute a separate part file within a part program using a simple line of text.

To configure a subroutine part for use, the user must first create a folder on the CNC hard drive named “SUBPARTS”. To create a folder on the hard drive, select Load From Disk. With the folder location highlighted, press the + key to create a new folder.

Save the part program in the SUBPARTS folder.

To execute the part, insert a line of code within the part program with the following format.

PFILENAME

Start the line of code with the letter P to indicate that a Sub Part is to be executed, followed by the filename for the desired part program.

Phoenix 9.76.0 Programmer’s Reference 806420 81

6 – Subparts

For example, to execute subpart L-Bracket after completing a simple 5" x 5" square with a programmed traverse, the part program would look something like the following example:

(Rectangle - Piece)

G20

G91

G99 X1 Y0 I0 J0

G41

M07

G01 X-5.2 Y0

G01 X0 Y5

G01 X5 Y0

G01 X0 Y-5.2

M08

G00 X.75 Y0

PL-BRACKET

G40

M02

When it is executed, this program will be represented as the original part plus the additional subpart and will include the programmed traverse.

82 Phoenix 9.76.0 Programmer’s Reference 806420

6 – Subparts

Note: Subparts can also contain subparts. After being translated by the CNC, the final text of the part will contain

the complete text of the original part and subpart.

Phoenix 9.76.0 Programmer’s Reference 806420 83

6 – Subparts

84 Phoenix 9.76.0 Programmer’s Reference 806420

Section 7

Marker Font Generator

The Marker Font Generator feature can be used to label or identify parts with a marking device before cutting. This is accomplished by use of a simple command string within the part program code to call existing text characters (fonts) and execute marking of the selected text.

The program code uses a specific format and is structured to provide information to be used when marking. Information on the font source location, scale factor, angle, marker tool, tool offset and text are entered as information blocks in the command string. Each section or information block in the command string is separated by a space. The format of this command code is outlined as follows.

Note: If a value is not present for a specific information block, the default values will be used. The default values are:

Font (F): Internal

Angle (A): 0

Offset (O): #1

Scale (S): One

Marker (M): #1

Example of a simple command string:

Where:

<: The program command must begin with the “<” symbol to indicate that the Marker Font Generator feature is being

used.

F: The first block of information is the Font Source location. The “F” is followed by a digit to indicate the location where

the font is stored:

 1 = an internal font in the control software

 2 = a font located on the CNC hard drive

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7 – Marker Font Generator

 3 = a font from diskette or USB memory

If no font is found at the selected location, the default internal font will be used. For the example given, the font location would be from the hard drive.

S: The second information block determines the scale of the text. The “S” is followed by a number that indicates the

scale factor. For the example given, the scale factor is twice the original font dimensions.

A: The third information block determines the angle of the text. The “A” is followed by a number that indicates the degree

of angle. For the example given, the degree of the angle is 45.

M: The fourth information block determines the Marker Tool to be used. The “M” is followed by the number of the marker

tool (Marker Enable Output) to be used. Up to two marker enables are supported.

O: The fifth information block determines which tool Offset to be used. The “O” is followed by a number indicates that

one of the nine different tool offsets previously configured in control setups is to be used. The example shown indicates that tool offset number two should be used.

< >: The final information block is used to specify the marker text to be executed. The text must be enclosed in the “<”

and “>” marks to be valid and understood as the selected text. For the example given, the marker text executed would be “TEST 123”

When the previous code example is translated by the CNC, it generates the Marker Text “TEST 123” onto the plate as shown here in ShapeWizard.

86 Phoenix 9.76.0 Programmer’s Reference 806420

7 – Marker Font Generator

To improve the ease of use for the part program designer and control operator, the marker font generator always inserts a traverse segment to return to the original start point at the beginning of the marking text.

Internal Fonts

The internal fonts located within the control software are 1" high and are limited to characters available on the control keypad. Alphabetical characters are limited to upper case letters only.

External Fonts

External fonts can be loaded from a floppy disk or from the control hard drive. When the CNC generates the text, the CNC searches for part files to correspond to the selected character. The part file names must be based on their ASCII numeric equivalent and have a .txt file extension.

For example, for the marker text “Ab 12”, the control searches for the following files to generate the text:

Text ASCII No. File Name

Capital A 65 ASCII65.txt

Lower case b 98 ASCII98.txt

Space 32 ASCII32.txt

No 1 49 ASCII49.txt

No 2 50 ASCII50.txt

For more information on ASCII codes, refer to the “ASCII Codes” chapter.

Font programs may be saved on the control hard drive by creating a folder labeled “Fonts” using the “Save to Disk” feature and saving the font programs within this folder. Remember, if a corresponding part file to text requested is not found at the selected source location, the internal font file will be used.

Custom Fonts

Custom fonts can be used when using the marker font generator. To construct these font files, certain guidelines should be adhered to.

 Programming format must be EIA.

 Only M09 and M10 can be used to enable and disable the marker.

 Only G00, G01, G02 and G03 codes can be used.

 The program must end in an M02.

 The proper file name must be assigned to the font program.

 The font program must begin in the lower left and end in the lower right.

 Font programs should have the consistent dimensional limits (i.e. 1' high, etc.).

Example: The letter “B” – File Name Ascii66.txt

Phoenix 9.76.0 Programmer’s Reference 806420 87

7 – Marker Font Generator

M09

G01 X0 Y1

G01 X0.321429 Y0

G02 X0 Y-0.5 I0 J-0.25

G01 X-0.321429 Y0

M10

G00 X0.321429 Y0

M09

G02 X0 Y-0.5 I0 J-0.25

G01 X-0.321429 Y0

M10

G00 X0.571 Y0

M02

The darker lines in the drawing represent the Traverse segment, and the lighter lines represent the Marking lines. You can see by this illustration that at the end of the font program, a traverse is used to continue motion to the bottom right corner.

Note: The Burny 3/5 style of programming for the Marker Font Generator feature is also supported for the default internal font source.

88 Phoenix 9.76.0 Programmer’s Reference 806420

Section 8

G59 Process Variables

Hypertherm CNCs provide cut charts for a variety of cutting processes: plasma, marker, laser, and waterjet. An operator can select a cut chart manually on the CNC, or the part program can issue codes that select the cut chart automatically.

Computer aided manufacturing (CAM) software places process variables, called G59 codes, in the part program to select the cut chart for a process. Using the process variables in the part program automates cut chart selection on the CNC. This section lists the G59 code and its variables and values supported by Hypertherm CNCs.

To use G59 codes in your part program, you must enable EIA G59 Code Override on the Cutting screen on the CNC.



G59 codes use the following format:

G59 Vxxx Fxx

Where:

 G59 = Load a variable

 Vxxx = The variable type

 Fxx = The variable value

 xx or xxx = the number of digits for the F value. When the F value has a decimal, the value is represented as xx.x

Example: G59 V507 F33

Where:

V507 = Plasma 1 Material Thickness

F33 = 0.5 inch

Phoenix 9.76.0 Programmer’s Reference 806420 89

8 – G59 Process Variables

Variable Types

The G59 code supports several variable types:

 V5xx selects the process and makes selections within the cut chart.

 V6xx selects plasma process parameters.

 V800 – V824 selects laser process parameters.

 V825 and up selects waterjet process parameters.

The value for each variable must be present in the cut chart on the CNC. For example, if the part program includes a G59 code with the material thickness variable with a value of ½ inch (G59 V507 F33) but the cut chart for that process does not include a material thickness of ½ inch, an “Invalid Process” error will display when the CNC loads the program. To clear the error, you must remove the unsupported code from the part program. For more information on resolving an “Invalid Process” or “Conflicting Process” errors, see the Conflicting process section of the Phoenix V9Series Installation and Setup manual.

In addition, V5xx variables must be issued in the part program in the same order that they are listed in the cut chart:

1. Tor c h Type

2. Material Type

3. Specific Material (optional)

4. Process Current

5. Plasma/Shield Gases

6. Material Thickness

7. Cutting Surface

8. Water Muffler (for some older plasma supplies)

90 Phoenix 9.76.0 Programmer’s Reference 806420

8 – G59 Process Variables

V6xx codes

overwrite these

settings after the

cut chart has

loaded

V5xx codes

select the cut

chart

The V6xx variables override other parameters that are part of the cut chart, such as Arc Voltage, Cut Height, Pierce Time, and Marker Amperage. The V6xx variables are not required when using process variables to select a cut chart; they are only needed when overriding the values in the cut chart. For example, to change the value of Set Arc Voltage in the Plasma 1 process from 120 VDC in the cut chart, to 125 VDC, issue a G59 V600 F125 code in the part program.

Phoenix 9.76.0 Programmer’s Reference 806420 91

8 – G59 Process Variables

Part program format

Hypertherm CNCs require that the G59 codes be in specific positions in the part program. Each cut in the part starts with an M07 (Cut On) and ends with the M08 (Cut Off). The M07 and M08 turn on the Cut Control output which activates the cutting tool.

 The G41 (Enable Left Kerf Compensation) or G42 (Enable Right Kerf Compensation) must immediately precede the

M07.

 The G59 V5xx codes select the cut chart and must precede the G41 or G42 code. Once the program selects the

cut chart, the V5xx codes do not need to be re-issued unless the program requires a change in process (a new cut chart).

 V6xx and V8xx codes are needed only when overriding a cut chart value.

Code Description

G20 English units

G91 Incremental mode

G99 X1 Y0 I0 J0 Set part options

G59 V503 F1.00 Plasma 1 material type mild steel

G59 V504 F130 Plasma 1 current 130 A

G59 V505 F2 Plasma 1 plasma/shield gas O2/air

G59 V507 F33 Plasma 1 material thickness 1/2 inch

G59 V525 F27 Marker 1 plasma/shield gas air/air

G59 V658 F10 Override Marker 1 current, set to 10 A

M36 T3 Select Marker 1 process

M50 Disable torch height control

M09 Marker on

G03 X0 Y0 I0.5 J0 Counterclockwise arc

M10 Marker Off

M51 Enable torch height control

G00 X-0.75 Y-1.299 Rapid traverse

M36 T1 Select Plasma 1 process

G59 V600 F125 Override Plasma 1 arc voltage setting, set to 125 V

G41 Enable left kerf

M07 Cut on

92 Phoenix 9.76.0 Programmer’s Reference 806420

Code Description

G01 X0.176777 Y0.176777 Line

G02 X0 Y0 I1.06066 J1.06066 Clockwise arc

G01 X-0.1 Y0 Line

M08 Cut off

G40 Disable kerf

M02 End program

8 – G59 Process Variables

Phoenix 9.76.0 Programmer’s Reference 806420 93

8 – G59 Process Variables

V5xx Variables

The following table lists the V5xx variable types. The G59 codes that contain these variables must be entered in the part program in the order they appear in the cut chart. Each variable type has a set of Fx values. The following sections list the values for each variable type.

Variable Plasma 1 Plasma 2 Marker 1 Marker 2 Laser Waterjet Oxyfuel

Torch Type V502 V512 V522 V532 V561

Material Type V503 V513 V523 V533 V543 V553 V562

Process Current V504 V514 V524 V534

Plasma/Shield Gases

Cutting Surface V506 V516 V526 V536

Material Thickness V507 V517 V527 V537 V547 V557 V564

Water Muffler V508 V518 V528 V538

Power Setting V544

Assist Gas V545

Focal Length V549

Laser nozzle size V550

Orifice Size V554

Nozzle Size V556

Cut Pressure (waterjet)

Fuel Gas V563

V505 V515 V525 V535

V558

Tip Size V565

Contact Hypertherm Technical Service for information about G59 codes for obsolete plasma supplies.



94 Phoenix 9.76.0 Programmer’s Reference 806420

8 – G59 Process Variables

Torch type

Add the torch type values to the these variables:

V502 Plasma 1 torch type V512 Plasma 2 torch type

V522 Marker 1 torch type V532 Marker 2 torch type

V561 Oxyfuel torch type

Example: G59 V512 F34 – Plasma 2, HPRXD torch.

F1 = MAX200 F2 = SE200 F3 = HT4400

F4 = FineLine200 F5 = FineLine100 F6 = LH2100S

F7 = LH2100T F8 = LH2125S F9 = LH2125T

F10 = PAC186 F11 = T80M F12 = MAX100

F13 = MAX100D F14 = ArcWriter F15 = PAC620

F16 = PAC123 F17 = PAC125 F18 = T60M

F19 = T100M F20 = HySpeed F21 = HPR

F22 = LH1510S F23 = LH1510T F24 = LH1575S

F25 = LH1575T F26 = FineLine260 F27 = FineCut

F28 = Spirit275 F29 = HSD F30 = Spirit400

F31 = HPR Bevel F32 = TDC_XT300 F33 = TDC_XT301

F34 = HPRXD F35 = HPRXD Bevel F36 = T45M

F37 = HPRXD Thick Pierce F38 = LF150 F39 = HyPro2000

F40 = TDC_XT300 Bevel F42 = M45 (Powermax45) F43 = M65 (Powermax65)

F44 = M85 (Powermax85) F45 = HyPro2000(Silver) F46 = Duramax

F47 = Harris Model 80 F48 = Harris Model 98 F49 = Victor MT 200

F50 = Victor MT 300 F52 = M105 (Powermax105) F53 = Low Speed FineCut

F54 = MAXPRO200 F55 = Duramax Hyamp F56 = Dialine 281

F57 = Dialine 300 F58 = FineCut Hyamp

Phoenix 9.76.0 Programmer’s Reference 806420 95

8 – G59 Process Variables

Material type

Add one of the following material type values to these variables:

V503 Plasma 1 material type V513 Plasma 2 material type

V523 Marker 1 material type V533 Marker 2 material type

V543 Laser material type V553 Waterjet material type

V562 Oxyfuel

Add .xx for Specific Material. Some specific material values are used for specialized cut charts, such as True Hole Example: G59 V503 F1.01 – Plasma 1, mild steel, specific material 1.

F1 = Mild Steel F1.99 = Mild Steel, True Hole (English

or metric)

F2 = Stainless Steel F2.99 = Stainless Steel, HDi (inox) F3 = Aluminum

F4 = Other F5 = Brass F6 = Copper

F1.97 Mild Steel, Fine Feature

Plasma current

Add one of the following process current values to these variables:

V504 Plasma 1 current V514 Plasma 2 current

V524 Marker 1 power current V534 Marker 2 current

Example: G59 V514 F100 – Plasma 2, 100 A process current.

F5 = 5 A F7 = 7 A F8 = 8 A

F9 = 9 A F10 = 10 A F15 = 15 A

F18 = 18 A F20 = 20 A F22 = 22 A

F25 = 25 A F30 = 30 A F35 = 35 A

F40 = 40 A F45 = 45 A F50 = 50 A

F55 = 55 A F60 = 60 A F65 = 65 A

F70 = 70 A F80 = 80 A F85 = 85 A

F100 = 100 A F105 = 105 A F125 = 125 A

F130 = 130 A F150 = 150 A F200 = 200 A

F260 = 260 A F275 = 275 A0 F300 = 300 A

96 Phoenix 9.76.0 Programmer’s Reference 806420

8 – G59 Process Variables

F340 = 340 A F400 = 400 A F500 = 500 A

F600 = 600 A F760 = 760 A F800 = 800 A

F1000 = 1000 A F1500 = 1500 A F2000 = 2000 A

F2500 = 2500 A F3000 = 3000 A F3500 = 3500 A

F4000 = 4000 A F4500 = 4500 A F5000 = 5000 A

F5500 = 5500 A F6000 = 6000 A

Plasma/shield gas or Laser assist gas

Add one of the following gas selection values to these variables:

V505 Plasma 1 plasma/shield gas V515 Plasma 2 plasma/shield gas

V525 Marker 1 plasma/shield gas V535 Marker 2 plasma/shield gas

V545 Laser assist gas

Example: G59 V505 F2 – Plasma 1, O2 plasma gas and air shield gas

F1 = Air/Air F2 = O2/Air F3 = O2/O2

F4 = N2/Air F5 = N2/CO2 F6 = None/N2

F7 = O2/N2 F8 = CH4 / N2 F9 = H35/N2

F10 = H5/N2 F11 = Air/N2 F12 = N2/N2

F13 = CO2/N2 F14 = None/Air F15 = CH4/Air

F16 = O2-N2/Air F17 = O2-N2/O2 F18 = O2

F19 = N2 F20 = N2/None F21 = Air

F22 = F5/N2 F23 = H35&N2/N2 F24 = H17/N2

F25 = Ar/Ar F26 = Air/Ar F27 = Ar/Air

Phoenix 9.76.0 Programmer’s Reference 806420 97

8 – G59 Process Variables

Cutting surface

Add one of the following cutting surface values to these variables:

V506 Plasma 1 cutting surface V516 Plasma 2 cutting surface

V526 Marker 1 cutting surface V536 Marker 2 cutting surface

Example: G59 V536 F2 – Marker 2, cutting 3 inches below water.

 1 = Above water

 2 = 3 inches below water

Material Thickness

Add one of the following material thickness values to these variables:

V507 Plasma 1 material thickness V517 Plasma 2 material thickness

V527 Marker 1 material thickness V537 Marker 2 material thickness

V547 Laser material thickness V557 Waterjet material thicknesse

V564 Oxyfuel material thickness

Example: G59 V507 F14 – Plasma 1, 1 mm thick.

The following table shows material thickness values sorted by the metric (decimal) thickness. To look up a material thickness by the Fxx value, see the table beginning on page 102.

Metric (Decimal) Gauge and Fraction Fx

None None 1

0.35 mm (0.015 in.) 28 GA 2 or 3

0.40 mm (0.016 in.) 27 GA 4 or 5

0.50 mm (0.018 in.) 26 GA 6 or 7

0.55 mm (Metric only) 25 GA 100

0.60 mm (0.024 in.) 24 GA 8 or 9

0.70 mm (Metric only) 23 GA 101

0.80 mm (0.030 in.) 22 GA 10 or 11

0.90 mm (0.036 in.) 20 GA 12 or 13

1 mm (0.040 in.) 19 GA 14

98 Phoenix 9.76.0 Programmer’s Reference 806420

8 – G59 Process Variables

Metric (Decimal) Gauge and Fraction Fx

1.2 mm (0.048 in.) 18 GA 15 or 16

1.5 mm (0.060 in.) 16 GA 17 or 18

1.6 mm (0.063 in.) 1/16 in. 19

2 mm (0.075 in.) 14 GA 20 or 21

2.2 mm (0.090 in.) 13 GA 47

2.4 mm (Metric only) 3/32 in. 22

2.5 mm (0.105 in.) 12 GA 23 or 24

3 mm (0.120 in.) 11 GA 48

3.2 mm (0.125 in.) 1/8 in. 25

3.5 mm (0.135 in.) 10 GA 26 or 27

3.8 mm (0.150 in.) 9 GA 49

4 mm (0.164 in.) 8 GA 52

4.5 mm (0.180 in.) 7 GA 50

4.8 mm (0.188 in.) 3/16 in. 28

5 mm (0.194 in.) 6 GA 53

5.5 mm (0.210 in.) 5 GA 51

6 mm (0.25 in.) 1/4 in. 29

7 mm (Metric only) 9/32 in. 102

8 mm (0.313 in.) 5/16 in. 30

9 mm (Metric only) 11/32 in. 92

10 mm (0.375 in.) 3/8 in. 31

11 mm (0.438 in.) 7/16 in. 32

12 mm (0.5 in.) 1/2 in. 33

13 mm (Metric only) 17/32 in. 103

14 mm (0.563 in.) 9/16 in. 34

15 mm (Metric only) 19/32 in. 93

16 mm (0.625 in.) 5/8 in. 35

17 mm (Metric only) 11/16 in. 104

Phoenix 9.76.0 Programmer’s Reference 806420 99

8 – G59 Process Variables

Metric (Decimal) Gauge and Fraction Fx

18 mm (Metric only) 23/32 in. 105

19 mm (0.75 in.) 3/4 in. 36

20 mm (Metric only) 25/32 in. 106

21 mm (Metric only) 13/16 in. 107

22 mm (0.875 in.) 7/8 in. 37

23 mm (Metric only) 29/32 in. 98

24 mm (Metric only) 15/16 in. 108

25 mm (1 in.) 1 in. 38

26 mm (Metric only) 1-1/32 in. 109

27 mm (Metric only) 1-1/16 in. 110

28 mm (Metric only) 1-3/32 in. 94

29 mm (1.125 in.) 1-1/8 in. 39

30 mm (Metric only) 1-3/16 in. 111

31 mm (Metric only) 1-7/32 in. 112

32 mm (1.25 in.) 1-1/4 in. 40

33 mm (Metric only) 1-5/16 in. 113

34 mm (Metric only) 1-11/32 in. 114

35 mm (Metric only) 1-3/8 in. 41

36 mm (Metric only) 1-7/16 in. 99

37 mm (Metric only) 1-15/32 in. 115

38 mm (1.5 in.) 1-1/2 in. 42

40 mm (Metric only) 1-5/8 in. 54

44 mm (Metric only) 1-23/32 in. 95

45 mm (1.75 in.) 1-3/4 in. 43

48 mm (Metric only) 1-7/8 in. 55

50 mm (2 in.) 2 in. 44

55 mm (Metric only) 2-1/8 in. 56

58 mm (Metric only) 2-9/32 in. 96

100 Phoenix 9.76.0 Programmer’s Reference 806420

Hypertherm Automation Family Instruction Manual (IM)

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Safety

RECOGNIZE SAFETY INFORMATION

FOLLOW SAFETY INSTRUCTIONS

ELECTRICAL HAZARDS

ELECTRIC SHOCK CAN KILL

CUTTING CAN CAUSE FIRE OR EXPLOSION

Fire prevention

Explosion prevention

TOXIC FUMES CAN CAUSE INJURY OR DEATH

GROUNDING SAFETY

STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS

COMPRESSED GAS EQUIPMENT SAFETY

GAS CYLINDERS CAN EXPLODE IF DAMAGED

A PLASMA ARC CAN CAUSE INJURY AND BURNS

ARC RAYS CAN BURN EYES AND SKIN

PACEMAKER AND HEARING AID OPERATION

NOISE CAN DAMAGE HEARING

A PLASMA ARC CAN DAMAGE FROZEN PIPES

DRY DUST COLLECTION INFORMATION

LASER RADIATION

ADDITIONAL SAFETY INFORMATION

WARNING LABELS

Symbols and marks

Product Stewardship

Introduction

National and local safety regulations

Certification test marks

Differences in national standards

Safe installation and use of shape cutting equipment

Procedures for periodic inspection and testing

Qualification of test personnel

Residual current devices (RCDs)

Higher-level systems

Environmental Stewardship

Introduction

National and local environmental regulations

Proper disposal of Hypertherm products

The WEEE directive

The RoHS directive

The REACH regulation

Proper handling and safe use of chemicals

Fumes emission and air quality

Shrink-wrap License Agreement

Shape Library

Text Editor

Shape Wizard

Teach Trace

Remnant Trace Mode

Teach Trace Mo de

ASCII Codes

Control Codes

All Codes

EIA RS-274D Program Support

Directly Supported EIA Codes

Mapped EIA Codes

Unsupported EIA Codes

EIA Comments

ESSI Code Support

Mapped ESSI Codes

Unsupported ESSI Codes

ESSI Comments

Advanced Feature Codes

Kerf Table Codes

Special Kerf and G59 Code Settings

Kerf Override

G59 Code Override

Parallel Kerf Enable for Hole Center Piercing

Tilt / Rotator Part Codes

Station Select Codes

Process Select Codes

Automatic Plate Alignment Codes

Automatic Torch Spacing

Automatic Torch Spacing Program Codes

Automatic Torch Spacing I/O

Example Part Program