Phoenix™ Software V9.76.0
Operator Manual
806400 | Revision 10 | English
© 2014 Hypertherm Inc.
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.
Microsoft, the Microsoft logo, and Windows are registered trademarks of Microsoft Corporation.
Other trademarks are the property of their respective owners.
Phoenix Software V9.76.0
Operator Manual
806400
Revision 10
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
Contents
Safety ........................................................................................................................................ SC-13
Recognize safety information ...............................................................................................................................................SC-13
Follow safety instructions ......................................................................................................................................................SC-13
Electrical hazards ....................................................................................................................................................................SC-13
Electric shock can kill ............................................................................................................................................................SC-14
Cutting can cause fire or explosion ....................................................................................................................................SC-15
Fire prevention .................................................................................................................................................................SC-15
Explosion prevention ......................................................................................................................................................SC-15
Toxic fumes can cause injury or death ...............................................................................................................................SC-16
Grounding safety ....................................................................................................................................................................SC-17
Static electricity can damage circuit boards ....................................................................................................................SC-17
A plasma arc can cause injury and burns .........................................................................................................................SC-18
Compressed gas equipment safety ...................................................................................................................................SC-18
Gas cylinders can explode if damaged .............................................................................................................................SC-18
Arc rays can burn eyes and skin .........................................................................................................................................SC-19
Pacemaker and hearing aid operation ...............................................................................................................................SC-20
Noise can damage hearing ...................................................................................................................................................SC-20
A plasma arc can damage frozen pipes ............................................................................................................................SC-20
Dry dust collection information ............................................................................................................................................SC-21
Laser radiation .........................................................................................................................................................................SC-22
Additional safety information ................................................................................................................................................SC-22
Warning labels ........................................................................................................................................................................SC-23
Symbols and marks ................................................................................................................................................................SC-25
Product Stewardship ............................................................................................................SC-27
Introduction ..............................................................................................................................................................................SC-27
National and local safety regulations ..................................................................................................................................SC-27
Certification test marks .........................................................................................................................................................SC-27
Phoenix Software V9.76.0 Operator Manual 806400 5
Contents
Differences in national standards .......................................................................................................................................SC-27
Safe installation and use of shape cutting equipment ...................................................................................................SC-28
Procedures for periodic inspection and testing ..............................................................................................................SC-28
Qualification of test personnel .............................................................................................................................................SC-28
Residual current devices (RCDs) .......................................................................................................................................SC-28
Higher-level systems ..............................................................................................................................................................SC-29
Environmental Stewardship ...............................................................................................SC-31
Introduction ..............................................................................................................................................................................SC-31
National and local environmental regulations ...................................................................................................................SC-31
The RoHS directive ................................................................................................................................................................SC-31
Proper disposal of Hypertherm products ..........................................................................................................................SC-31
The WEEE directive ...............................................................................................................................................................SC-31
The REACH regulation ..........................................................................................................................................................SC-32
Proper handling and safe use of chemicals .....................................................................................................................SC-32
Fumes emission and air quality ...........................................................................................................................................SC-32
Shrink-wrap License Agreement....................................................................................... SC-33
1 Operating the CNC ....................................................................................................................... 35
Operator Console ...........................................................................................................................................................................35
Touch Screen LCD ........................................................................................................................................................................36
LCD Display .............................................................................................................................................................................36
Screen Navigation ..........................................................................................................................................................................36
Help ...................................................................................................................................................................................................37
Show Bookmarks ....................................................................................................................................................................37
Automated Operations ..................................................................................................................................................................38
Align Wizard .............................................................................................................................................................................38
CutPro™ Wizard ......................................................................................................................................................................38
Using Phoenix with a keyboard ...................................................................................................................................................39
PC Keyboard ...................................................................................................................................................................................39
Custom Keypad ..............................................................................................................................................................................42
Updating the Phoenix Software ..................................................................................................................................................46
Updating the software ...........................................................................................................................................................46
Updating the cut charts .........................................................................................................................................................46
Backing up modified cut charts ...................................................................................................................................46
Updating the cut charts .................................................................................................................................................47
Updating the help ...................................................................................................................................................................47
Updating the manuals ............................................................................................................................................................47
6 Phoenix Software V9.76.0 Operator Manual 806400
Contents
2 The Main Screen ...........................................................................................................................49
Preview Window ............................................................................................................................................................................ 50
Watch Window .............................................................................................................................................................................. 50
Soft keys .......................................................................................................................................................................................... 50
3 Loading Parts................................................................................................................................. 53
Loading a part from the Shape Library ..................................................................................................................................... 53
Loading a part ............................................................................................................................................................................... 55
Downloading a part from a host computer .............................................................................................................................. 57
Saving a part file ............................................................................................................................................................................ 58
Uploading part files to a host computer ................................................................................................................................... 60
Importing DXF files ........................................................................................................................................................................ 61
Raw DXF files ........................................................................................................................................................................ 63
4 Arranging Parts ............................................................................................................................. 65
Repeating parts .............................................................................................................................................................................. 67
Straight repeat ........................................................................................................................................................................ 67
Staggered repeat ................................................................................................................................................................... 68
Nested repeat ......................................................................................................................................................................... 69
Aligning parts .................................................................................................................................................................................. 70
Align Wizard ............................................................................................................................................................................ 70
Aligning parts manually ................................................................................................................................................................. 71
Nesting parts .................................................................................................................................................................................. 72
Manual nesting ....................................................................................................................................................................... 72
Nester setup ............................................................................................................................................................................ 74
Using Manual Nester ............................................................................................................................................................. 75
Adding parts .................................................................................................................................................................... 75
Saving a nest .................................................................................................................................................................. 76
Hypernest
Nest summary ......................................................................................................................................................................... 84
Main screen view of nest ..................................................................................................................................................... 86
®
CNC automatic nesting .................................................................................................................................. 77
Setting up Hypernest on the CNC ............................................................................................................................ 78
Using Nesting ................................................................................................................................................................. 80
Removing a part from a nest ....................................................................................................................................... 83
5 Cutting Parts .................................................................................................................................. 87
CutPro™ Wizard ............................................................................................................................................................................. 87
Cutting in manual mode ............................................................................................................................................................... 89
Multitasking ..................................................................................................................................................................................... 91
Pausing cutting .............................................................................................................................................................................. 92
Manual operations ......................................................................................................................................................................... 95
Phoenix Software V9.76.0 Operator Manual 806400 7
Contents
Rip cutting ........................................................................................................................................................................................97
Manual options ................................................................................................................................................................................98
Home axes ........................................................................................................................................................................................99
True Hole verification ..................................................................................................................................................................101
Plasma cutting tips ...................................................................................................................................................................... 103
Cut quality issues ................................................................................................................................................................103
Basic steps to improve cut quality ...................................................................................................................................107
Bevel cutting tips .........................................................................................................................................................................110
Types of bevel cuts .............................................................................................................................................................110
Bevel cutting tips .................................................................................................................................................................111
6 Cutting Screen and Watch Window Setup..........................................................................117
Cutting setup ................................................................................................................................................................................ 117
Status/Program Code ................................................................................................................................................................ 120
Watch Window Setup ...............................................................................................................................................................122
Multiple Watch Windows .......................................................................................................................................................... 124
7 Cut Processes and Cut Charts................................................................................................ 125
Process overview .........................................................................................................................................................................125
Cut processes and part programs .......................................................................................................................................... 125
Before you begin ......................................................................................................................................................................... 125
Processes selected in Special Setups ........................................................................................................................... 126
System models selected in Station Configuration ....................................................................................................... 126
When to use Plasma 1 and 2 and Marker 1 and 2 ...................................................................................................... 127
Activate privileges in Special Setups .............................................................................................................................. 128
Cutting screen, Process screen, and cut charts .................................................................................................................. 128
Cutting screen ...................................................................................................................................................................... 129
Process screen .................................................................................................................................................................... 129
Timing diagrams ................................................................................................................................................................... 130
Saving a cut process .......................................................................................................................................................... 130
Cut Chart screen .................................................................................................................................................................131
Common soft keys ............................................................................................................................................................... 131
Plasma process ............................................................................................................................................................................132
Plasma 1 and Plasma 2 process screens ...................................................................................................................... 132
Plasma cut chart ..................................................................................................................................................................134
Cut charts for the HPRXD
Thin stainless steel inox (HDi) ...................................................................................................................................136
Fine Feature mild steel ................................................................................................................................................136
Underwater mild steel .................................................................................................................................................137
200 A bevel mild steel ................................................................................................................................................ 137
®
Technology Advancements ............................................................................................136
8 Phoenix Software V9.76.0 Operator Manual 806400
Contents
Marker process ............................................................................................................................................................................139
Marker 1 and Marker 2 process screens ....................................................................................................................... 139
Running a marker process ................................................................................................................................................. 139
Marker cut chart ...................................................................................................................................................................141
Using cut consumables for marking ................................................................................................................................142
Oxyfuel process ...........................................................................................................................................................................143
Oxyfuel process screen ......................................................................................................................................................143
Oxyfuel cut chart ..................................................................................................................................................................147
Fiber Laser process ....................................................................................................................................................................149
Fiber laser process screen ................................................................................................................................................149
Fiber laser cut chart ............................................................................................................................................................151
Setting up staged pierce ...................................................................................................................................................153
Marking, Vaporization, and Fine Feature modes ...........................................................................................................154
Laser process (non-fiber laser) ................................................................................................................................................155
Laser cut charts (non-fiber laser) .....................................................................................................................................157
Waterjet process ......................................................................................................................................................................... 159
Waterjet pierce types .........................................................................................................................................................159
Dynamic pierce ............................................................................................................................................................. 159
Circular pierce ..............................................................................................................................................................159
Wiggle pierce ...............................................................................................................................................................160
Stationary pierce .......................................................................................................................................................... 160
Waterjet process screen .................................................................................................................................................... 161
Waterjet process screen (with Sensor height control) ...............................................................................................163
Waterjet Watch Window ................................................................................................................................................... 166
Adjusting the pierce time ................................................................................................................................................... 167
Waterjet cut chart ................................................................................................................................................................ 168
Saving a waterjet cut chart ................................................................................................................................................170
Saving changes to a cut chart .................................................................................................................................................. 172
Creating a new cut chart .................................................................................................................................................... 172
Retrieving the new cut chart .............................................................................................................................................173
8 Torch Height Controls ............................................................................................................... 175
About plasma torch height control .......................................................................................................................................... 175
ArcGlide THC and Sensor THC operating modes ..............................................................................................................177
Automatic modes .................................................................................................................................................................177
Sample Arc Voltage mode ......................................................................................................................................... 177
Set Arc Voltage ............................................................................................................................................................179
Voltage control off – ArcGlide THC or
IHS in Manual – Sensor THC ...................................................................................................................................179
Manual mode ........................................................................................................................................................................179
Phoenix Software V9.76.0 Operator Manual 806400 9
Contents
Methods for changing the Set Arc Voltage ........................................................................................................................... 180
THC voltage offsets ............................................................................................................................................................ 180
Increase or decrease voltage soft keys .......................................................................................................................... 181
Raise and Lower buttons or inputs ..................................................................................................................................182
Process screen or cut chart .............................................................................................................................................. 182
Initial height sense ....................................................................................................................................................................... 182
Performing a first IHS .........................................................................................................................................................182
THC sequence of operations ...................................................................................................................................................183
THC Process screen .................................................................................................................................................................. 185
THC Mode .............................................................................................................................................................................186
Cut Chart Values ................................................................................................................................................................. 186
Options ..................................................................................................................................................................................187
Automatically-set ................................................................................................................................................................. 188
Marker Setup ................................................................................................................................................................................ 191
THC Mode .............................................................................................................................................................................191
Cut Chart Values ................................................................................................................................................................. 192
Options ..................................................................................................................................................................................193
Automatically-set ................................................................................................................................................................. 193
Watch Window ............................................................................................................................................................................ 195
Sensor THC ..........................................................................................................................................................................195
ArcGlide .................................................................................................................................................................................197
Status messages ......................................................................................................................................................................... 198
ArcGlide Diagnostics screen .................................................................................................................................................... 200
9 Command THC Setup ................................................................................................................203
Command THC Main Cut Screen ...........................................................................................................................................206
Automatic THC Mode .........................................................................................................................................................206
Manual THC Mode ..............................................................................................................................................................207
Machine Interface ........................................................................................................................................................................ 208
10 Diagnostics and Troubleshooting..........................................................................................209
Remote Help ................................................................................................................................................................................. 209
HPR Error Help ............................................................................................................................................................................ 209
CNC Information .......................................................................................................................................................................... 211
I/O, Drives and Motors, Machine Interface ............................................................................................................................ 212
Using the Oscilloscope Function ............................................................................................................................................. 213
Saving the Oscilloscope File ............................................................................................................................................214
Loading an Oscilloscope File ...........................................................................................................................................214
Viewing an Oscilloscope File ............................................................................................................................................ 215
HPR plasma system .................................................................................................................................................................... 216
Powermax 65, 85, 105, and 125 systems ............................................................................................................................217
10 Phoenix Software V9.76.0 Operator Manual 806400
Contents
Fiber laser diagnostics screen ..................................................................................................................................................218
MAXPRO200 diagnostics screen ...........................................................................................................................................219
Fault and error messages ..........................................................................................................................................................221
Faults ......................................................................................................................................................................................221
Errors ......................................................................................................................................................................................222
Fault messages ....................................................................................................................................................................223
Error message reference ............................................................................................................................................................229
Changing Consumables ............................................................................................................................................................248
Saving System Files ....................................................................................................................................................................250
Phoenix Software V9.76.0 Operator Manual 806400 11
Contents
12 Phoenix Software V9.76.0 Operator Manual 806400
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-13
• 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-14 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-15
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-16 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-17
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-18 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
(ANSIZ49.1:2005)
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-19
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-20 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-21
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-22 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-23
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-24 Safety and Compliance
Safety
s
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-25
Safety
SC-26 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-27
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-28 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-29
Product Stewardship
SC-30 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-31
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
June1, 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-32 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-33
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-34 Safety and Compliance
Section 1
Data Transfer
Power Switch
Part program controls
Station Controls
Manual motion controls
Operating the CNC
Phoenix software runs on the Hypertherm computer numerical controls (CNCs) including the EDGE® Pro and
MicroEDGE
keyboard and mouse for entering information and navigating the software.
®
Pro, and EDGE® Pro Ti. Phoenix supports either a touch screen or LCD display with a USB-connected
Operator Console
An optional operator console provided by Hypertherm, an OEM, or a system integrator powers up the CNC and controls
machine motion such as station selection, raising or lowering the cutting tool, and positioning the cutting tool before
starting a part program.
The EDGE Pro operator console is shown below. The operator console on your CNC may look different and have other
controls than those shown here.
Phoenix Software V9.76.0 Operator Manual 806400 35
1 – Operating the CNC
Touch Screen LCD
The Phoenix software is designed for 38 cm (15 inch) touch screens with 1024 x 768 or higher resolution. When your
CNC is equipped with a touch screen, you can enter data into the software by touching the window controls and fields.
Any field that requires data input automatically displays an onscreen keypad when you touch it.
LCD Display
The MicroEDGE Pro can support an LCD display and requires 1024 x 768 resolution with a 4:3 aspect ratio.
Screen Navigation
The eight keys located at the bottom of the screen are called soft keys. The soft keys correspond to the function keys on
a PC keyboard. OK and Cancel soft keys let you save or cancel changes that you make in a screen.
The features shown on each screen vary depending on the user level (Beginner, Intermediate, or Advanced) and the
features enabled on the Special Setups and Station Configuration screens. This manual assumes the CNC is in
Advanced Mode and shows all features.
36 Phoenix Software V9.76.0 Operator Manual 806400
Help
Choose the Help soft key to display information about each screen.
Choose OK to exit the Help screen and return to the Main screen.
1 – Operating the CNC
The Show Bookmarks soft key opens the navigation pane. Press Ctrl + F to use full text search.
The Help screen may also display buttons for other types of information. For example, the manual for the plasma system
or torch height control installed on your system, or provided by your table manufacturer.
Show Bookmarks
Choose the Show Bookmarks soft key on the Help screen to view the contents of the help file. Click on a topic in the list
to view it.
If you are operating the MicroEDGE Pro with a keyboard, use the Page Up/Page down
keys to scroll through the document on screen.
Phoenix Software V9.76.0 Operator Manual 806400 37
1 – Operating the CNC
Automated Operations
The Phoenix software includes two wizards that automate plate alignment and part cutting operations.
Align Wizard
The Align Wizard automates several tasks including aligning a nest on a plate, adjusting for a skewed plate, and
positioning the torch at the program start location.
To start the Align Wizard, choose Shape Library on the Main screen, then choose Shape Wizard, Shape Options, Align.
The Align Wizard may launch automatically. If not, choose the Align Wizard soft key.
For more information, see Align Wizard on page 70.
CutPro™ Wizard
The CutPro Wizard automates common cutting tasks including loading a part or nest, selecting the cutting process,
aligning the part or nest on the plate, and starting the program.
The CutPro Wizard may launch automatically when you start the CNC. If not, choose the CutPro Wizard soft key on the
Main screen to start the wizard. For more information on the CutPro Wizard see the Cutting Parts section.
38 Phoenix Software V9.76.0 Operator Manual 806400
1 – Operating the CNC
Using Phoenix with a keyboard
Hypertherm CNCs can support a built-in keypad or a USB, PC keyboard instead of the touch screen to perform
functions and data entry in the Phoenix software. To enable keyboard-only operation, choose Setups > Password >
Special Setups and Touch Screen Not Installed.
IMPORTANT!
The following features are not supported when the touch screen is disabled:
CutPro Wizard
Align Wizard
Interface diagnostics
When the CNC is switched to keyboard operation, the soft keys display with pictures of the key combinations:
PC Keyboard
Hypertherm CNCs can support a USB, PC keyboard. You can use a keyboard to perform functions and data entry in the
Phoenix software.
Phoenix Software V9.76.0 Operator Manual 806400 39
1 – Operating the CNC
The following tables present common key combinations you will need to navigate and enter data into the CNC using only
a keyboard.
Key Function
F1 to F8 Soft Keys F1 to F8
F1 through F8 activate the lower row of soft keys from left to right.
Shift
+
Enter
Enter Enter moves from field to field on the screen the same way Tab does.
Left Bracket
[
Right Bracket
]
Shift + Enter accepts changes in a screen and equals the OK soft key.
[+Function key accesses the upper row of screen soft keys from left to right. For example,
[+F2 opens the Plasma 1 cut chart screen.
[+F12 opens Cutting Tips
Right bracket is equivalent to the R-Shift on onscreen messages. For example, in the message
below, press
]+F8 to add a folder.
]+F4 opens remote Help.
]+F2 opens MultiTasking
]+0–9 changes the Watch Window.
Tab Tab moves from field to field on the screen. Shift + Tab moves to the previous field.
F9 Program start
F10
Pause
F11 Toggles between Manual and Main screens.
Program stop
40 Phoenix Software V9.76.0 Operator Manual 806400
1 – Operating the CNC
Key Function
F12 Opens the help file. Press F8 to exit the help file.
Arrow keys In Manual mode, the arrow keys control manual motion.
Up arrow and Down Arrow scroll through selections in a list.
Left Arrow and Right Arrow select radio buttons. For example, use the Left and Right Arrow
keys to select the On and Off radio buttons shown below.
Esc Escape exits a screen without saving changes and equals the Cancel soft key.
+/- Plus and minus on the numeric keypad Zoom In/Out in the part window.
Zoom In/Out is enabled when you choose View Sheet on the Main screen.
Backspace Backspace deletes the last character entered.
Phoenix Software V9.76.0 Operator Manual 806400 41
1 – Operating the CNC
Custom Keypad
Many legacy Hypertherm CNCs are equipped with a custom keypad similar to the one below. The row of eight gray keys
correspond to the Phoenix soft keys on screen. The following graphic shows the keypad from the EDGE
example. Phoenix Version 9.71 can be controlled by this and other keypads.
®
II CNC as an
The following tables present common key combinations you will need to navigate and enter data using a
keypad-equipped CNC.
42 Phoenix Software V9.76.0 Operator Manual 806400
Key Description
Screen soft keys F1 – F8, lower row, left to right.
Left Shift + Right Shift + Enter
Accepts changes in a screen and equals the OK soft key.
Left Shift (purple up arrow)
Left Shift + F1 – F8 access the upper row of screen soft keys, from left to right. For
example, Left Shift + F2 opens the Plasma 1 Cut Chart.
1 – Operating the CNC
When entering data, press Left Shift with a number to enter the purple characters on the
keypad. For example, Left Shift + 7 enters A.
Left Shift + ? opens Cutting Tips.
Left Shift 0+ Right Shift + Enter accepts changes made to a screen.
Left Shift is equivalent to the Left Bracket [.
Right Shift (blue up arrow)
Right Shift+F8 performs an action specified in the screen prompt “Double-click to
perform a function”.
When entering data, press Right Shift with a number to access the blue characters on
the keypad. For example, Right Shift + 7 enters N.
Right Shift + F4 opens Remote Help.
Phoenix Software V9.76.0 Operator Manual 806400 43
1 – Operating the CNC
Key Description
Right Shift + F2 opens MultiTasking.
Right Shift + 0 – 9 changes the Watch window.
Next/Prev
Moves from field to field on the screen.
Next works the same as the Tab key on a PC keyboard.
Enter
Moves from field to field on the screen.
Enter works the same as the Tab key on a PC keyboard.
Page Up/Page Down pages through a list of options in a drop-down list.
Cancel
Exits a screen without saving changes.
Same as Escape (Esc) on a PC keyboard and the Cancel soft key on screen.
Plus (+) and Minus (-) control Zoom In and Zoom Out in the part window.
The Zoom soft keys are enabled when you choose View Sheet on the Main screen.
The? key opens the Phoenix help file. Press F8 to exit help.
The Manual key toggles between the Main screen and Manual screen.
44 Phoenix Software V9.76.0 Operator Manual 806400
Key Description
Arrow Keys
Up Arrow and Down Arrow scroll through selections in a list.
Left Arrow and Right Arrow select radio buttons. For example, use the Left and Right
Arrows to select the radio buttons Off and On.
Space changes state for a selection in a list. For example, on the Cutting Screen, use
Space to toggle between Enabled and Disabled for program code status.
Space changes the state for a checkbox.
1 – Operating the CNC
Backspace deletes the last character entered.
Program Start and Stop perform only these functions on the keypad.
Phoenix Software V9.76.0 Operator Manual 806400 45
1 – Operating the CNC
Updating the Phoenix Software
Hypertherm provides regular updates to the Phoenix software. You can download the most current software from
www.hypertherm.com.
Phoenix software update (update.exe)
Phoenix Help file (Help.exe)
Cut charts (CutChart.exe)
Follow the instructions on the web page to download the updates in your language.
Before you update the Phoenix software, follow these guidelines:
Back up your system files: On the Main screen, choose Files> Save to Disk> Save System Files to Disk. See the
section Saving System Files on page 250 for more information.
Copy the files that you download from Hypertherm.com to the root folder of a USB memory stick.
Be prepared to restart the CNC after you have updated the software.
Updating the software
1. At the CNC, insert the memory stick that contains the file update.exe into a USB port.
Verify that update.exe resides in the root folder of the memory stick.
2. On the Main screen, choose Setups > Password. If you are not using a keyboard, double-tap the screen to display
an onscreen keyboard.
3. Enter updatesoftware (all lower case, one word) and choose Enter. The Phoenix software automatically reads the
memory stick and installs the new software.
Updating the cut charts
Hypertherm provides cut charts in two different file types: .fac and .usr. The .fac files are the factory-default cut charts.
These cut charts cannot be changed. The .usr cut charts contain any changes you have made to a cut chart and saved
with the Save Process soft key.
The cut chart update file (CutChart.exe) contains both .fac and .usr cut chart files. The update automatically overwrites all
of the .usr cut charts. Before installing the update, back up your modified cut charts.
Hypertherm recommends saving modified cut charts as custom cut charts. When you create a custom cut chart, Phoenix
creates a .usr file with a unique name. This prevents the custom cut charts from being overwritten by the .usr files in
CutChart.exe. See Creating a new cut chart on page 172.
Backing up modified cut charts
1. At the CNC, connect a memory stick into a USB port.
2. On the Main screen, choose one of the cut chart soft keys, such as Plasma 1 Cut Chart.
3. Choose the Save Cut Charts soft key. Phoenix copies all the cut charts associated with the Plasma 1 Torch Type
onto the memory stick.
46 Phoenix Software V9.76.0 Operator Manual 806400
1 – Operating the CNC
Updating the cut charts
1. At the CNC, insert the memory stick that contains the file CutChart.exe into a USB port.
Verify that CutChart.exe resides in the root folder of the memory stick.
2. On the Main screen, choose Process, and choose one of the cut chart soft keys such as Plasma 1 Cut Chart.
3. Choose the Load Cut Charts soft key, then choose Yes when prompted to load cut charts from the memory stick.
Phoenix extracts the cut charts and copies them to the hard drive.
4. If you have modified cut charts to copy back onto the hard drive, you will need to exit Phoenix and use Windows
Explorer to copy the .usr files back onto the hard drive. The cut chart folder is c:\Phoenix\CutCharts.
Updating the help
1. At the CNC, insert the memory stick that contains the file Help.exe into a USB port.
Verify that Help.exe resides in the root folder of the memory stick.
®
2. On the Main screen, choose Setups > Password. If you are not using a keyboard, double-tap the screen to display
an onscreen keyboard.
3. Enter updatehelp (all lower case, one word) and choose Enter. The Phoenix software automatically reads the memory
stick and installs the new help file.
Updating the manuals
Follow these steps to load new or updated manuals onto your CNC.
1. To obtain the newest manuals available from Hypertherm, visit www.hypertherm.com and choose the Downloads
Library link.
2. In the Downloads Library, choose Product Type, then select a product name. For example, choose MAXPRO200 to
display a list of manuals and other literature available for that product.
3. Choose the Manuals link and click to download a manual file.
4. Save the file in the root folder of a USB memory stick. Do not change the name of the file from its name in the
Downloads Library. It will have a name like 807700r0.pdf.
To load the manual onto your CNC, follow these steps. You can load more than one manual at a time onto the CNC as
long as the files are in the root folder of the memory stick.
1. Insert the memory stick containing one or more Hypertherm product manuals into a USB port on the CNC.
2. Choose Setups > Password, and enter updatemanuals (all lowercase, one word). The CNC copies the manuals
from the memory stick to the hard drive.
Phoenix Software V9.76.0 Operator Manual 806400 47
1 – Operating the CNC
48 Phoenix Software V9.76.0 Operator Manual 806400
The Main screen is the first screen you see when the CNC power is turned on.
Section 2
The Main Screen
Phoenix Software V9.76.0 Operator Manual 806400 49
2 – The Main Screen
Preview Window
The preview window shows the current part program and its dimensions. The name of the part program is displayed
under this window, as well as the message, “with True Hole Technology” if the program uses this feature.
Watch Window
The watch window is the right part of the screen where monitoring features, such as a speedometer, job keys, positions
indicators, cut mode, and time are displayed. You can configure this part of the screen, using the 10 different monitoring
features in the Setups window. See Watch Window Setup on page 122 for more information.
Soft keys
Each of the Main Screen soft keys is described below:
Shape Manager opens the Shape Manager screen where you can load a simple shape, edit a part using the text editor
or shape wizard or teach trace a part.
Files opens the Files screen where you can load, save, download or upload part files.
Current Part Options allows the part to be scaled, rotated, mirrored, and repeated.
Setups opens the Cutting screen which allows access to the Process, Watch Window setup, Diagnostics, and the
password-protected setup screens.
View Part/View Sheet toggles the display of the part in the preview window. Phoenix displays the sheet dimensions
that have been entered in Cutting screen.
50 Phoenix Software V9.76.0 Operator Manual 806400
2 – The Main Screen
Zoom +/- magnifies the part. After zooming out, the display can be zoomed in again by pressing the + key, which
causes horizontal and vertical scroll bars to be displayed. Press the - key to zoom back out.
Manual Options lets you perform rip cuts, home the machine axes, and other manual operations.
Scroll Bars While the scroll bars are displayed and the control is not cutting, the view of the plate can be shifted
horizontally and vertically by pressing and moving the scroll bar or by holding down a shift key and pressing
the arrow keys on the keypad.
While the control is cutting, the view automatically shifts as the cut path reaches one of the edges of the
view.
Change Cut Mode selects trial, oxyfuel, plasma, waterjet and laser cut modes, depending on the tooling selected in the
Special Setups screen.
Change Consumable opens the Change Consumable screen.
Zero Positions sets the current positions to zero on the Transverse, Rail, and Dual Gantry axes.
Phoenix Software V9.76.0 Operator Manual 806400 51
2 – The Main Screen
52 Phoenix Software V9.76.0 Operator Manual 806400
Section 3
Loading Parts
This section describes how to load a part from the Shape Library, a memory stick, or a host computer, save files, and
import DXF files.
Loading a part from the Shape Library
The CNC contains a built-in Shape Library with more than 68 commonly used shapes. These shapes are parametric, that
is, shapes whose size or geometry you can edit. The shapes in the library are color-coded from simplest (green) to most
complex (black).
Phoenix Software V9.76.0 Operator Manual 806400 53
3 – Loading Parts
To select a simple shape:
1. On the Main screen, choose Shape Library.
2. Choose a shape.
3. Press OK.
Keypad operation:
1. Use the arrow keys to navigate to a shape.
2. Press Enter.
The shape is displayed with the default parameters or the parameters from the last time this shape was edited.
54 Phoenix Software V9.76.0 Operator Manual 806400
3 – Loading Parts
Loading a part
You can load part programs from the CNC hard drive, a USB memory stick or external mapped drives (network option)
into working memory on the CNC.
The following screen is used to load a part from a USB memory stick or the hard drive. After all the parameters are set,
press Enter on the keyboard to load the part
Permission to add or remove files and folders from the hard drive is assigned in the
Status/Feature list on the password-protected Special Setups screen.
Load from Select the source from which to load a part: USB memory stick, or a folder on the hard drive. To add or
remove a folder, double-click on the touch screen where indicated.
Keypad operation: To select a different folder, use the ↑ and ↓ keys. To add or remove new folder use the
+ or - key.
Files Lists the files in the folder you selected. Choose the name of the file that you want to load. You can select multiple
files only if you are loading them from a USB memory stick to the hard drive.
Keypad operation: To scroll through different files, use the ↑, ↓, Page Up and Page Down keys. To remove
a file, use the - key. To select multiple files to load, highlight the first file selection, then use the ↑ and ↓ keys
while pressing the shift key to highlight the remaining files.
Phoenix Software V9.76.0 Operator Manual 806400 55
3 – Loading Parts
File name Displays the name of the file you selected. To remove a file, highlight the file name and double-click on the
touch screen where indicated.
Keypad operation: To remove a file using the keyboard, use the - key.
Preview Check this box to preview the files you selected in the Preview Window.
Load to Select the destination for the part: load it for cutting or save it in a folder on the hard drive. To add or remove a
folder, double-click on the touch screen where indicated. This selection is available only if you are loading
the part from the USB memory stick.
Keypad operation: To select a different folder, use the ↑ and ↓ keys. To add a new folder, use the + key. To
remove a folder, use the - key.
Hard drive file name Enter the name for the file that you are loading on the hard drive. This selection is only available if
you are loading the part from the USB memory stick.
Show Certain Files Allows you to search the selected folder for specific part files by using wildcard searches with both
the asterisk (*) and question mark (?).
Keypad operation: To input the asterisk when using a keypad, press the left shift key and the backspace
key. To input the question mark, press the right shift key and the backspace key.
Show All Files Allows you to switch from viewing the selected files to viewing all files with the predetermined file
extensions selected in the Special Setups screen.
56 Phoenix Software V9.76.0 Operator Manual 806400
3 – Loading Parts
Downloading a part from a host computer
Use the screen below to download a part from a host computer through a RS-232C/ RS-422 serial port. After all the
parameters below are set, press Enter on the keyboard to start the download.
Permission to add or remove files and folders from the hard drive is assigned in the
Status/Feature list on the Special Setups screen.
Download from Selects the folder on the host computer from which you want to download a part. To add or remove a
folder, double-click on the touch screen where indicated.
Keypad operation: To select a different folder, use the ↑ and ↓ keys on the keyboard. To add or remove
new folder use the + or - key.
Files Lists the files in the download from folder that can be downloaded from the host computer.
Keypad operation: To scroll through different files, use the ↑, ↓, PAGE UP and PAG E DOWN keys. To
select multiple files to download, highlight the first file selection, then use the ↑ and ↓ keys while pressing
the shift key to highlight the remaining files.
Remote file name Enter the name of the remote file that will be downloaded from the host computer.
Preview Check this box to preview the file that you selected in the Files list box. To check or uncheck the box, press the
Spacebar on the keyboard when the Preview box has the focus.
Phoenix Software V9.76.0 Operator Manual 806400 57
3 – Loading Parts
Download to Select where you want to download the part: to the current part in memory or to a folder on the local hard
drive. If you select one of the local folders, the Local file name field displays.
Keypad operation: To select a different folder, use the ↑ and ↓ keys. To add a new folder, use the + key. To
remove a folder, use the - key.
Local file name The user-defined file name assigned to the file that is being downloaded to the hard drive.
Saving a part file
Use the following screen to save a part to a USB memory stick or the hard drive. After you have made all your selections
and entries, choose OK to save the part.
Permission to add or remove files and folders from the hard drive is assigned in the
Status/Feature list on the Special Setups screen.
Save to Select to save the file to the USB memory stick or to a folder on the hard drive. To add or remove a folder,
double-click on the touch screen where indicated.
Keypad operation: To select a different folder, use the ↑ and ↓ keys on the keyboard. To add a new folder,
use the + key on the keyboard. To remove a folder, use the - key on the keyboard.
File name Enter the file name that you are giving the file you are loading on the disk.
58 Phoenix Software V9.76.0 Operator Manual 806400
3 – Loading Parts
Save Original Text Hypertherm CNCs can import part files programmed for other CNCs. When you import one of
these files, the Phoenix operating software translates the file into the format used by the Hypertherm CNC.
The Save Original Text option saves the imported part file in its original format instead of the Hypertherm
CNC format. This selection is not available if you are saving the file to the USB memory stick from the hard
drive.
Save From Select whether you save from the current part or from a folder on the hard drive. To add or remove a folder,
double-click on the touch screen where indicated. This selection is available only if saving to the USB
memory stick from the hard drive.
Keypad operation: To select a different folder, use the ↑ and ↓ keys on the keyboard. To add a new folder,
use the + key on the keyboard. To remove a folder, use the - key on the keyboard.
Files Select one or more part files from the list of all the files that are in the Load from folder that can be loaded from the
disk. To remove a file, double-click on the touch screen where indicated. This selection and Multiple file
selection are only available if you are saving files to the USB memory stick from the hard drive.
Keypad operation: To scroll through different files, use the ↑, ↓, PAGE UP and PAG E DOWN keys. To
remove a file, use the - key. To select multiple files, highlight the first file selection, then use the ↑ and ↓ keys
while pressing the shift key to highlight the remaining files.
Hard drive file name Enter the name that you are giving to the file if you are loading it on the hard drive. This selection
is available only if you are saving files to the USB memory stick from the hard drive.
Preview Check this box to preview the file that is selected in the Files list box. This selection is available only if you are
saving files to the USB memory stick from the hard drive.
Keypad operation: To check or uncheck the box, press the Space key on the keypad when the Preview box
has the focus.
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Uploading part files to a host computer
Use this screen to upload a part to a host computer. After all the parameters are set, press Enter on the keyboard to start
the upload.
Upload to Select the folder on the host computer to which you want to upload a file. To add or remove a folder,
double-click on the touch screen where indicated.
Keypad operation: To select a different folder, use the ↑ and ↓ keys. To add a new folder, use the + key. To
remove a folder, use the - key.
Remote file name Enter the name of the file that you are uploading to the host computer.
Upload from Select whether you upload the current part in memory or from a folder on the local hard drive. If you select
one of the local directories, the Files, Local file name and Preview fields display. To add or remove a folder,
double-click it on the touch screen. This selection is available only if you are saving a file to the USB memory
stick from the hard drive.
Keypad operation: To select a different folder, use the ↑ and ↓ keys. To add a new folder, use the + key. To
remove a folder, use the - key.
Files Lists all the files in the upload from folder that can be uploaded to the host computer. To remove a file, double-click
on the touch screen.
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Keypad operation: To scroll through different files, use the ↑, ↓, Page Up and Page Down keys. To remove
a file, use the - key. To select multiple files to upload, highlight the first file selection, then use the ↑ and ↓
keys while pressing the shift key to highlight the remaining files.
Local file name The name of the local file that will be uploaded to the host computer.
Preview If you check this box, you can preview the file you selected in the Preview window.
Keypad operation: To check or uncheck the box, press the Spacebar on the keyboard when the Preview
box has the focus.
Importing DXF files
Hypertherm CNCs offer two styles of automated DXF import. The first DXF feature allows the CAD designer to prepare a
DXF file that includes the location of pierces, pierce order and direction. When this file is loaded, the CNC translates the
file into an EIA format part program.
The second type of DXF file is a fully automatic DXF import feature that allows the operator to select lead style and length.
The CNC Auto DXF software automatically places the lead-in and lead-out based on the operator selections and creates
an EIA format part program ready for use and the CNC.
To load a DXF file, open the Files, Load from Disk screen and select the source location and file.
Notes:
Before you can load DXF files into the CNC, enter DXF as a file extension in the Setups > Password > Special
Setups screen.
Verify the plate size for the job in the Setups > Cutting screen:
Then, in the DXF file, check the distance between the part origin and the part geometry. The CNC requires that the
location of the part geometry in relation to the part origin be less than the plate size dimensions.
When the CNC translates a DXF file, it saves the resulting EIA text file in the same location as the source DXF file. If
you are retrieving your DXF files from a network location, the CNC must have read and write privileges for that
network location. Either make sure the CNC can write to the network location, or transfer any DXF file that you expect
to translate for use on the CNC to the CNC and avoid translating DXF files from network locations.
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3 – Loading Parts
Load from Select DXF from the dropdown list.
File name Select a DXF file from the scroll box.
Preview Check this box to preview the selected file.
Show Certain Files This soft key allows you to show only certain files from the selected folder. Both the asterisk and
question mark may be used in defining the files to show.
Keypad operation: The asterisk is generated by holding down the left shift key and pressing the
backspace key. The question mark is generated by holding down the right shift key and pressing the
backspace key.
Show All Files This soft key allows the operator to undo Show Certain Files.
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Raw DXF files
If the CNC does not detect pierce information in the DXF file, you have the option to use the Hyper DXF translation utility
to import the file and add lead-in and lead-out information.
If you select Yes, a configuration screen displays fields to define the lead-in and lead-out format.
Lead In and Lead Out Select a Straight or Radius lead-in or lead-out.
Length and Radius Select the lead-in or lead-out length or radius.
Angle Select the angle, in degrees, for the lead-in or lead-out.
Auto Position Lead-in If this box is checked, the software attempts to find a suitable corner for the lead-in.
Auto Corner Align Lead-in If this box is checked, the software attempts to find a suitable corner for the lead-in.
Inside Lead-out If this box is checked, a lead-out is used on both internal and external cuts. If the box is not checked,
lead-outs are added to external cuts only.
Overburn Overburn provides an overlapping cut in the lead-in and lead-out area of a hole.
After import, an EIA part program with a .txt extension is created and placed in the source folder.
When the CNC translates a DXF file, it saves the resulting EIA text file in the same location as the source DXF file. If
you are retrieving your DXF files from a network location, the CNC must have read and write privileges for that network
location. Either make sure the CNC can write to the network location, or transfer any DXF file that you expect to
translate for use on the CNC to the CNC and avoid translating DXF files from network locations.
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Section 4
Arranging Parts
The Current Part Options screen lets you customize the layout of the current part. The Preview window shows the effects
of each part option.
Scale Factor Allows the operator to scale the current part in memory by a programmed factor. After a new scale factor
has been entered, the part is redrawn and its overall dimensions shown. The scale factor must be greater
than zero.
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Rotate Angle Allows the operator to rotate the current part in memory by a programmed value. After a new rotate angle
has been entered, the new part is displayed in the Preview window. The rotate angle can be any positive or
negative angle.
Mirror X/Mirror Y These check boxes make the X or Y dimensions negative. The result is a mirror image of the current
part in memory.
Keypad operation: Press the Next or Enter key to toggle to the X or Y field. When the cursor is on the field,
press the Space key to enter a check mark in the current highlighted field.
Kerf Press the Kerf soft key to show the kerf path in light blue. This helps you see the Kerf path before cutting. Press the
button again to turn the Kerf part graphics off.
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Repeating parts
The control has three built-in automatic repeat types: straight, staggered, and nested.
Straight repeat
4 – Arranging Parts
Repeat Type Selects the type of the three repeat: Straight, Staggered or Nested.
Start Corner Selects the corner of the plate to start the shape repeat.
Number of Rows Enter the number of rows to cut.
Number of Columns Enter the number of columns to cut.
X Pattern Offset/Y Pattern Offset Automatically calculates the pattern offset based on the dimension of the current
part in memory.
Scrap Clearance Inserts scrap clearance between parts in the grid pattern. The same value is used for X and Y
dimensions.
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4 – Arranging Parts
Staggered repeat
X Nest Distance/Y Nest Distance Automatically calculates the nest offset based on the dimension of the current part
in memory. This parameter is only available for the Nested type of repeat.
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Nested repeat
4 – Arranging Parts
Pattern Offsets Automatically calculates the minimum spacing required between repeated parts. The spacing is based
on the size of the part (including lead-in and lead-out), the kerf value and scrap clearance. This calculated
spacing allows the part to be repeated without overlapping.
You can use this pre-calculated value or select new values manually. If you enter new pattern offset values,
Phoenix automatically draws the new pattern with the new values.
Nest Distance Automatically calculates the minimum spacing required between nested parts. The spacing is based on
the size of the part (including lead-in and lead-out), the kerf value and scrap clearance. This calculated
spacing allows the part to be repeated without overlapping.
You can choose to use this pre-calculated value or select new values manually. As you enter new offset
values, the CNC automatically draws the new nested pattern with the new values.
Tip: If you change Nest Distance values manually, start with a simple nest (1 column, 1 row) and perform
adjustments based on the display. The pattern in the Preview window changes as you change values. When
the Nest Distance is what you want, increase the nest size to a 2-column, 2-row nest, then adjust the X and
Y pattern offsets again. When you have the nest spacing you want, increase the nest size to the maximum
that the plate allows.
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Aligning parts
This screen allows you to:
Launch the Align Wizard.
Align the current part to one of the four corners of the plate. This is common with parts that have an internal pierce
point such as a flange.
Accommodate skewed plates when aligning the part. This is commonly used with a nest of parts that has a small
margin of error for placement of the nest on the plate.
Align Wizard
The Align Wizard automates the sequence of operations to enter coordinates for a skewed plate on the table and to align
parts to a skewed or aligned plate.
The Align Wizard opens automatically from the Align screen or you can press the Align Wizard soft key on the Align
window.
As you work with the Align Wizard, it keeps track of your progress and displays it at the bottom of the wizard window in
the progress bar.
You can choose to use the torch or a laser pointer to align the plate. If you choose the laser pointer, you must have a
marker offset value of at least 1 entered for Marker Offset 10, 11, or 12 on the Special Setups screen.
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Aligning parts manually
To align a part manually on the plate:
1. Set parameters that are needed to align your part in the upper right corner of the screen.
2. Move the torch to the first corner location (Corner to Align with) using the jog keys.
3. Press At Corner.
4. If you are aligning a part, go to step 7.
5. Move the torch to a point along the edge of the plate toward the selected Skew Reference.
6. Press At Skew Point.
7. Press OK. The machine will move to the start point for the part and return to the Main screen and be ready for cutting.
Corner to Align Selects the corner of the plate to align the part in.
Scrap Clearance This is the amount of clearance between the edge of the plate and the part the control will add in
when moving to the start point of the part.
Skew Adjustment This determines if the control will adjust for plate skew when performing the align function.
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Skew Reference This is the skew reference corner which you will move towards and mark a point along the edge. This
is only available if Skew Adjustment is On.
At Corner Press this soft key when at the corner of the plate you want to align the part in.
At Skew Point Press this soft key when at the edge of the plate for skew adjustment. This is only available if Skew
Adjustment is On.
Nesting parts
Manual nesting
To open the Nesting screen, choose the Shape Manager soft key on the Main screen, then choose Nester.
The main viewing area is the largest area of the screen and is located in the upper left corner. The edge of the plate is
displayed in dark green. The plate size displayed is based on plate information that has been selected in the Cutting
screen (choose the Setups soft key to open the Cutting screen).
The upper right corner of the main screen displays the part program list for the nest in order of cut sequence. In the lower
right, part position and orientation information for the selected part program is displayed and can be manipulated for use
as new parts are added.
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4 – Arranging Parts
Add Part Allows you to select a part program from a selected source to add to the nest.
Remove Part Remove the selected part from the nest parts list.
Cut Earlier Pressing the Cut Earlier soft key will move the selected part program to an earlier position in the part cut list.
The sequence in which the parts are cut changes, but not the selected part location in the nest.
Cut Later Pressing the Cut Later soft key will move the selected part program to a later position in the part cut list. The
sequence in which the parts are cut changes, but not the selected part location in the nest.
View Sheet / View Part View Sheet allows the viewing of a part as it would appear on the plate. After pressing the
View Sheet soft key, the display window zooms out to show the part in relationship to the entire plate.
After zooming out, the display can be zoomed in again by pressing the + key, which causes horizontal and
vertical scroll bars to be displayed. Pressing the - key will zoom back out.
Arrow Key (Distance) The Arrow Key allows you to select one of five different preset move distances when the arrow
keys are pressed to locate parts in the nest. These five distances are definable and are selected in the
Nester setup screen.
Clear Nest Clear Nest will delete all the parts located in the nested parts list from temporary memory.
Setup Pressing the Setup soft key accesses the Nester setup screen for configuring the variable parameters when using
Nester.
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4 – Arranging Parts
Nester setup
The following Setup parameters are used to configure the manual nesting process.
Nesting Select Manual.
Arrow Increment 1 – 5 At this screen, you can select different move increment dimensions. These dimensions are used
as move distance references when the control arrow keys are pressed to place parts in position on the plate.
Autoposition Autoposition is an automated feature of the Nester software that enables block nesting. This type of
nesting compares the overall block dimensions of the selected part and searches for the next available block
on the plate that is large enough for the part.
Autoposition does not allow parts to be placed on top of other parts or inside other parts. However, it can be
disabled if you want to add parts to scrap areas.
If Autoposition is not selected, imported parts are stacked in the lower left corner of the plate and must be
manually arranged.
Search Increment The distance for the next available block on the plate that can be used for the next nested part.
Scrap Clearance The amount of space that is added to a block in the nest.
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4 – Arranging Parts
Using Manual Nester
To begin, first select the plate size requirements for the nest at the Cutting screen. This information is used to display the
plate size and plate orientation at the main view screen to place parts on the plate. The plate information is retained with
the nested part program when saved.
Press the Nester soft key from the Shape Manager screen then enter the Nester Setup Screen to configure the nesting
software. Press OK to return to the Nester Main Screen to begin placing parts in the nest.
Adding parts
At the Nester Screen, press the Add Part soft key to add a new part to the nesting part list. The first screen viewed will
allow you to select a part from the Simple Shape Library, from a disk or from the host computer via link communications.
After a part has been selected from either location, you will be prompted to select the number of pieces desired.
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4 – Arranging Parts
As new parts are added, they are displayed on the selected plate in preparation for final placement.
At this screen, the part can be oriented, scaled and moved to final position. This is done by moving to the Nester Part List
and highlighting the file name. Then select the desired field to manually offset, rotate, mirror and scale the part.
To position the selected part, use the manual direction keys. The view screen will be outlined by a bold blue border
indicating that the arrow keys are active. Pressing the arrow keys will allow movement of the part to the desired location
on the plate. Each time the arrow keys are pressed, the selected part will move in the direction of the arrow by the
increment set by the Arrow Key distance soft key. Use the arrow distance key, arrow keys and zooming in the view field, to
place the part exactly as you need it.
Add more parts to the nest in the same fashion as described above. To customize your nest, you may decide to delete
parts or add parts to the list and change the order in which they are cut by use of the soft keys displayed. When finished,
press OK to return to the Main Cut screen and begin cutting the nest. The part nest is currently saved as a temporary file
until another part is loaded.
Saving a nest
From the Main screen, press the Files soft key then Save to Disk. From here the part can be saved to a hard disk folder on
the CNC, Diskette or USB memory stick. The nested parts file may be saved as a nest or a part. Saving as a nest using
the save as Nester File feature, will create a larger file which will allow future modification of the nest through Nester.
Nested parts saved as a part file cannot be modified.
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4 – Arranging Parts
Hypernest® CNC automatic nesting
The main viewing area of the Nester screen is in the upper left corner and is used to preview manual nests. During an
automatic nest, this area remains blank. The plate size used during Automatic nesting is based on plate information that
has been selected at the main setup screen.
The upper right corner of the Main screen displays the list of part programs and quantities of parts that have been
selected for nesting. In the lower right are fields for saving the nest with a name and to a folder.
This software feature is protected both by a software enable and a hardware key (dongle) installed on the CNC.
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4 – Arranging Parts
Setting up Hypernest on the CNC
Pressing the Setup soft key accesses the following setup parameters and can be used to configure the automatic nesting
process for use.
If this feature is not available (grayed out), the feature has not been enabled on your CNC. Contact your CNC vendor
for details on how to enable the Automatic Nesting feature.
Nesting Switching the Nesting Parameter to Automatic enables the feature.
Arrow Increment 1 – 5 At this screen, you can select different move increment dimensions. These dimensions are used
as move distance references when the control arrow keys are pressed to place parts in position on the plate.
Autoposition Autoposition is an automated feature of the Nester software that enables block nesting. This type of
nesting compares the overall block dimensions of the selected part and searches for the next available block
on the plate that is large enough for the part.
Autoposition does not allow parts to be placed on top of other parts or inside other parts. However, it can be
disabled if you want to add parts to scrap areas.
If Autoposition is not selected, imported parts are stacked in the lower left corner of the plate and must be
manually arranged.
Search Increment The distance for the next available block on the plate that can be used for the next nested part.
Scrap Clearance The amount of space that is added to a block in the nest.
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4 – Arranging Parts
Part Spacing The Part Spacing feature sets the spacing between parts during the Automatic Nesting process.
Plate Edge Spacing This parameter allows you to set spacing around the edge of the plate to be used during the
Autoposition Nesting process.
Program Origin The Program Origin (nest start location) may be set to lower left, upper left, lower right, upper right.
Cut Direction Cut Direction allows you to select the direction the parts will be placed in during the automatic nesting
process. Options are Left or Right, Right to Left, Top to Bottom and Bottom to Top.
Nest Direction Select the direction in which nests are placed in the automatic nesting process.
Return to Nest Start When enabled, the Return to Nest Start feature will insert a traverse segment back to the start
point at the end of the nest.
Use Remnant If remnants are created and saved for future use, select On to use one of these remnants for automatic
nesting.
Generate and Cut Offcut Select On to generate offcuts for standard, rectangular nests. If this feature is enabled,
offcuts are created when 30% or more of the sheet remains after nesting. The offcut is cut after a pause at
the end of the nest on the last nested rectangular sheet.
M65 Auto Reload Select On to allow new sheets to be reloaded automatically. When this feature is selected, there is a
pause at the end of each sheet until the operator presses Start to Resume. Then, a new sheet automatically
loads and runs. Auto reload works with standard, rectangular nests only.
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4 – Arranging Parts
Using Nesting
1. On the Main screen, choose Shape Manager > Nester.
2. On the Nester screen, choose the Add Part soft key to add a new part to the nesting part list.
3. Select a part from the Shape Library, from a disk or from the host computer via link communications.
4. In the popup that displays, enter the number of pieces to be included in the nest.
5. As new parts are added, the part file name and quantity are listed in the Files window in preparation for final
placement during the automatic nesting process.
6. Select a folder for the nest in the Save to dropdown list.
7. Enter the name of the nest in the File name field.
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8. Press OK.
A progress window will be displayed during the nesting process.
4 – Arranging Parts
The nest process progresses quickly and not all shapes may be visible on screen or other drawing anomalies may be
noted during the nesting process.
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4 – Arranging Parts
If more parts are selected than can fit on one plate, multiple plates or sheet (nested program) files will be generated and
saved in the selected folder with the selected file name, but a numeric suffix will be added. For example, saving the part
file as Nest may generate multiple part files named NEST1.txt, NEST2.txt, NEST3.txt, etc.
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Removing a part from a nest
1. Highlight the selected part in the Files list.
2. Press the Remove Part soft key.
4 – Arranging Parts
The software feature on the CNC is protected by a hardware key or dongle. If the hardware key has been removed
from the CNC, the following message will appear when the Nest Parts soft key has been pressed.
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4 – Arranging Parts
Nest summary
Upon completion of the nest, the software will provide a summary of the Automatic Nesting process.
Statistical analysis of the process is provided for the number of sheets, time to execute nest, total nest utilization and total
number of shapes nested.
Sheets that are generated with the exact same part configuration will be listed as “Sheet No. #”.
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4 – Arranging Parts
Scroll down to view an analysis of the parts used and to view the individual sheets produced and a listing of the net
utilization for the specific sheet.
Press OK to accept the nest and have the first sheet become the current part. Press the Cancel key to reject the nest and
return to the main nesting screen to add or remove parts from the nest.
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4 – Arranging Parts
Main screen view of nest
Parts with open loops or other invalid geometries may not be able to be automatically nested. It may be possible to
manually nest parts which have been rejected by the Automatic Nesting function.
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Section 5
Cutting Parts
CutPro™ Wizard
The CutPro Wizard automates the sequence of choices and selections required for cutting parts. If you have parts, nests,
and cutting processes stored on your system, you can use the CutPro Wizard to simplify cutting operations.
The CutPro Wizard also helps you to align parts and handle plate skew with the Align Wizard. For more information on the
Align Wizard, see Arranging Parts.
The CutPro Wizard opens automatically from the Main screen or you can press the CutPro Wizard soft key on the Main
screen. As you work with the CutPro Wizard, it keeps track of your progress and displays it at the bottom of the wizard
window in the progress bar.
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5 – Cutting Parts
The CutPro Wizard is unavailable if you are operating the CNC in keyboard-only mode.
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5 – Cutting Parts
Cutting in manual mode
After you verify that the cut mode, cut speed and kerf values are set correctly, press the Start key on the Main or Manual
window to cut a part. The following window is displayed.
To cut the part:
1. Verify that the Cut Mode is set to the selected cut type and that the Kerf and Cut Speed settings are correct.
2. Press the Start key on the front panel (or F9 on a keyboard). This starts cutting in the selected Cut Mode.
To preview the path:
1. Press the Change Cut Mode soft key until Trial appears in the Cut Mode window.
2. Press the Start key to have the cutting device follow the cut path without cutting. Motion is performed at the
programmed speed.
3. Press the Stop key on the front panel to stop a cut. The machine decelerates to a smooth stop along the cut path. If
the cutting process was on when you pressed the Stop key, it is deactivated according to the programmed cut logic.
During a cut, the Watch window displays information about the part being cut, such as the current cut speed, current
axes positions, and path position.
In Sheet view, the control automatically scrolls to keep the cut location centered within the view screen. This feature is
useful during normal cutting to zoom in and follow the cut path.
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5 – Cutting Parts
View Sheet is useful when proper plate size values have been entered in Cutting setups and when the machine has been
homed. If you attempt to view large parts with a fully zoomed screen, the part may not be fully drawn on the screen before
the next view location displays and the screen may flash. Zoom out to correct this and view a larger area.
Increase Speed Increases the current cut speed by 3%.
Decrease Speed Decreases the current cut speed by 3%. Double-click the speed field to enter a new speed value.
Keyboard operation: To change the current cut speed while cutting a part, press the Enter key once to
highlight the current cut speed, enter the new cut speed, and press Enter again.
Repeats If a Shape Repeat option has been enabled, press the Repeats soft key to see the number of rows and columns
remaining to be cut. The Repeats soft key operates with the Extend soft key which is only active during
initiation of the cut sequence.
Cut Delay Timers Cut Delay Timers define the timing logic for the cut and are available for both oxy fuel and plasma at
the Cut Types setup screen. In cut mode, the control displays the preset delays as they are executed in the
lower right corner of the screen. For certain delay times, such as Preheat and Pierce, a countdown timer
shows the preset time and time remaining. An example of the Preheat Timer is illustrated below. The Preheat
times, Total, Completed and Remaining, are shown to a tenth of a second.
When you activate the Cut Sense input, the Preheat delay time cycle ends. The time at the point of activation becomes
the new Preheat time for subsequent cuts. Use the soft keys to change the Preheat cycle in progress:
Extend Extends the Preheat timer until it is stopped with either the Set-Now or Release soft key.
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5 – Cutting Parts
Set Now Ends the selected delay timer and saves the new set time. Use the Set Now soft key with the Extend soft key to
modify the preset Preheat time.
Release Ends the selected delay timer, but does not modify the original delay time.
Press the Start key twice to bypass the Preheat and Pierce Time Delays and begin the cut in the Oxyfuel cut mode.
Multitasking
Multitasking allows you to load and configure a new part program while another part program is cutting. This feature is
only available in advanced operation mode.
To use the multitasking feature:
1. On the Shape Manager screen, press the Multitasking soft key. The current part program displays in the lower right
corner of the Preview Window.
2. Select another part program from the Shape Library or a storage device. The new program displays in the Preview
Window.
3. Press the multitasking soft key to switch between programs.
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5 – Cutting Parts
Pausing cutting
If the cut process fails, the CNC has the following recovery capabilities:
Cut Loss Recovery The Cut Loss Recovery features of the CNC are available from the Pause screen which displays
when the operator presses Stop or if cut sense is lost. Press the Cancel key on the Pause screen to cancel
the current part.
Return to Start This feature allows the operator to return to the initial starting point of the part program. If you use the
Return to Start function after a cut loss, all information about the current position of the cutting device on the
path is lost.
Backup and Forward on Path Use these two soft keys to move backward and forward along the cut path at the
selected move speed to locate the pierce restart point. Press the Start key to resume the cut at the
programmed cut speed. In addition to all segments of a standard part, the Backup and Forward on Path
functions allow full movement through all sections of Shape Repeat part as well.
Like the Manual Mode functions, Backup and Forward on Path use the currently selected move speed. The
different speeds allow moving rapidly along the path, or precisely positioning the cutting device.
When a cut loss occurs, the initial backup and forward speed is the one that was used last. To toggle
between the move speeds, press the Change Move Speed soft key in the Pause window. The
corresponding speed is displayed in the Move Speed window.
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5 – Cutting Parts
Move to Pierce/Mark Press the Move to Pierce/Mark soft key to move directly to any pierce point.
Enter the information for the pierce point and press Enter. The cutting device moves directly to the selected
pierce point.
Change Cut Mode Alternates the restart mode between Cut and Trial. This allows the operator to move through the part
partially as a trial cut and partially as an actual cut.
Change Move Speed Cycles through the four move speeds that are available: Maximum Machine Speed, High Jog
Speed, Medium Jog Speed and Low Jog Speed from the Speeds setups.
On-Path Restart To restart the cut at the pierce point that you selected using On-Path Backup, press the START key.
The cut speed and the cut mode are the same as they were before the motion was paused unless the values
have been edited in the Watch window.
While the Pause Window displays, the manual arrow keys are fully functional so you can move the cutting
device. This allows you to move the machine in any direction (not necessarily along the path) to inspect the
partially cut piece. Once the cutting device is moved off the cut path, the Off-path Pause Window displays.
Return to Path Press the Return to Path soft key in the Off-path Pause window to return the cutting device to the point
on the cut path from which it was jogged away. This feature is useful for inspecting or replacing components
after cut loss and then returning to the cut loss point. When the cutting device is back on the cut path, the
On-path Pause Window is restored and cutting can resume.
Move Part Moves the entire part on the plate. The point along the cut path to which the cutting device moves becomes
the current position of the cutting device. The On-path Pause window displays again because the cutting
device is on path.
Off-Path Restart Press the Start key from the Off-path Pause window, to construct a lead-in from the off-path point
back to the original part.
In a cut loss situation, the operator can use the Backup on Path key in the On-path Pause window menu to
position the cutting device on the cut path where the cut was lost. The operator can then use the manual
arrow keys to jog the cutting device off path to a suitable pierce point.
Press Start at this point to cut a new lead-in from the off-path pierce point to the point along the path from
which the cutting device was jogged away. When the cutting device is back on path, it continues along the
path to cut the remainder of the part.
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Rush Job Interrupt Allows you to pause the current part program and retain the part and current position information.
On the Pause screen, press the Cancel key. A prompt displays on the screen to allow you to save the part
information.
If you select Yes, the Resume Last Part button displays on the Files Screen. You can load and execute
another part program and then return to the original part using the Resume Last Part soft key. The part
program and position resumes.
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Manual operations
The manual key is identified by the hand icon. If the manual key is not displayed, press [Shift + F11 or [ + F11 to show
the manual operations screen.
Press the manual key on the screen to view the following screen. The directional jog keys are active when they are green.
Whenever the manual keys are active, the cursor icon in the graphics display window is the shape of a hand.
From the Manual window, the machine can be moved in one of eight directions using the arrow keys. The cutting device
moves while you hold an arrow key down. When the key is released, the cutting device comes to a smooth stop.
If the latched manual key feature is enabled in the control setups, press the manual key a second time to allow motion to
continue without holding down the arrow key.
This feature is available for the manual direction keys in the Manual, Align and Pause screens. When this feature is
activated, the dialog “Latched Manual Keys On” will be displayed in red at the bottom right corner of the part window.
Motion can be paused by use of the Stop, Cancel or an arrow key. The latched manual key feature can be turned off by
pressing the manual key again.
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Return to Start Whenever the Manual window is opened, the transverse and rail positions at that point are saved.
After rip cutting or other manual operations, it may be necessary to return to this “start” position.
Press the Return to Start soft key to generate motion in the transverse and rail axes from the machine’s
current position to the position that was saved when the Manual window opened.
Move Distance When Move Only is displayed in the Manual Mode window, the second soft key from the left changes to
Move Distance.
The Move Distance soft key allows you to perform moves over exact distances. After you press Move
Distance, the CNC prompts you for traverse and rail distance values for the machine’s motion. Enter the
appropriate values and press ENTER.
The cutting device moves the distance you entered in a straight line without executing any cut logic.
As with any automatic motion, you may press STOP on the front panel at any time to bring the machine
smoothly to a stop before the programmed motion is complete.
Cut Distance When Rip Cut mode is selected in the Manual Mode window, the second soft key from the left changes to
Cut Distance.
This soft key allows you to make rip cuts of an exact length. After you press Cut Distance, the control
prompts you for traverse and rail distance values for machine motion. Enter the appropriate values and press
ENTER.
After the cutting device executes the cut logic sequence, it moves the distance you entered in a straight line.
If you enter incorrect values, press the CANCEL key at any time.
After motion has begun, press STOP on the front panel to bring the machine smoothly to a stop before the
programmed motion is complete.
Rip Cut mode is useful for making a cut along a specified linear path. Motion stops and cutting action
ceases when the new position is reached or when the STOP key is pressed.
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If you do not know the exact distance, enter a distance longer than needed in the right direction, and then
press STOP to end the cut.
Manual Options Press the Manual Options soft key to access the Manual Options screen.
Home Axes Press the Home Axes soft key to access the Homes Axes screen.
View Sheet/View Part View Sheet allows you to view a part as it would appear on the plate. After you press the View
Sheet soft key, the display window zooms out to show the part in relationship to the entire plate.
After the display zooms out, you can zoom in again by pressing the + key, which adds horizontal and vertical
scroll bars. Press the - key to zoom out again.
While the scroll bars are displayed, you can hold down the scroll bar and move it to adjust the view of the
machine horizontally and vertically. This mode is useful in normal cutting to closely follow the cut path while in
zoom.
While cutting in sheet view, the control automatically scrolls to keep the cut location centered within the view
screen. This feature is useful in normal cutting to follow the cut-path while zoomed in.
View Sheet is more useful when proper plate size values have been entered in cutting setups and when the
machine has already been homed. If you are viewing large parts being cut with the display fully zoomed, the
system may not be able to draw the part on screen before it has to move to the next view location. In this
case, the view screen may flash but you can correct this by zooming out to a larger view area.
Change Manual Mode This soft key alternates the control Manual Mode between Move Only and Rip Cut.
If you press this soft key the second soft key from the left to changes function from Move Distance to Cut
Distance. Rip Cutting is described in more detail below.
Change Move Speed This soft key toggles through the four Move Speeds: maximum machine speed, high jog speed,
medium jog speed and low jog speed from the Speeds setups.
Zero Positions Press this soft key to return all axes positions to 0 (zero).
Rip cutting
When the Manual Mode window displays Rip Cut, you can use the arrow keys to begin a cut sequence and machine
motion in the chosen direction.
To initiate a rip cut:
1. Verify that the correct cut mode has been selected.
2. Verify that the proper cut speed is displayed in the Cut Speed window (editable in Rip Cut mode).
3. Press the arrow key corresponding to the desired start direction for the cut.
The cutting sequence proceeds even after the key is released; however, machine motion is generated only as long as
an arrow key is held down, unless the latched manual key feature has been enabled.
4. Use the arrow keys to change direction.
5. Press Stop, Cancel, or Manual to stop the operation of the cutting device.
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Manual options
Raise Torch Raises the cutting torch while the soft key is pressed or until the Torch Up sense input is activated. If a
Sensor THC is installed, the CNC uses the THC Jog speed selections.
Lower Torch Lowers the cutting torch while the soft key is pressed or until the torch down sense input is activated. If the
torch down output has been enabled to stay on during the cut in plasma setups, press the Lower Torch soft
key to keep the torch in the down position until the Lower Torch soft key is depressed a second time. If a
Sensor THC is installed, the CNC uses the THC Jog speed selections.
Manual Offset Manual Offset is useful for cutting tables that have a laser alignment tool attached and allows you to use
your laser alignment tool for aligning a part to a plate.
The offset will stay in place until it is turned off from this screen or a part is cut in either oxyfuel or plasma cut
mode.
You can select the following manual offsets:
User Defined: Uses the selected X / Y Offset distance.
Laser pointer to Plasma 1: Offset 10
Laser pointer to Plasma 2: Offset 11
Laser pointer to Oxy Fuel: Offset 12
This setting is displayed in the Laser Pointer group box on this screen.
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Send Tilt Rotator Home Executes a move to the predefined rotate home position.
Move Rotate Axis Moves to a specified rotate axis position. Enter the position in the dialog box that displays after you
press this key.
Move Tilt Axis Moves to a specified tilt axis position. Enter the position in the dialog box that displays after you press
this key.
Adjust Dual Gantry Skew Allows you to move the master rail motor using the directional manual jog arrow keys to
correct or realign gantry skew. This movement is only allowed after you enter a password.
Consult the table manufacturer’s documentation to prevent damage to machinery.
Space Torches Performs the torch spacing routine. (This feature requires special program codes. See the Phoenix
Software V9 Series Programmer’s Reference for more information). The number of torches to space and the
distance can be entered in this screen. Pressing Space Torches generates a .txt file and moves multiple
torches to evenly spaced positions along the transverse axis.
Home axes
From the Home screen, each axis or all axes can be “homed”. In addition, the transverse and rail axes can be sent to one
of up to 12 programmed alternate home positions.
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The home feature sets a known, absolute physical position location on the cutting table that is used for referencing future
manual “Go to Home” and other motion commands. This is generally performed through activation of a home switch
positioned on the appropriate axis giving it a known physical location.
When the homing command is entered at the CNC, the CNC moves the axis toward the home switches at the fast home
speed until the switches have been activated. After the switches have been activated, motion stops and the axis moves in
the opposite direction off switch at the slow home speed.
When switch is deactivated, the position is recorded at the CNC and provides an absolute reference point for future
motion commands.
Transverse Press the Transverse soft key to initiate the automated homing procedure. This procedure generally
produces machine motion in the transverse axis, depending on the homing parameters set in the Setups.
Rail Press the Rail soft key to initiate the automated homing procedure. This procedure generally produces machine
motion in the Rail axis, depending on the homing parameters set in the Setups.
CBH Press the CBH soft key to initiate the automated homing procedure. This procedure generally produces machine
motion in the CBH axis, depending on the homing parameters set in the Setups.
THC Press the THC soft key to initiate the automated homing procedure for the Sensor THC. This procedure generally
produces machine motion in the THC axis, depending on the homing parameters set in the Setups.
Tilt Press the Tilt soft key to initiate the automated homing procedure for the Tilt Axis.
Rotate Press the Rotate soft key to initiate the automated homing procedure for the Rotate Axis.
If tilt and rotate axes are enabled, the following window will appear and allow access to
the Tilt/ Rotate or other axes.
Select Yes to access Homing for the Tilt and Rotate Axes.
Select No to access the Homing functions for the other axes.
All Press the All soft key to initiate the automated homing procedure. This procedure generally produces machine motion
in one or more axes, depending on the homing parameters set in the Setups.
Go To Home Position Press one of the four Go To Home Position soft keys to move the transverse and rail axes to the
predefined position set in the corresponding edit window. The Go To Positions are absolute and require that
an automated home procedure already be executed.
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