Hypertherm Automation Family Instruction Manual (IM)

SensorTM THC Plasma Lifter

Installation Manual

808970 – REVISION 3

ENGLISH

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Benefits of registration

5 Safety: Registration allows us to contact you in the unlikely event a safety or quality notification

is required.

5 Education: Registration gives you free access to online product training content via the

Hypertherm Cutting Institute.

5 Confirmation of ownership: Registration can serve as proof of purchase in case of an

insurance loss.

Go to www.hypertherm.com/registration for easy and fast registration.

If you experience any problems with the product registration process, please contact
[e-mail].

For your records

Serial number: __________________________________________________________________________

Purchase date: __________________________________________________________________________

Distributor: _____________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

Maintenance notes: ______________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

Sensor, Phoenix, EDGE, MicroEDGE, HPRXD, HPR130XD, HPR260XD, HPR400XD, and Hypertherm are trademarks of
Hypertherm, Inc. and may be registered in the United States and other countries. All other trademarks are the property of their
respective holders.

Environmental stewardship is one of Hypertherm’s core values.www.hypertherm.com/environment

© 2016 – 2022 Hypertherm, Inc. 100% Associate-owned.

SensorTM THC Plasma Lifter

Installation Manual

808970

REVISION 3

English

Original instructions

September 2022

Hypertherm, Inc.

Hanover, NH 03755 USA

www.hypertherm.com

Hypertherm, Inc.

21 Great Hollow Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
[e-mail] (Main Office)

800-643-9878 Tel (Technical Service)

[e-mail] (Technical Service)

800-737-2978 Tel (Customer Service)

[e-mail] (Customer Service)

Hypertherm México, S.A. de C.V.

52 55 5681 8109 Tel
52 55 5681 7978 Tel
[e-mail] (Technical Service)

Hypertherm Plasmatechnik GmbH

Sophie-Scholl-Platz 5
63452 Hanau
Germany
00 800 33 24 97 37 Tel
00 800 49 73 73 29 Fax

31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)

[e-mail] (Technical Service)

Hypertherm (Singapore) Pte Ltd.

Solaris @ Kallang 164
164 Kallang Way #03-13
Singapore 349248, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
[e-mail] (Marketing)
[e-mail] (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
[e-mail] (Main Office)
[e-mail] (Technical Service)

Hypertherm Europe B.V.

Laan van Kopenhagen 100
3317 DM Dordrecht
Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)

31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)

[e-mail] (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

B301, 495 ShangZhong Road
Shanghai, 200231
PR China
86-21-80231122 Tel
86-21-80231120 Fax

86-21-80231128 Tel (Technical Service)

[e-mail] (Technical Service)

South America & Central America: Hypertherm Brasil Ltda.

Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP – Brasil
CEP 07115-030
55 11 2409 2636 Tel
[e-mail] (Technical Service)

Hypertherm Korea Branch

#3904. APEC-ro 17. Heaundae-gu. Busan.
Korea 48060
82 (0)51 747 0358 Tel
82 (0)51 701 0358 Fax
[e-mail] (Marketing)
[e-mail] (Technical Service)

Hypertherm Pty Limited

GPO Box 4836
Sydney NSW 2001, Australia
61 7 3103 1695 Tel
61 7 3219 9010 Fax
[e-mail] (Main Office)
[e-mail] (Technical Service)

Hypertherm (India) Thermal Cutting Pvt. Ltd

A-18 / B-1 Extension,
Mohan Co-Operative Industrial Estate,
Mathura Road, New Delhi 110044, India
91-11-40521201/ 2/ 3 Tel
91-11 40521204 Fax
[e-mail] (Main Office)
[e-mail] (Technical Service)

For training and education resources, go to the Hypertherm Cutting Institute (HCI) online at

www.hypertherm.com/hci.

ENGLISH

WARNING! Before operating any Hypertherm equipment, read the safety
instructions in your product’s manual, the Safety and Compliance Manual (80669C),

Waterjet Safety and Compliance Manual (80943C), and Radio Frequency Warning
Manual (80945C). Failure to follow safety instructions can result in personal injury

or in damage to equipment.
Copies of the manuals can come with the product in electronic and printed formats.

Electronic copies are also on our website. Many manuals are available in multiple
languages at www.hypertherm.com/docs.

BG (БЪЛГAPCКИ/BULGARIAN)

ПРЕДУПРЕЖДЕНИЕ! Преди да работите с което и да е оборудване
Hypertherm, прочетете инструкциите за безопасност в ръководството на вашия
продукт, „Инструкция за безопасност и съответствие“ (80669C), „Инструкция
за безопасност и съответствие на Waterjet“ (80943С) и „Инструкция
за предупреждение за радиочестота“ (80945С).

Продуктът може да е съпроводен от копия на ръководствата в електронен
и в печатен формат. Тези в електронен формат са достъпни също на уебсайта
ни. Много ръководства са налице на няколко езика
на адрес www.hypertherm.com/docs.

CS (ČESKY/CZECH)

VAROVÁNÍ! Před uvedením jakéhokoli zařízení Hypertherm do provozu si přečtěte
bezpečnostní pokyny v příručce k produktu a v Manuálu pro bezpečnost

a dodržování předpisů (80669C), Manuálu pro bezpečnost a dodržování
předpisů při řezání vodním paprskem (80943C) a Manuálu varování ohledně
rádiových frekvencí (80945C).

Kopie příruček mohou být součástí dodávky produktu, a to v elektronické i tištěné
formě. Elektronické kopie jsou k dispozici i na našich webových stránkách. Mnoho
příruček je k dispozici v různých jazycích na stránce www.hypertherm.com/docs.

DA (DANSK/DANISH)

ADVARSEL! Inden Hypertherm udstyr tages i brug skal sikkerhedsinstruktionerne
i produktets manual og i Manual om sikkerhed og overholdelse af krav (80669C),
Manual om sikkerhed og overholdelse af krav for vandstråleskæring (80943C),
og Manual om radiofrekvensadvarsel (80945C), gennemlæses.

Kopier af manualerne kan leveres med produktet i elektronisk og trykt format.
Elektroniske kopier findes også på vores hjemmeside. Mange manualer
er tilgængelige på flere sprog på www.hypertherm.com/docs.

DE (DEUTSCH/GERMAN)

WARNUNG! Bevor Sie ein Hypertherm-Gerät in Betrieb nehmen, lesen Sie bitte die
Sicherheitsanweisungen in Ihrer Bedienungsanleitung, das Handbuch für Sicherheit

und Übereinstimmung (80669C), das Handbuch für Sicherheit und Compliance bei
Wasserstrahl-Schneidanlagen (80943C) und das Handbuch für Hochfrequenz­Warnung (80945C).

Bedienungsanleitungen und Handbücher können dem Gerät in elektronischer Form
oder als Druckversion beiliegen. In elektronischer Form liegen sie auch auf unserer
Website vor. Viele Handbücher stehen in verschiedenen Sprachen auf

www.hypertherm.com/docs zur Verfügung.

ES (ESPAÑOL/SPANISH)

¡ADVERTENCIA! Antes de operar cualquier equipo Hypertherm, lea las
instrucciones de seguridad del manual de su producto, del Manual de seguridad

y cumplimiento (80669C), del Manual de seguridad y cumplimiento en corte con
chorro de agua (80943C) y del Manual de advertencias de radiofrecuencia

(80945C).
El producto puede incluir copias de los manuales en formato digital e impreso.

Las copias digitales también están en nuestra página web. Hay diversos manuales
disponibles en varios idiomas en www.hypertherm.com/docs.

ET (EESTI/ESTONIAN)

HOIATUS! Enne Hyperthermi mis tahes seadme kasutamist lugege läbi toote
kasutusjuhendis olevad ohutusjuhised ning Ohutus- ja vastavusjuhend (80669C),
Veejoa ohutuse ja vastavuse juhend (80943C) ja Raadiosageduse hoiatusjuhend
(80945C). Ohutusjuhiste eiramine võib põhjustada vigastusi ja kahjustada
seadmeid.

Juhiste koopiad võivad tootega kaasas olla elektrooniliselt või trükituna.
Elektroonilised koopiad on saadaval ka meie veebilehel. Paljud kasutusjuhendid
on erinevates keeltes saadaval veebilehel www.hypertherm.com/docs.

FI (SUOMI/FINNISH)

VAROITUS! Ennen minkään Hypertherm-laitteen käyttöä lue tuotteen
käyttöoppaassa olevat turvallisuusohjeet, turvallisuuden ja vaatimustenmukaisuuden

käsikirja (80669C), vesileikkauksen turvallisuuden ja vaatimustenmukaisuuden
käsikirja (80943C) ja radiotaajuusvaroitusten käsikirja (80945C).

Käyttöoppaiden kopiot voivat olla tuotteen mukana sähköisessä ja tulostetussa
muodossa. Sähköiset kopiot ovat myös verkkosivustollamme. Monet käyttöoppaat
ovat myös saatavissa useilla kielillä www.hypertherm.com/docs.

FR (FRANÇAIS/FRENCH)

AVERTISSEMENT! Avant d’utiliser tout équipement Hypertherm, lire les consignes
de sécurité dumanuel de votre produit, duManuel de sécurité et de conformité
(80669C), du Manuel de sécurité et de conformité du jet d’eau (80943C)
et du Manuel d'avertissement relatif aux radiofréqunces (80945C).

Les exemplaires des manuels qui accompagnent le produit peuvent être sous forme
électronique ou papier. Les manuels sous forme électronique se trouvent également
sur notre site Internet. Plusieurs manuels sont offerts en plusieurs langues
à www.hypertherm.com/docs.

GR (ΕΛΛΗΝΙΚΆ/GREEK)

ΠΡΟΕΙΔΟΠΟΙΗΣΗ! Πριν θέσετε σε λειτουργία οποιονδήποτε εξοπλισμό της
Hypertherm, διαβάστε τις οδηγίες ασφαλείας στο εγχειρίδιο του προϊόντος και στο

εγχειρίδιο ασφάλειας και συμμόρφωσης (80669C), στο εγχειρίδιο ασφάλειας και
συμμόρφωσης του waterjet (80943C) και στο εγχειρίδιο προειδοποιήσεων για τις
ραδιοσυχνότητες (80945C).

Το προϊόν μπορεί να συνοδεύεται από αντίγραφα των εγχειριδίων σε ηλεκτρονική
και έντυπη μορφή. Τα ηλεκτρονικά αντίγραφα υπάρχουν επίσης στον ιστότοπό μας.
Πολλά εγχειρίδια είναι διαθέσιμα σε διάφορες γλώσσες στο

www.hypertherm.com/docs.

HU (MAGYAR/HUNGARIAN)

VIGYÁZAT! Mielőtt bármilyen Hypertherm berendezést üzemeltetne,
olvassa el a biztonsági információkat a termék kézikönyvében, a Biztonsági

és szabálykövetési kézikönyvben (80669C), a Vízsugaras biztonsági
és szabálykövetési kézikönyvben (80943C) és a Rádiófrekvenciás
figyelmeztetéseket tartalmazó kézikönyvben (80945C).

A termékhez a kézikönyv példányai elektronikus és nyomtatott formában is mellékelve
lehetnek. Az elektronikus példányok webhelyünkön is megtalálhatók. Számos
kézikönyv áll rendelkezésre több nyelven a www.hypertherm.com/docs weboldalon.

ID (BAHASA INDONESIA/INDONESIAN)

PERINGATAN! Sebelum mengoperasikan peralatan Hypertherm, bacalah petunjuk
keselamatan dalam manual produk Anda, Manual Keselamatan dan Kepatuhan
(80669C), Manual Keselamatan dan Kepatuhan Jet Air (80943C), dan Manual
Peringatan Frekuensi Radio (80945C). Kegagalan mengikuti petunjuk keselamatan
dapat menyebabkan cedera pribadi atau kerusakan pada peralatan.

Produk mungkin disertai salinan manual atau petunjuk dalam format elektronik
maupun cetak. Salinan elektronik juga tersedia di situs web kami. Berbagai manual
tersedia dalam beberapa bahasa di www.hypertherm.com/docs.

IT (ITALIANO/ITALIAN)

AVVERTENZA! Prima di usare un’attrezzatura Hypertherm, leggere le istruzioni sulla
sicurezza nel manuale del prodotto, nel Manuale sulla sicurezza e la conformità
(80669C), nel Manuale sulla sicurezza e la conformità Waterjet (80943C) e nel
Manuale di avvertenze sulla radiofrequenza(80945C).

Copie del manuale possono accompagnare il prodotto in formato cartaceo
o elettronico. Le copie elettroniche sono disponibili anche sul nostro sito web. Molti
manuali sono disponibili in diverse lingue all’indirizzo www.hypertherm.com/docs.

JA (日本語/JAPANESE)

警告 ! Hypertherm 機器を操作する前に、この製品説明書にある安全情報、「安全
とコンプライアンスマニュアル」 (80669C) 、「ウォータージェットの安全とコ
ンプライアンス」 (80943C)、「高周波警告」 (80945C) をお読みください。

説明書のコピーは、電子フォーマット、または印刷物として製品に同梱されて
います。電子コピーは当社ウェブサイトにも掲載されています。説明書の多く
は www.hypertherm.com/docs にて複数の言語でご用意しています。

KO (뼑뼑霢꽩 KOREAN)

陲隕+\SHUWKHUP녚ꟹꌱꩡ끞뼍韥놹꾅뇑븽꫙ꐺ꫑꿵껽놹ꗄ鞑뇊늵ꯍ
꫙ꐺ꫑&낁뫥뇤껽놹ꗄ鞑뇊늵ꯍ꫙ꐺ꫑&鞭ꍡ隕ꓩ꫕늱볁ꯍ
陲隕꫙ꐺ꫑&꾅驍꿵넽鱉껽놹덵렝냹넲냱겢겑꿙

놹녅뿊겒隱넭ꭹ鷑뿊겒냱ꈑ꫙ꐺ꫑ꩡꚭ넩뇑븽隱뼝颍뇑險鷕ꯍ넽걪鱽鲙
놹녅ꩡꚭ鵹+\SHUWKHUP낮ꩡ넩뱭꾅꫑ꚩ겙ꯍ넽냱ꐥ꫙ꐺ꫑ꩡꚭ냵

www.hypertherm.com/docs 꾅꫑꾡ꆡ꽭꽩ꈑ뇑險鷞鱽鲙

NE (NEDERLANDS/DUTCH)

WAARSCHUWING! Lees voordat u Hypertherm-apparatuur gebruikt
de veiligheidsinstructies in de producthandleiding, in de Veiligheids-

en nalevingshandleiding (80669C) in de Veiligheids- en nalevingshandleiding
voor waterstralen (80943C) en in de Waarschuwingshandleiding radiofrequentie

(80945C).
De handleidingen kunnen in elektronische en gedrukte vorm met het product worden

meegeleverd. Elektronische versies zijn ook beschikbaar op onze website. Veel
handleidingen zijn in meerdere talen beschikbaar via www.hypertherm.com/docs.

NO (NORSK/NORWEGIAN)

ADVARSEL! Før du bruker noe Hypertherm-utstyr, må du lese
sikkerhetsinstruksjonene i produktets håndbok, håndboken om sikkerhet og
samsvar (80669C), håndboken om vannjet sikkerhet og samsvar (80943C),
og håndboken om radiofrekvensadvarsler (80945C).

Eksemplarer av håndbøkene kan følge med produktet i elektronisk og trykt form.
Elektroniske eksemplarer finnes også på nettstedet vårt. Mange håndbøker
er tilgjengelig i flere språk på www.hypertherm.com/docs.

PL (POLSKI/POLISH)

OSTRZEŻENIE! Przed rozpoczęciem obsługi jakiegokolwiek systemu
firmy Hypertherm należy się zapoznać z instrukcjami bezpieczeństwa zamieszczonymi
w podręczniku produktu, w podręczniku bezpieczeństwa i zgodności (80669C),
podręczniku bezpieczeństwa i zgodności systemów strumienia wody (80943C)
oraz podręczniku z ostrzeżeniem o częstotliwości radiowej (80945C).

Do produktu mogą być dołączone podręczniki użytkownika wformie elektronicznej
idrukowanej. Kopie elektroniczne znajdują się również wnaszej witrynie internetowej.
Wiele podręczników jest dostępnych wróżnych językach pod adresem

www.hypertherm.com/docs.

PT (PORTUGUÊS/PORTUGUESE)

ADVERTÊNCIA! Antes de operar qualquer equipamento Hypertherm,
leia as instruções de segurança no manual do seu produto, no Manual

de Segurança e de Conformidade (80669C), no Manual de Segurança
e de Conformidade do Waterjet (80943C) e no Manual de Advertência
de radiofrequência (80945C).

Cópias dos manuais podem vir com o produto nos formatos eletrônico e impresso.
Cópias eletrônicas também são encontradas em nosso website. Muitos manuais
estão disponíveis em vários idiomas em www.hypertherm.com/docs.

RO (ROMÂNĂ/ROMANIAN)

AVERTIZARE! Înainte de utilizarea oricărui echipament Hypertherm, citiți
instrucțiunile de siguranță din manualul produsului, manualul de siguranță
și conformitate (80669C), manualul de siguranță și conformitate Waterjet (80943C)
și din manualul de avertizare privind radiofrecvența (80945C).

Produsul poate fi însoțit de copii ale manualelor în format tipărit și electronic.
Exemplarele electronice sunt disponibile și pe site-ul nostru web.
Numeroase manuale sunt disponibile în mai mult limbi la adresa:

www.hypertherm.com/docs.

RU (PУССКИЙ/RUSSIAN)

БЕРЕГИСЬ! Перед работой с любым оборудованием Hypertherm ознакомьтесь
с инструкциями по безопасности, представленными в руководстве, которое
поставляется вместе с продуктом, в Руководстве по безопасности и

соответствию (80669С), в Руководстве по безопасности и соответствию для
водоструйной резки (80943C) и Руководстве по предупреждению о
радиочастотном излучении (80945С).

Копии руководств, которые поставляются вместе с продуктом, могут быть
представлены в электронном и бумажном виде. Электронные копии также
доступны на нашем веб-сайте. Целый ряд руководств доступны на нескольких
языках по ссылке www.hypertherm.com/docs.

SK (S LOVENČINA/SLOVAK)

VÝSTRAHA! Pred použitím akéhokoľvek zariadenia od spoločnosti Hypertherm si
prečítajte bezpečnostné pokyny v návode na obsluhu vášho zariadenia a v Manuáli

o bezpečnosti a súlade s normami (80669C), Manuáli o bezpečnosti a súlade
snormami pre systém rezania vodou (80943C) avManuáli sinformáciami
orádiofrekvencii (80945C).

Návod na obsluhu sa dodáva spolu sproduktom velektronickej atlačenej podobe.
Jeho elektronický formát je dostupný aj na našej webovej stránke. Mnohé znávodov
na obsluhu sú dostupné vo viacjazyčnej mutácii na stránke

www.hypertherm.com/docs.

SL (S LOVENŠČINA/SLOVENIAN)

OPOZORILO! Pred uporabo katerekoli Hyperthermove opreme preberite varnostna
navodila v priročniku vašega izdelka, v Priročniku za varnost in skladnost (80669C),
v Priročniku za varnost in skladnost sistemov rezanja z vodnim curkom (80943C)
in v Priročniku Opozorilo o radijskih frekvencah (80945C).

Izvodi priročnikov so lahko izdelku priloženi v elektronski in tiskani obliki. Elektronski
izvodi so na voljo tudi na našem spletnem mestu. Številni priročniki so na voljo
v različnih jezikih na naslovu www.hypertherm.com/docs.

SR (SRPSKI/SERBIAN)

UPOZORENJE! Pre rukovanja bilo kojom Hyperthermovom opremom pročitajte
uputstva o bezbednosti u svom priručniku za proizvod, Priručniku o bezbednosti

i usaglašenosti (80669C), Priručniku o bezbednosti i usaglašenosti Waterjet
tehnologije (80943C) i Priručniku sa upozorenjem o radio-frekvenciji (80945C).

Уз производ се испоручују копије приручника у електронском или штампаном
формату. Електронске копије су такође доступне на нашем веб-сајту. Многи
приручници су доступни на више језика на адреси www.hypertherm.com/docs.

SV (SVENSKA/SWEDISH)

VARNING! Läs häftet säkerhetsinformationen i din produkts säkerhets- och
efterlevnadsmanual (80669C), säkerhets- och efterlevnadsmanualen för Waterjet

(80943C) och varningsmanualen för radiofrekvenser (80945C) för viktig
säkerhetsinformation innan du använder eller underhåller Hypertherm-utrustning.

Kopior av manualerna kan medfölja produkten i elektroniskt och tryckt format.
Elektroniska kopior finns också på vår webbplats. Många manualer finns på flera
språk på www.hypertherm.com/docs.

THࡗࡩࡠࡩࡷࡎ࡙THAI

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Contents

Safety...................................................................................................................................... SC-9

Product Stewardship.......................................................................................................... SC-17

Environmental Stewardship.............................................................................................. SC-19

Electromagnetic Compatibility (EMC) ............................................................................ SC-21

Warranty............................................................................................................................... SC-23

1 Overview..................................................................................................................................... 25

2 Specifications and parts ......................................................................................................... 27

Upon receipt...................................................................................................................................................................... 27

Claims............................................................................................................................................................. 27

Sensor THC Plasma Lifter.......................................................................................................................................... 28

Data plate....................................................................................................................................................... 30

Lifter interface cable ..................................................................................................................................................... 31

Motors and drives........................................................................................................................................................... 31

Motor couplings ........................................................................................................................................... 33

Sensor THC Plasma Lifter Installation Manual 808970 7

Contents

Replacement parts......................................................................................................................................................... 34

Lifter parts...................................................................................................................................................... 34

Breakaway parts........................................................................................................................................... 36

Wiring diagram ................................................................................................................................................................. 36

3 Install .......................................................................................................................................... 39

Install the motor .............................................................................................................................................................. 39

Move the connector for the lifter interface cable (optional).................................................................... 41

Install the lifter ................................................................................................................................................................. 43

Ground the lifter .............................................................................................................................................................. 45

Install the THC drive...................................................................................................................................................... 45

Install voltage divider board/VDC3....................................................................................................................... 45

4 Connect....................................................................................................................................... 47

Connect the lifter to the THC drive ....................................................................................................................... 47

Connect the THC drive to the network ............................................................................................................... 49

Connect the VDC3 board............................................................................................................................................ 49

8 808970 Installation Manual Sensor THC Plasma Lifter

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

Carefully read 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.

RESPONSIBILITY FOR SAFETY

The person or entity responsible for the safety of the workplace must:

• Make sure that operators and their supervisors are trained in the safe
use of their equipment, the safe use of the process, and emergency
procedures.

• Make sure that all hazards and safety precautions identified herein
are communicated to and understood by workers before the start of
work.

• Designate approved cutting areas and establish procedures for safe
cutting.

• Be responsible for authorizing cutting operations in areas not
specifically designed or approved for such processes.

• Make sure that only approved equipment, such as torches and
personal protective equipment, are used.

DANGER WARNING CAUTION

American National Standards Institute (ANSI) guidelines are used for
safety signal words and symbols. The 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.

INSPECT EQUIPMENT BEFORE USING

All cutting equipment must be inspected as required to make sure it is in
safe operating condition. When found to be incapable of reliable and
safe operation, the equipment must be repaired by qualified personnel
prior to its next use or withdrawn from service.

• Select contractors who provide trained and qualified personnel, and
who have awareness of the risks involved, to do cutting.

• Tell contractors about flammable materials or hazardous conditions
that are specific to the site, or hazardous conditions that they may not
be aware of.

• Make sure that the quality and quantity of air for ventilation is such
that personnel exposures to hazardous contaminants are below the
allowable limits.

• Make sure that ventilation in confined spaces is sufficient to allow
adequate oxygen for life support, to prevent accumulation of
asphixiants or flammable explosive mixtures, to prevent
oxygen-enriched atmospheres, and to keep airborne contaminants in
breathing atmospheres below allowable limits.

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.

STATIC ELECTRICITY CAN DAMAGE PRINTED CIRCUIT BOARDS

Use proper precautions when handling printed circuit boards:

• Store printed circuit boards in anti-static containers.

• Wear a grounded wrist strap when handling printed circuit boards.

Safety and compliance SC-9

Safety

GROUNDING SAFETY

Work lead Attach the work lead securely to the workpiece or the

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

Cutting table Connect the cutting table to an earth ground, in
accordance with appropriate national and local electrical regulations.

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.

ELECTRIC SHOCK CAN KILL

Input power

• Make 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, make 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. Tighten the
retaining nut.

• Tighten all electrical connections to avoid excessive heating.

• 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.

• Prior to operating the equipment after moving, opening, or servicing,
make sure to close the enclosure and make sure that there is proper
earth ground continuity to the enclosure.

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

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.

• In machine torch applications, never touch the torch body,
workpiece, or water in a water table when the plasma system is
operating.

Electric shock prevention

All 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 the work and ground using dry insulating
mats or covers big enough to prevent any physical contact with the
work or ground. If you must cut 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, make sure that it is correctly connected
to an earth ground.

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

• 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 lead 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 a proper grounding
conductor first.

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

SC-10 Safety and compliance

CUTTING CAN CAUSE FIRE OR EXPLOSION

Safety

Fire prevention

• Make sure the cutting 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 containers.

• Do not cut containers that have held combustible materials.

Explosion Hazard

Hydrogen Detonation with Aluminum Cutting

When you use a plasma torch to cut aluminum alloys under water or
on a water table, a chemical reaction between the water and the
workpiece, parts, fine particles, or molten aluminum droplets
generates significantly more hydrogen gas than occurs with other
metals. This hydrogen gas may get trapped under the workpiece. If
exposed to oxygen or air, the plasma arc or a spark from any source
can ignite this trapped hydrogen gas, causing an explosion that may
result in death, personal injury, loss of property, or equipment damage.

Consult with the table manufacturer and other experts prior to cutting
aluminum to implement a risk assessment and mitigation plan that
eliminates the risk of detonation by preventing hydrogen
accumulation.

WARNING

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.

WARNING

Explosion Hazard

Underwater Cutting with Fuel Gases

Containing Hydrogen

• Do not cut underwater with fuel gases containing hydrogen.

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

WARNING

Also, make sure that the water table, fume extraction (ventilation), and
other parts of the cutting system have been designed with aluminum
cutting in mind.

Do not cut aluminum alloys underwater or on a water table
unless you can prevent the accumulation of hydrogen gas.

Note: With proper mitigation, most aluminum alloys can be plasma
cut on a water table. An exception is aluminum-lithium alloys. Never
cut aluminum-lithium alloys in the presence of water. Contact

your aluminum supplier for additional safety information regarding
hazards associated with aluminum-lithium alloys.

MACHINE MOTION CAN CAUSE INJURY

When an original equipment manufacturer (OEM) makes a cutting system by combining Hypertherm equipment with other equipment, the end-use
customer and the OEM are responsible for providing protection against the hazardous moving parts of this cutting system. However, we advise the
following to prevent operator injury and equipment damage:

• Read and follow the instruction manual provided by the OEM.

• Maintain a restricted-access area larger than the maximum
movement range of the cutting system’s moving parts.

• Where there is a risk of collision, do not allow personnel or
equipment near the cutting system’s moving parts.

• Avoid accidental contact with the CNC touchscreen or joystick.
Accidental contact can activate commands and result in
unintended motion.

Safety and compliance SC-11

• Do not service or clean the machinery during operation.

• If servicing is required, enable the safety interlock or disconnect
and lock out/tag out power to disable the motors and prevent
motion.

• Allow only qualified personnel to operate, maintain, and service the
machinery.

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 regulations.

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.

The 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.

The 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 on 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 cutting area and to make sure that the air quality in the
workplace meets all local and national standards and regulations.

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 regulations.

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

• Keep the protective cap in place over the 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.

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 workplace.

• Personal protective equipment.

• Number of welding and cutting systems in operation.

• Other workplace 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
workplace 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.

• Make sure 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 make sure air
quality is safe.

SC-12 Safety and compliance

A PLASMA ARC CAN CAUSE INJURY AND BURNS

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
regulations.

• 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.

• Wear gauntlet gloves, safety shoes, and hat.

• Wear flame-retardant clothing to cover all exposed areas.

• Wear cuffless trousers to prevent entry of sparks and slag.

Also, 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

Instant-on torches

A plasma arc ignites 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.

ARC RAYS CAN BURN EYES AND SKIN

Minimum protective

Arc current

Less than 40 A 5 5 8 9
41 A to 60 A 6 6 8 9
61 A to 80 A 8 8 8 9
81 A to 125 A 8 9 8 9
126 A to 150 A 8 9 8 10
151 A to 175 A 8 9 8 11
176 A to 250 A 8 9 8 12
251 A to 300 A 8 9 8 13
301 A to 400 A 9 12 9 13
401 A to 800 A101410N/A

shade number

(ANSIZ49.1:2012)

Suggested shade

number for comfort

(ANSI Z49.1:2012)

OSHA 29CFR

1910.133(a)(5)

Europe

EN168:2002

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.

Safety and compliance SC-13

To reduce magnetic field hazards:

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

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

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

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

Safety

NOISE CAN DAMAGE HEARING

Cutting with a plasma arc can exceed acceptable noise levels as
defined by local regulations 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 site have verified personal hearing
protection is not necessary per relevant international, regional, and
local regulations.

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 and limit
operator exposure time, and screen off noisy areas and/or take
measures to reduce reverberation in cutting areas by putting up noise
absorbers.

DRY DUST COLLECTION INFORMATION

In some workplaces, dry dust can represent a potential explosion
hazard.

The U.S. National Fire Protection Association’s 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 standard 68 has been “adopted by
reference” in your local building codes.

Refer to NFPA standard 68 for definitions and explanations of
regulatory terms such as deflagration, AHJ, adopted by reference, the
Kst value, deflagration index, and other terms.

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 equipment such as ear muffs
or ear plugs with a noise reduction rating appropriate for the
situation. Warn others near the cutting area of possible noise
hazards. In addition, ear protection can prevent hot splatter from
entering the ear.

Note 1 – Unless a site-specific evaluation has been completed that
determines that none of the dust generated is combustible, then
NFPA standard 68 requires the use of explosion vents. Design the
explosion vent size and type to conform to the worst-case Kst value
as described in Annex F of NFPA standard 68. NFPA standard 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 should consult and comply with all applicable
national, state, and local regulations. Publications do not 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.

SC-14 Safety and compliance

Safety

LASER RADIATION

Exposure to the laser beam from a laser pointer can result in serious eye injury. Avoid direct eye exposure.

On products that use a laser pointer for alignment, 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, pulse duration are 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, 1 Batterymarch Park, Quincy, MA
02169-7471

9. NFPA Standard 70, National Electrical Code, National Fire
Protection Association, 1 Batterymarch Park, Quincy, MA
02169-7471

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/

Safety and compliance SC-15

Safety

SC-16 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:

• 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 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 Documents Library on the Hypertherm web site at

www.hypertherm.com/docs

.

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:

•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.

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.

Safety and Compliance SC-17

Product Stewardship

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.

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.

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.

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.

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.

SC-18 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.

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 Hypertherm products that fall within the scope of the RoHS
Directive. These RoHS-compliant products also have a “RoHS mark”
near the “CE Marking” on the data plate. Parts 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, and there is no “RoHS mark” on their
data plates.

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.

• In other countries, check national and local laws.

• Consult with legal or other compliance experts when appropriate.

A variety of options for sustainable disposal of Hypertherm products are
available on our website at www.hypertherm.com/recycle

.

The WEEE Directive

The European Parliament and the Council of the European Union
authorized Directive 2012/19/EU or WEEE (Waste Electrical and
Electronic Equipment) Recast.

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 options for
Hypertherm systems can be found at www.hypertherm.com/recycle

The URL is printed on the symbol-only warning label for each CE version
Hypertherm plasma system since 2006. The CSA versions of products
manufactured by Hypertherm are either out of scope or exempt from
WEEE.

.

The REACH regulation

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

Component manufacturers and other downstream users, such as
Hypertherm, are obligated to obtain assurances from its suppliers that
all chemicals used in or on Hypertherm products will have a European
Chemical Agency (ECHA) registration number. To provide chemical
information as required by the REACH regulation, Hypertherm requires
suppliers to provide REACH declarations and identify any known use of
REACH SVHC. Any use of SVHC in amounts exceeding 0.1% w/w of
the parts has been eliminated.

The 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).

Safety and Compliance SC-19

Environmental Stewardship

Proper handling and safe use of chemicals

Chemical Regulations in the USA, Europe, and other locations require
that Material Safety Data Sheets (MSDS) or Safety Data Sheets (SDS)
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 Documents Library on the Hypertherm web site at

www.hypertherm.com/docs

Safety Data Sheets” in the Category drop-down menu.

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.

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.

. In the Documents Library, select “Material

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.

SC-20 Safety and Compliance

Electromagnetic Compatibility (EMC)

Introduction

Hypertherm’s CE-marked equipment is built in compliance with standard
EN60974-10. The equipment should be installed and used in
accordance with the information below to achieve electromagnetic
compatibility.

The limits required by EN60974-10 may not be adequate to completely
eliminate interference when the affected equipment is in close proximity
or has a high degree of sensitivity. In such cases it may be necessary to
use other measures to further reduce interference.

This cutting equipment is designed for use only in an industrial
environment.

Installation and use

The user is responsible for installing and using the plasma equipment
according to the manufacturer’s instructions.

If electromagnetic disturbances are detected then it shall be the
responsibility of the user to resolve the situation with the technical
assistance of the manufacturer. In some cases this remedial action may
be as simple as earthing the cutting circuit, see Earthing of the
workpiece. In other cases, it could involve constructing an
electromagnetic screen enclosing the power source and the work
complete with associated input filters. In all cases, electromagnetic
disturbances must be reduced to the point where they are no longer
troublesome.

Methods of reducing emissions

Mains supply

Cutting equipment must be connected to the mains supply according to
the manufacturer’s recommendations. If interference occurs, it may be
necessary to take additional precautions such as filtering of the mains
supply.

Consideration should be given to shielding the supply cable of
permanently installed cutting equipment, in metallic conduit or
equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the cutting mains supply so
that good electrical contact is maintained between the conduit and the
cutting power source enclosure.

Maintenance of cutting equipment

The cutting equipment must be routinely maintained according to the
manufacturer’s recommendations. All access and service doors and
covers should be closed and properly fastened when the cutting
equipment is in operation. The cutting equipment should not be modified
in any way, except as set forth in and in accordance with the
manufacturer’s written instructions. For example, the spark gaps of arc
striking and stabilizing devices should be adjusted and maintained
according to the manufacturer’s recommendations.

Cutting cables

Assessment of area

Before installing the equipment, the user shall make an assessment of
potential electromagnetic problems in the surrounding area. The
following shall be taken into account:

a. Other supply cables, control cables, signaling and telephone

cables; above, below and adjacent to the cutting equipment.

b. Radio and television transmitters and receivers.
c. Computer and other control equipment.
d. Safety critical equipment, for example guarding of industrial

equipment.

e. Health of the people around, for example the use of

pacemakers and hearing aids.

f. Equipment used for calibration or measurement.

g. Immunity of other equipment in the environment. User shall

ensure that other equipment being used in the environment is
compatible. This may require additional protection measures.

h. Time of day that cutting or other activities are to be carried

out.

The size of the surrounding area to be considered will depend on the
structure of the building and other activities that are taking place. The
surrounding area may extend beyond the boundaries of the premises.

The cutting cables should be kept as short as possible and should be
positioned close together, running at or close to the floor level.

Equipotential bonding

Bonding of all metallic components in the cutting installation and
adjacent to it should be considered.

However, metallic components bonded to the workpiece will increase
the risk that the operator could receive a shock by touching these
metallic components and the electrode (nozzle for laser heads) at the
same time.

The operator should be insulated from all such bonded metallic
components.

Safety and compliance SC-21

Electromagnetic Compatibility (EMC)

Earthing of the workpiece

Where the workpiece is not bonded to earth for electrical safety, nor
connected to earth because of its size and position, for example, ship’s
hull or building steel work, a connection bonding the workpiece to earth
may reduce emissions in some, but not all instances. Care should be
taken to prevent the earthing of the workpiece increasing the risk of injury
to users, or damage to other electrical equipment. Where necessary, the
connection of the workpiece to earth should be made by a direct
connection to the workpiece, but in some countries where direct
connection is not permitted, the bonding should be achieved by suitable
capacitances selected according to national regulations.

Note: The cutting circuit may or may not be earthed for safety reasons.
Changing the earthing arrangements should only be authorized by a
person who is competent to assess whether the changes will increase
the risk of injury, for example, by allowing parallel cutting current return
paths which may damage the earth circuits of other equipment.
Further guidance is provided in IEC 60974-9, Arc Welding Equipment,
Part 9: Installation and Use.

Screening and shielding

Selective screening and shielding of other cables and equipment in the
surrounding area may alleviate problems of interference. Screening of the
entire plasma cutting installation may be considered for special
applications.

SC-22 Safety and compliance

Warranty

Attention

Genuine Hypertherm parts are the factory-recommended replacement
parts for your Hypertherm system. Any damage or injury caused by the
use of other than genuine Hypertherm parts may not be covered by the
Hypertherm warranty, and will constitute misuse of the Hypertherm
Product.

You are solely responsible for the safe use of the Product. Hypertherm
does not and cannot make any guarantee or warranty regarding the safe
use of the product in your environment.

General

Hypertherm Inc. warrants that its Products shall be free from defects in
materials and workmanship for the specific periods of time set forth
herein and as follows: if Hypertherm is notified of a defect (i) with respect
to the plasma power supply within a period of two (2) years from the date
of its delivery to you, with the exception of Powermax brand power
supplies, which shall be within a period of three (3) years from the date of
delivery to you, and (ii) with respect to the torch and leads within a period
of one (1) year from its date of delivery to you, with the exception of the
HPRXD short torch with integrated lead, which shall be within a period of
six (6) months from the date of delivery to you, and with respect to torch
lifter assemblies within a period of one (1) year from its date of delivery to
you, and with respect to Automation products one (1) year from its date
of delivery to you, with the exception of the EDGE Connect CNC,
EDGE Connect T CNC, EDGE Connect TC CNC, EDGE Pro CNC,
EDGE Pro Ti CNC, MicroEDGE Pro CNC, and ArcGlide THC, which
shall be within a period of two (2) years from the date of delivery to you,
and (iii) with respect to HyIntensity fiber laser components within a
period of two (2) years from the date of its delivery to you, with the
exception of laser heads and beam delivery cables, which shall be within
a period of one (1) year from its date of delivery to you.

This warranty shall not apply to any Powermax brand power supplies that
have been used with phase converters. In addition, Hypertherm does not
warranty systems that have been damaged as a result of poor power
quality, whether from phase converters or incoming line power. This
warranty shall not apply to any product which has been incorrectly
installed, modified, or otherwise damaged.

Hypertherm provides repair, replacement or adjustment of the Product as
the sole and exclusive remedy, if and only if the warranty set forth herein
properly is invoked and applies. Hypertherm, at its sole option, shall
repair, replace, or adjust, free of charge, any defective Products covered
by this warranty which shall be returned with Hypertherm’s prior
authorization (which shall not be unreasonably withheld), properly
packed, to Hypertherm’s place of business in Hanover, New Hampshire,
or to an authorized Hypertherm repair facility, all costs, insurance and
freight pre paid by the customer. Hypertherm shall not be liable for any
repairs, replacement, or adjustments of Products covered by this
warranty, except those made pursuant to this paragraph and with
Hypertherm’s prior written consent.

The warranty set forth above is exclusive and is in lieu of all other
warranties, express, implied, statutory, or otherwise with respect to the
Products or as to the results which may be obtained therefrom, and all
implied warranties or conditions of quality or of merchantability or fitness
for a particular purpose or against infringement. The foregoing shall
constitute the sole and exclusive remedy for any breach by Hypertherm
of its warranty.

Distributors/OEMs may offer different or additional warranties, but
Distributors/OEMs are not authorized to give any additional warranty
protection to you or make any representation to you purporting to be
binding upon Hypertherm.

Patent indemnity

Except only in cases of products not manufactured by Hypertherm or
manufactured by a person other than Hypertherm not in strict conformity
with Hypertherm’s specifications and in cases of designs, processes,
formulae, or combinations not developed or purported to be developed
by Hypertherm, Hypertherm will have the right to defend or settle, at its
own expense, any suit or proceeding brought against you alleging that
the use of the Hypertherm product, alone and not in combination with
any other product not supplied by Hypertherm, infringes any patent of
any third party. You shall notify Hypertherm promptly upon learning of any
action or threatened action in connection with any such alleged
infringement (and in any event no longer than fourteen (14) days after
learning of any action or threat of action), and Hypertherm’s obligation to
defend shall be conditioned upon Hypertherm’s sole control of, and the
indemnified party’s cooperation and assistance in, the defense of the
claim.

Limitation of liability

In no event shall Hypertherm be liable to any person or entity for
any incidental, consequential direct, indirect, punitive or
exemplary damages (including but not limited to lost profits)
regardless of whether such liability is based on breach of
contract, tort, strict liability, breach of warranty, failure of
essential purpose, or otherwise, and even if advised of the
possibility of such damages. Hypertherm shall not be liable for
any losses to Distributor based on down time, lost production or
lost profits. It is the intention of the Distributor and Hypertherm
that this provision be construed by a court as being the
broadest limitation of liability consistent with applicable law.

National and local codes

National and local codes governing plumbing and electrical installation
shall take precedence over any instructions contained in this manual.
In no event shall Hypertherm be liable for injury to persons or property
damage by reason of any code violation or poor work practices.

Safety and compliance SC-23

Warranty

Liability cap

In no event shall Hypertherm’s liability, if any, whether such
liability is based on breach of contract, tort, strict liability,
breach of warranties, failure of essential purpose or otherwise,
for any claim, action, suit or proceeding (whether in court,
arbitration, regulatory proceeding or otherwise) arising out of or
relating to the use of the Products exceed in the aggregate the
amount paid for the Products that gave rise to such claim.

Insurance

At all times you will have and maintain insurance in such quantities and
types, and with coverage sufficient and appropriate to defend and to hold
Hypertherm harmless in the event of any cause of action arising from the
use of the products.

Transfer of rights

You may transfer any remaining rights you may have hereunder only in
connection with the sale of all or substantially all of your assets or capital
stock to a successor in interest who agrees to be bound by all of the
terms and conditions of this Warranty. Within thirty (30) days before any
such transfer occurs, you agree to notify in writing Hypertherm, which
reserves the right of approval. Should you fail timely to notify Hypertherm
and seek its approval as set forth herein, the Warranty set forth herein
shall be null and void and you will have no further recourse against
Hypertherm under the Warranty or otherwise.

Waterjet product warranty coverage

Product Parts coverage

HyPrecision pumps 27 months from the ship date, or 24 months

from the date of proven installation, or
4,000 hours, whichever occurs first

PowerDredge
abrasive removal
system

EcoSift abrasive
recycling system

Abrasive metering
devices

On/off valve air
actuators

Diamond orifices 600 hours of use with the use of a thimble

Consumable parts are not covered by this warranty. Consumable parts
include, but are not limited to, high-pressure water seals, check valves,
cylinders, bleed-down valves, low-pressure seals, high-pressure tubing,
low- and high-pressure water filters and abrasive collection bags. All
third-party pumps, pump accessories, hoppers, hopper accessories,
dryer boxes, dryer box accessories and plumbing accessories are
covered by the respective manufacturers’ warranties and not covered by
this warranty.

15 months from the ship date or 12 months
from the date of proven installation,
whichever occurs first

15 months from the ship date or 12 months
from the date of proven installation,
whichever occurs first

15 months from the ship date or 12 months
from the date of proven installation,
whichever occurs first

15 months from the ship date or 12 months
from the date of proven installation,
whichever occurs first

filter and compliance with Hypertherm’s
water quality requirements

SC-24 Safety and compliance

Overview

The Hypertherm Sensor THC Plasma Lifter accessory supplies lifter mechanics that you combine
with a motor and drive for torch height control.

The Sensor THC Plasma Lifter is compatible with the Phoenix

®

run on EDGE
computer numerical controllers (CNCs).

Pro, MicroEDGE® Pro, EDGE Connect, EDGE Connect T, and EDGE Connect TC

®

Sensor THC software features that

Sensor THC Plasma Lifter Installation Manual 808970 25

Overview

1

26 808970 Installation Manual Sensor THC Plasma Lifter

Upon receipt

 Make sure that you received all items on your order in good condition. Contact your

distributor if any parts are damaged or missing.

 Inspect the items for damage that may have occurred during shipment. If you find evidence

of damage, see Claims, below. All communications regarding this equipment must include
the model number and the serial number.

 Before you set up this equipment, read the safety information included with your equipment.

Failure to follow safety instructions can result in personal injury or in damage to equipment.

Specifications and parts

Claims

 Claims for damage during shipment – If your equipment was damaged during shipment, file

a claim with the carrier. You can contact Hypertherm for a copy of the bill of lading. If you
need additional assistance, call the nearest Hypertherm office listed in the front of this
manual.

 Claims for defective or missing merchandise – If any component is missing or defective,

contact your Hypertherm distributor. If you need additional assistance, call the nearest
Hypertherm office listed in the front of this manual.

Sensor THC Plasma Lifter Installation Manual 808970 27

Specifications and parts

2

Sensor THC Plasma Lifter

The Hypertherm Sensor THC Plasma Lifter has the following specifications.

Tabl e 1 – Specifications

Upper limit switch (Home) +24 VDC

Lower limit switch +24 VDC

Breakaway switch +24 VDC

Sensor signal type PNP N/O (normally open)

Maximum Z-axis speed 15,200 mm/min (600 in/min)

Maximum Z-axis stroke 239 mm (9.40 in.)

Lead screw pitch 5.0 mm/revolution (0.20 in/revolution)

(recommended maximum)

Lifter capacity 11.3 kg (25.0 lb)

(recommended maximum)

Motor mount 60 mm (2.36 in.) flange with a 70 mm (2.756 in.) bolt circle diameter

Note: Hypertherm does not offer a motor for the Sensor THC Plasma
Lifter. See Figure 2 on page 32 for motor mount specifications.

For signal and lifter interface specifications, see Table 7 on page 48.



The following Sensor THC Plasma Lifter assemblies are available from Hypertherm.

Tabl e 2 – Assemblies

Part number Torch mounting block Magnetic breakaway

090187 Not included (lifter only) Not included (lifter only)

090188 Not included 4.5 kg (10 lb)

090189 Not included 11 kg (25 lb)

090190 35 mm (1-3/8 in.) 4.5 kg (10 lb)

090191 35 mm (1-3/8 in.) 11 kg (25 lb)

090192 44 mm (1-3/4 in.) 4.5 kg (10 lb)

090193 44 mm (1-3/4 in.) 11 kg (25 lb)

090194 51 mm (2 in.) 4.5 kg (10 lb)

090195 51 mm (2 in.) 11 kg (25 lb)

090197 57 mm (2-1/4 in.) 11 kg (25 lb)

28 808970 Installation Manual Sensor THC Plasma Lifter

2

149.10 mm (5.87 in.)

186.70 mm (7.35 in.)

78.40 mm
(3.09 in.) 152.00 mm

(5.98 in.)

60.60 mm
(2.38 in.)

526.50 mm
(20.73 in.)

Optional

66.04 mm
(2.60 in.)

107. 93 m m
(4.25 in.)

Laser pointer

offset

11.27 kg
(24.85 lb)

(without torch mounting block or
breakaway)

Specifications and parts

Figure 1 – Lifter dimensions (090195 model shown)

Sensor THC Plasma Lifter Installation Manual 808970 29

Specifications and parts

2

090###

##########

1

2

3

1 Part number

2 Serial number (YYMM######, where YY is the year

and MM is the month of manufacture)

3 Serial number bar code

Data plate

The data plate shows the lifter’s part number and serial number. If you contact Hypertherm Technical
Service, they ask for this information.

30 808970 Installation Manual Sensor THC Plasma Lifter

2

Lifter interface cable

Specifications and parts

The lifter interface cable connects the lifter interface board and the lifter drive. See Ta b l e 7 on
page 48 for pinout information.

Tabl e 3 – Lifter interface cables

Part number Description Quantity

223472 8 m (25 ft) 1

223473 15 m (50 ft) 1

223614 30 m (100 ft) 1

Motors and drives

Hypertherm does not offer a drive, motor, brake, or motor cables for the lifter.

We strongly recommend a motor and brake combination.



To select a compatible motor, see Figure 2 on page 32 for the motor mount specifications. Select a
drive that is compatible with your motor.

Sensor THC Plasma Lifter Installation Manual 808970 31

Specifications and parts

2

1

1

2

3

4

6

5

7

9

8

Customer-supplied motor

1 Motor mount flange: 60 mm (2.362 in.) square

2 Screws: four M4 X 0.70 mm screws on 70 mm

(2.756 in.) bolt circle diameter

3 Coupling maximum diameter: 41 mm (1.615 in.)

4 Coupling maximum length: 45 mm (1.772 in.)

5 Linear slide shaft diameter: 6 mm (0.236 in.)

6 Linear slide shaft height: 10.6 mm (0.416 in.)

Customer-supplied motor specifications:

7 Pilot maximum length: 3.56 mm (0.140 in.)

8 Pilot maximum diameter: 50.50 mm (1.988 in.)

9 Motor shaft maximum length: 42.55 mm

(1.675 in.)

Figure 2 – Motor mount specifications

32 808970 Installation Manual Sensor THC Plasma Lifter

2

Motor couplings

031165 031164

11 mm (0.43 in.) 14 mm (0.55 in.)

25 mm (0.98 in.)

Couplings join the linear slide shaft and the motor shaft. Hypertherm supplies 2 flexible couplings
(031165 and 031164). If you supply your own coupling, see Figure 2 for coupling specifications.



Specifications and parts

For a strong connection, make sure that when you insert the linear slide
shaft and the motor shaft into the coupling, each of them reaches at least
past the coupling screws.

Figure 3 – Hypertherm couplings

Tabl e 4 – Hypertherm couplings

Part number Description

031165 25 mm (0.98 in.) flexible coupling with 11 mm (0.43 in.) motor shaft diameter

031164 25 mm (0.98 in.) flexible coupling with 14 mm (0.55 in.) motor shaft diameter

Coupling screws hex head size is 2.50 mm (0.098 in.), with a torque rating of 9.2 kg∙cm (8.0 in∙lb).

Sensor THC Plasma Lifter Installation Manual 808970 33

Specifications and parts

2

1

2

7

8

6

5

4

3

3

3

3

8

8

3

9

Replacement parts

Lifter parts

34 808970 Installation Manual Sensor THC Plasma Lifter

Specifications and parts

2

Tabl e 5 – Replacement lifter parts

Item Kit number Description Quantity

1 428453 Laser pointer 1

2 428452 Interface board 1

3 428651 Exterior hardware:

• Ground hex head bolt (1) and washers (2)

• Lifter screws (18)

• Interface cable ground screw (1)

• Interface cable connector screws (4)

• Breakaway cable track and bracket screws (4)

4 428449 Side shields 2

5 428451 Slide 1

6 428450 Upper/lower limit switch 1

7 428612 Sealing strip 1

8 127505 Sealing strip hardware 1

9 428611 Grease gun 1

30

Sensor THC Plasma Lifter Installation Manual 808970 35

Specifications and parts

2

1

2

3

6

5

4

Breakaway parts

Tabl e 6 – Breakaway replacement parts

Item Kit number Description Quantity

1 428606 11.34 kgf (25 lbf) magnetic breakaway 1

2 104473 35.7 kgf (78.7 lbf) replacement magnet for

2 428610 35.7 kgf (78.7 lbf) replacement magnets for

3 428607 4.54 kgf (10 lbf) magnetic breakaway 1

4 104513 20 kgf (45 lbf) replacement magnet for

4 428609

5 428448 Breakaway cable and sensor 1

6 428608 Magnetic breakaway retaining tether 1

Wiring diagram

1

11.34 kgf (25 lbf) magnetic breakaway

4

11.34 kgf (25 lbf) magnetic breakaway (set of 4)

1

4.54 kgf (10 lbf) magnetic breakaway

20 kgf (45 lbf) replacement magnets for

4.54 kgf (10 lbf) magnetic breakaway (set of 5)

5

See Figure 4.

36 808970 Installation Manual Sensor THC Plasma Lifter

2

01

013399

ELEC SCHEM: S-THC LIFTER

SHEET 1 OF 1

24VDC-5VDC

REGULATOR

LOWER
LIMIT
SWITCH

UPPER

LIMIT

SWITCH

LOWER
LIMIT
SWITCH

BREAKAWAY

LASER POINTER KIT

BLK SIGNAL

BLU COMMON

BRN +24VDC

J1

J3

J4

428453

428448

11

BLU COMMON

BLK SIGNAL

BRN +24VDC

BLU COMMON

BLK SIGNAL

BRN +24VDC

1

RED +3.6 TO 5VDC

BLK COMMON

UPPER/LOWER LIMIT SWITCH KIT

428450

WHT

2

3

RED

1

COLORS POSITION

4

LASER POINTER MODULE

+24VDC

LIFTER DESTINATION

COMMON

BREAKAWAY SIGNAL

COMMON

UPPER LIMIT SIGNAL

PAIR

6

5

ORG

WHT

BLK

WHT

CPC

COMMON

7

WHT

LOWER LIMIT SIGNAL

8

BRN

NO CONNECT

9

RING TERMINAL TO LIFTER SCREW

DRAIN

SHIELD

223472 7.6M (25FT)

223473 15.2M (50FT)

223614 30.5M (100FT)

CONNECT TO I/O

+24VDC POWER TO LIFTER PCB

COMMON

POSITIVE LOGIC INPUT

COMMON

COMMON

POSITIVE LOGIC INPUT

POSITIVE LOGIC INPUT

DRAIN WIRE TO CHASSIS

1

1

1

TO/FROM I/O

ZERO VDC = NORMAL
+24VDC = LIMIT

ZERO VDC = NORMAL
+24VDC = LIMIT

ZERO VDC = BREAKAWAY (COLLISION)
+24VDC = NORMAL

OUTPUT LOW = LASER POINTER ON

LASER

MODULE

PCB LOCATED INSIDE LIFTER HOUSING

NOTES:

1. PINS 3, 5, AND 7 MUST CONNECT TO I/O COMMON

2. 24VDC POWER SUPPLY COMMON MUST CONNECT TO EITHER PIN 3, 5, OR 7

SWITCH KIT

KIT INCLUDES BRACKET

PNP TYPE PROXIMITY SWITCH

PNP TYPE PROXIMITY SWITCH

PNP TYPE PROXIMITY SWITCH

WIRE

SENSOR THC LIFTER

WITHOUT MOTOR

INTERFACE PCB KIT

428452

J2

J2

Specifications and parts

Figure 4

Sensor THC Plasma Lifter Installation Manual 808970 37

Specifications and parts

2

38 808970 Installation Manual Sensor THC Plasma Lifter

Install the motor

1

2

3

4



1. Loosen the 2 screws on the front of the lifter
interface enclosure.

2. Move the front panel up and off the 2 screws
and the studs on the sides of the interface
enclosure.

Install

Hypertherm does not offer a motor for the lifter. For motor mount
specifications, see Figure 2 on page 32.

3. Remove the 2 screws from the motor
coupling cover.

4. Remove the motor coupling cover.

Sensor THC Plasma Lifter Installation Manual 808970 39

Install

3

6

7

8

5. Put a coupling on the end of the motor shaft.

 Hypertherm supplies 2 couplings. See Figure 3

on page 33 for more information.

 If you supply your own coupling, see Figure 2 on

page 32 for coupling specifications.

6. Put the motor and coupling on the linear slide shaft.

For a strong connection, make sure that when



you connect the linear slide shaft and the motor
shaft with the coupling, each of them reaches
at least past the coupling screws.

7. Rotate the motor as necessary to keep the motor
cables away from the gantry and the connector for
the lifter interface cable.

 If necessary, move the connector for the lifter

interface cable to the side of the interface
enclosure. See Move the connector for the lifter
interface cable (optional) on page 41 for more
information.

8. Make sure that you can access the 2 hex head screws on the coupling.

9. Use four M4 X 0.70 screws to attach the motor to the motor flange.

10. Tighten the 2 screws on the coupling to a torque of 9.2 kg∙cm (8.0 in∙lb).

11 . Install the motor coupling cover.

12. Install the front panel of the interface enclosure.

40 808970 Installation Manual Sensor THC Plasma Lifter

3

Move the connector for the lifter interface cable (optional)

6

5

Flat side

The lifter comes with the connector for the lifter interface cable on the top of the interface enclosure.
You can move it to the side of the interface enclosure.

The connector and the lifter interface board are one piece.



1. Remove the front panel of the interface
enclosure. For more information, see step 1
on page 39.

2. Disconnect the 3 wire harnesses from the
lifter interface board.

3. Remove the 4 screws that attach the
connector to the interface enclosure.

4. Remove the connector from the interface
enclosure.

Install

5. Remove the cover of the connector hole on
the side of the interface enclosure.

6. Install the cover for the hole on the top of the interface enclosure.

Make sure that the flat side of the cover is on the underside of the



interface enclosure.

Sensor THC Plasma Lifter Installation Manual 808970 41

Install

3

7. Install the connector in the hole on the side of the interface enclosure.

Make sure that the connectors for the 3 wire harnesses point toward the



front of the lifter enclosure.

8. Connect the 3 wire harnesses to the lifter interface board.

9. Install the front panel of the interface enclosure.

42 808970 Installation Manual Sensor THC Plasma Lifter

3

Install the lifter

1

2

3

1. Remove the 4 screws on each side of the lifter slide.



2. Remove the 2 side shields.

3. Remove the 2 side panels.

Install

Slide the torch mounting plate up or down as necessary to access all
4 screws on each side.

Sensor THC Plasma Lifter Installation Manual 808970 43

Install

3

1

234

9X 44.45 mm
(1.75 in.)

114.30 mm (4.50 in.)

149.10 mm
(5.87 in.)

Screw holes Diagonal pattern

1

42

3

4. Loosely tighten a minimum of four 1/4-in. or M6 socket head cap screws to attach the lifter to
the gantry.

 Make sure that the lifter is high enough that the torch does not touch the table, but low

enough that the torch can touch the workpiece. The bottom of the lifter must be within
203 mm (8 in.) of the thinnest workpiece.

 Slide the torch mounting plate up or down as necessary to access all the screw holes. If the

motor is already installed on the lifter, release the brake or remove the motor so you can
move the torch mounting plate.

 Use the vertical side of the lifter to level the lifter.
 Attach the screws in a diagonal pattern (see , , , ).

5. Tighten the screws in a diagonal pattern to a torque of 86 kg∙cm (75 in∙lb).

6. Install the 2 side panels and 2 side shields.

44 808970 Installation Manual Sensor THC Plasma Lifter

3

Ground the lifter



1. Remove the M6 X 12 mm hex head
bolt and
assembly from the bottom of the
en

2 washers

closure.

The lifter must be grounded correctly to do an accurate initial height
se

nse (IHS).

of the grounding

Install

2. Put a ground wire terminal on the he
h

ead bolt between the 2 washers.

3. Loosely tighten the hex head bolt with
the washers and terminal into
bot

tom of the enclosure.

4. Make sure that the terminal is
cont

act with both

ad bolt.

he

5. Tighten the hex head bolt to a torque

51.8 kg∙cm (45.0 in∙lb).

6. Connect the other end of the grou
wire t

o a terminal on the table

bus

bar on the cutting machine.

7. Make sure that the ground wire is not in the path of the lifter mechanics.

Install the THC drive

x

the

in

washers and the hex

of

nd

ground

Install the THC drive into the table’s drive enclosure.

Hypertherm does not offer a drive for the lifter. Select a drive that is compatible with your motor.

Install voltage divider board/VDC3

A VDC3 board (141201) supplies the necessary arc voltage feedback from the plasma power
supply to the CNC. You install the VDC3 board inside the plasma power supply.

 If you have an EDGE Connect/T/TC CNC with an HPRXD plasma power supply, see the

Field Service Bulletin HPR130XD®, HPR260XD®, and HPR400XD® EtherCAT® and
VDC3 Boa

Sensor THC Plasma Lifter Installation Manual 808970 45

rd Installation (809260) for instructions.

Install

3

46 808970 Installation Manual Sensor THC Plasma Lifter

Connect the lifter to the THC drive

1. Connect the motor and encoder cables from the lifter to the THC drive.

2. Connect the brake, and wire it to energize and de-energize as follows:

 Energize when the CNC enables the THC drive
 De-energize when the CNC disables the THC drive

Connect

Sensor THC Plasma Lifter Installation Manual 808970 47

Connect

4

3. Connect the female end of the lifter interface cable to the
male connector on the lifter interface enclosure.

In the figure at right the connector for the lifter



interface cable is on top of the enclosure. These
instructions are the same if you moved the
connector to the side of the enclosure.

4. To ground the interface cable, remove the screw and
2

washers of the cable grounding assembly from

of th

e enclosure.

the top

5. Put the ground wire terminal on the screw between th
2w

ashers.

6. Loosely tighten the screw with the washers and terminal
into the top of the enclosure.

7. Make sure that the terminal is in contact with both
washers and the screw.

8. Tighten the screw to a torque of 17.3 kg∙cm (15.0 in∙lb).

9. Connect the loose wires on the other end of the lifte

interface c
th

e pinouts.

Tabl e 7 – Pinouts for the interface cable to the drive

Pin no. Color Signal

1 Red Power +24 VDC (customer supplied)

2 White Laser pointer enable (active low)

3 White 24 VDC ground (customer supplied)

able to the I/O on your drive. See Ta b l e 7

r

for

e

4 Orange Torch collision input (active high)

5 White 24 VDC ground (customer supplied)

6 Black Upper limit switch input (active high)

7 White 24 VDC ground (customer supplied)

8 Brown Lower limit switch input (active high)

9 Not connected

The sensor signal type is PNP N/O (normally open).



48 808970 Installation Manual Sensor THC Plasma Lifter

4

Connect the THC drive to the network

Connect the THC drive to the network.

Hypertherm does not offer a drive for the lifter. Select a drive that is compatible with your motor.

Connect the VDC3 board

If you have an EDGE Connect/T/TC CNC with an HPRXD plasma power supply, see the Field
Service Bulletin HPR130XD®, HPR260XD®, and HPR400XD® EtherCAT® and VDC3 Board
Installation (809260) for instructions.

Connect

Sensor THC Plasma Lifter Installation Manual 808970 49

Connect

4

50 808970 Installation Manual Sensor THC Plasma Lifter