Command®THC
X-Y Table
Torch Height Control
(THC) System
Instruction Manual
802780 – Revision 11
EN50199
EN60974-1
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Instruction Manual
(P/N 802780)
Revision 11 – February 2009
© Copyright 2009 Hypertherm, Inc.
All Rights Reserved
Hypertherm, HyPerformance, HPR, HSD and CommandTHC are trademarks of Hypertherm, Inc.,
and may be registered in the United States and/or other countries
Command®THC
X-Y Table
Torch Height Control
(THC) System
Hypertherm, Inc.
Hanover, NH USA
www.hypertherm.com
10/14/08
Hypertherm, Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
info@hypertherm.com (Main Office Email)
800-643-9878 Tel (Technical Service)
technical.service@hypertherm.com (Technical Service Email)
800-737-2978 Tel (Customer Service)
customer.service@hypertherm.com (Customer Service Email)
Hypertherm Automation
5 Technology Drive, Suite 300
West Lebanon, NH 03784 USA
603-298-7970 Tel
603-298-7977 Fax
Hypertherm Plasmatechnik GmbH
Technologiepark Hanau
Rodenbacher Chaussee 6
D-63457 Hanau-Wolfgang, Deutschland
49 6181 58 2100 Tel
49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm (S) Pte Ltd.
82 Genting Lane
Media Centre
Annexe Block #A01-01
Singapore 349567, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
65 6841 2489 (Technical Service)
Hypertherm (Shanghai) Trading Co., Ltd.
Unit A, 5th Floor, Careri Building
432 West Huai Hai Road
Shanghai, 200052
PR China
86-21 5258 3330/1 Tel
86-21 5258 3332 Fax
Hypertherm Europe B.V.
Vaartveld 9
4704 SE
Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
Hypertherm Japan Ltd.
801 Samty Will Building
2-40 Miyahara 1-Chome,
Yodogawa-ku, Osaka
532-0003, Japan
81 6 6170 2020 Tel
81 6 6170 2015 Fax
HYPERTHERM BRASIL LTDA.
Avenida Doutor Renato de
Andrade Maia 350
Parque Renato Maia
CEP 07114-000
Guarulhos, SP Brasil
55 11 2409 2636 Tel
55 11 2408 0462 Fax
ELECTROMAGNETIC COMPATIBILITY (EMC)
Hypertherm i
4-08
EMC Introduction
Hypertherm’s CE-marked equipment is built in compliance
with standard EN60974-10. The equipment should be
installed and used in ac cor dance with the information
below to achieve elec tro mag net ic compatibility.
The limits required by EN60974-10 may not be adequate
to com plete ly eliminate in ter fer ence when the affected
equip ment is in close proximity or has a high degree of
sensitivity. In such cases it may be nec es sary to use other
mea s ures to fur ther reduce interference.
This cutting equipment is designed for use only in an
indus tri al environment.
Installation and use
The user is responsible for installing and using the plasma
equipment according to the manufacturer’s instructions.
If elec tro mag net ic disturbances are detected then it shall
be the re spon si bil i ty of the user to re solve the situation
with the technical as sis tance of the man u fac tur er. In some
cases this remedial action may be as sim ple as earthing
the cutting circuit, see Earthing of Workpiece. In other
cas es it could in volve con struct ing an elec tro mag net ic
screen enclosing the pow er source and the work
complete with associated input filters. In all cases
electromag net ic dis tur banc es must be reduced to the
point where they are no longer trou ble some.
Assessment of area
Before installing the equipment the user shall make an
assessment of po ten tial elec tro mag net ic problems in the
sur round ing area. The following shall be taken into
account:
a. Other supply cables, control cables, signalling and
telephone ca bles; above, below and adjacent to the
cutting equip ment.
b. Radio and television transmitters and receivers.
c. Computer and other control equip ment.
d. Safety critical equipment, for example guarding of
industrial equipment.
e. Health of the people around, for example the use of
pacemakers and hear ing aids.
f. Equipment used for calibration or mea sure ment.
g. Immunity of other equipment in the en viron ment. User
shall ensure that other equip ment being used in the
environment is com pat i ble. This may require ad di tion al
protection measures.
h. Time of day that cutting or other ac tiv i ties are to be
carried out.
The size of the sur round ing area to be considered will
depend on the structure of the building and other
activities that are tak ing place. The surrounding area may
ex tend beyond the bound aries of the pre mises.
Methods of reducing emissions
Mains supply
Cutting equipment must be con nect ed to the mains
supply according to the man u fac tur er’s recommendations.
If interfer ence occurs, it may be necessary to take
additional precautions such as filtering of the mains supply.
Consideration should be given to shield ing the supply
cable of per ma nent ly installed cutting equip ment, in
metallic conduit or equiva lent. Shield ing should be
electrical ly continuous through out 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 pow er source enclosure.
Maintenance of cutting equipment
The cutting equipment must be rou tine ly main tained
according to the man u fac tur er’s rec om men da tions. All
access and service doors and covers should be closed
and properly fastened when the cutting equipment is in
op er a tion. The cutting equipment should not be modified
in any way except for those chang es and adjust ments
covered in the manufacturer’s instructions. In par tic u lar,
the spark gaps of arc striking and stabilizing devices
should be adjusted and maintained according to the
manufacturer’s rec om men da tions.
Cutting cables
The cutting cables should be kept as short as possible
and should be po si tioned 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 com po nents bonded to the workpiece
will increase the risk that the op er a tor could receive a
shock by touch ing these metallic compo nents and the
electrode (nozzle for laser heads) at the same time.
The op er a tor should be in su lat ed from all such bonded
metallic components.
ELECTROMAGNETIC COMPATIBILITY (EMC)
ii Hypertherm
4-08
Earthing of workpiece
Where the workpiece is not bonded to earth for electrical
safety, nor connected to earth because of its size and
position, for ex am ple, ship’s hull or building steel work, a
con nec tion bonding the work piece to earth may reduce
emis sions in some, but not all instances. Care should be
taken to prevent the earthing of the work piece in creas ing
the risk of injury to users, or damage to other elec tri cal
equip ment. Where necessary, the con nec tion 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 se lect ed according to
national regulations.
Note: the cutting circuit may or may not be earthed for
safety reasons. Changing the earthing arrangements
should only be au tho rized by a person who is competent
to assess whether the chang es will in crease the risk of
injury, for example, by al low ing parallel cutting cur rent
return paths which may damage the earth cir cuits of other
equipment. Further guid ance is given in IEC/TS 62081
Arc Welding Equip ment Installation and Use.
Screening and shielding
Selective screening and shielding of other cables
and equipment in the surrounding area may alleviate
problems of in ter fer ence. Screening of the entire
plasma cutting installation may be con sid ered for
special applications.
WARRANTY
Hypertherm iii
4-08
Attention
Genuine Hypertherm parts are the factory-recommended
replacement parts for your Hypertherm system. Any
damage caused by the use of other than genuine
Hypertherm parts may not be covered by the
Hypertherm warranty.
You are 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, if Hypertherm
is notified of a defect (i) with respect to the 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, 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 laser heads 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, 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. Hypertherm shall not be liable for any repairs,
replacement, or adjustments of Products covered by this
war ranty, except those made pursuant to this paragraph
or with Hypertherm’s prior written consent. The warranty
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
war ranties 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 pro tection to you or
make any repre sentation to you purporting to be binding
upon Hypertherm.
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 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 significantly modified in a manner that
creates a hazard or non-conformance.
• 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.
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.
Differences in national standards
Differences in standards include, but are not limited to:
• Voltages
• Plug and cord ratings
• Language requirements
• Electromagnetic compatibility requirements
WARRANTY
iv Hypertherm
4-08
These differences in national 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 they 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:
• 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.
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 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, or water
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 higherlevel systems, it is necessary to verify that any external
interconnecting cables are suitable for the end-use
installation site.
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 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 Hypertherm’s
obligation to indemnify 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, indirect,
or punitive damages (including but not limited to
lost profits) regardless of whether such liability is
based on breach of contract, tort, strict liability,
breach of warranties, failure of essential purpose or
otherwise and even if advised of the possibility of
such damages.
Liability cap
In no event shall Hypertherm’s liability, 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 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.
WARRANTY
Hypertherm v
4-08
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.
National and Local codes
National and Local codes governing plumbing and
electrical installation shall take precedent 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.
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.
Proper disposal of Hypertherm
products
Hypertherm plasma cutting systems, like all electronic
products, may contain materials or components, such as
printed circuit boards, that cannot be discarded with
ordinary waste. It is your responsibility to dispose of any
Hypertherm product or component part in an
environmentally acceptable manner according to national
and local codes.
• In the United States, check all federal, state, and local
laws.
• In the European Union, check the EU directives, national,
and local laws. For more information, visit
www.hypertherm.com/weee.
• In other countries, check national and local laws.
TABLE OF CONTENTS
CommandTHC for X-Y Table Instruction Manual vii
11
ELECTROMAGNETIC COMPATIBILITY (EMC) ..................................................................................................................i
WARRANTY................................................................................................................................................................................ii
Section 1 SAFETY ..............................................................................................................................................................1-1
Recognize safety information...................................................................................................................................................................1-2
Follow safety instructions .........................................................................................................................................................................1-2
Cutting can cause fire or explosion........................................................................................................................................................1-2
Electric shock can kill................................................................................................................................................................................1-3
Static electricity can damage circuit boards........................................................................................................................................1-3
Toxic fumes can cause injury or death...................................................................................................................................................1-4
A plasma arc can cause injury and burns.............................................................................................................................................1-5
Arc rays can burn eyes and skin.............................................................................................................................................................1-5
Grounding safety........................................................................................................................................................................................1-6
Compressed gas equipment safety .......................................................................................................................................................1-6
Gas cylinders can explode if damaged.................................................................................................................................................1-6
Noise can damage hearing.......................................................................................................................................................................1-7
Pacemaker and hearing aid operation ...................................................................................................................................................1-7
A plasma arc can damage frozen pipes ................................................................................................................................................1-7
Additional safety information....................................................................................................................................................................1-8
Symbols and markings..............................................................................................................................................................................1-8
Warning labels............................................................................................................................................................................................1-9
Dry dust collection information.............................................................................................................................................................1-11
Section 1a SÉCURITÉ ......................................................................................................................................................1a-1
dentifier les consignes de sécurité ......................................................................................................................................................1a-2
Suivre les instructions de sécurité .......................................................................................................................................................1a-2
Le coupage peut provoquer un incendie ou une explosion ...........................................................................................................1a-2
Les chocs électriques peuvent être fatals..........................................................................................................................................1a-3
L’électricité statique peut endommager les cartes de circuits imprimés ....................................................................................1a-3
Les vapeurs toxiques peuvent provoquer des blessures ou la mort ............................................................................................1a-4
L’arc plasma peut provoquer des blessures ou des brûlures ........................................................................................................1a-5
Les rayons de l’arc peuvent brûler les yeux et la peau....................................................................................................................1a-5
Mise à la masse et à la terre..................................................................................................................................................................1a-6
Sécurité des bouteilles de gaz comprimé ..........................................................................................................................................1a-6
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .................................................................................1a-6
Le bruit peut provoquer des problèmes auditifs ...............................................................................................................................1a-7
Pacemakers et prothèses auditives .....................................................................................................................................................1a-7
Un arc plasma peut endommager les tuyaux gelés..........................................................................................................................1a-7
Symboles et marquage...........................................................................................................................................................................1a-8
Étiquettes de sécurité .............................................................................................................................................................................1a-9
Information sur le dépoussiérage.......................................................................................................................................................1a-11
Section 1b SEGURIDAD .................................................................................................................................................1b-1
Reconocimiento de información de seguridad .................................................................................................................................1b-2
Siga las instrucciones de seguridad ...................................................................................................................................................1b-2
Los cortes pueden provocar incendios o explosiones....................................................................................................................1b-2
El choque eléctrico puede provocar la muerte.................................................................................................................................1b-3
TABLE OF CONTENTS
viii CommandTHC for X-Y Table Instruction Manual
11
Electricidad estática puede dañar tablillas de circuito....................................................................................................................1b-3
Humos tóxicos pueden causar lesiones o muerte ...........................................................................................................................1b-4
El arco de plasma puede causar lesiones y quemaduras ..............................................................................................................1b-5
Los rayos del arco pueden producir quemaduras en los ojos y en la piel .................................................................................1b-5
Seguridad de toma a tierra....................................................................................................................................................................1b-6
Seguridad de los equipos de gas comprimido.................................................................................................................................1b-6
Los cilindros de gas pueden explotar si están dañados.................................................................................................................1b-6
El ruido puede deteriorar la audición...................................................................................................................................................1b-7
Operación de marcapasos y de audífonos ........................................................................................................................................1b-7
Un arco plasma puede dañar tubos congelados..............................................................................................................................1b-7
Símbolos y marcas ..................................................................................................................................................................................1b-8
Etiquetas de advertencia........................................................................................................................................................................1b-9
Información sobre la colección de polvo seco...............................................................................................................................1b-11
Section 2 DESCRIPTION & SPECIFICATIONS
General .........................................................................................................................................................................................................2-3
Specifications..............................................................................................................................................................................................2-4
THC control module........................................................................................................................................................................2-4
Plasma interface assembly ............................................................................................................................................................2-5
X-Y lifter assembly............................................................................................................................................................................2-6
Operator pendant.............................................................................................................................................................................2-7
X-Y lifter breakaway option.......................................................................................................................................................................2-8
Section 3 SETUP
Upon receipt................................................................................................................................................................................................3-2
Standard components ....................................................................................................................................................................3-2
Optional components .....................................................................................................................................................................3-2
Claims ...........................................................................................................................................................................................................3-2
Power requirements...................................................................................................................................................................................3-2
System unit mounting................................................................................................................................................................................3-3
THC control module........................................................................................................................................................................3-3
Plasma interface assembly ............................................................................................................................................................3-4
X-Y lifter assembly............................................................................................................................................................................3-5
Torch mounting block kit.................................................................................................................................................................3-6
Torch breakaway kit (optional) ......................................................................................................................................................3-8
Install the torch (without torch breakaway option).................................................................................................................3-10
Install the torch (with torch breakaway option) ......................................................................................................................3-11
System interconnections........................................................................................................................................................................3-12
THC system cables.......................................................................................................................................................................3-12
Machine interface cable...............................................................................................................................................................3-14
THC selectable responses....................................................................................................................................................................3-16
DIP switch positions .....................................................................................................................................................................3-17
CommandTHC serial protocol..............................................................................................................................................................3-18
Grounding requirements ........................................................................................................................................................................3-20
Power cord grounding .................................................................................................................................................................3-20
Protective earth ground ...............................................................................................................................................................3-20
Lifter I/O Cable.........................................................................................................................................................................................3-21
TABLE OF CONTENTS
CommandTHC for X-Y Table Instruction Manual ix
11
Plasma interface cable............................................................................................................................................................................3-22
CNC interface cable ...............................................................................................................................................................................3-23
Pendant extension cable........................................................................................................................................................................3-25
Motor drive cable .....................................................................................................................................................................................3-26
HD3070 system interconnections .......................................................................................................................................................3a-1
HT2000 system interconnections........................................................................................................................................................3b-1
HT2000LHF system interconnections................................................................................................................................................3c-1
HT4001 system interconnections........................................................................................................................................................3d-1
MAX100 System interconnections......................................................................................................................................................3e-1
MAX200 System interconnections.......................................................................................................................................................3f-1
POWERMAX system interconnections..............................................................................................................................................3g-1
HT4400 system interconnections........................................................................................................................................................3h-1
HPR system interconnections................................................................................................................................................................3i-1
HSD system interconnections................................................................................................................................................................3j-1
HD4070 system interconnections..................................................................................................................................See IM 803760
Section 4 OPERATION
Operating controls ....................................................................................................................................................................................4-2
THC control module........................................................................................................................................................................4-2
Operator pendant ............................................................................................................................................................................4-2
Pendant display screens................................................................................................................................................................4-4
Pendant programmable fields ......................................................................................................................................................4-6
Automatic operation screen ....................................................................................................................................................4-6
Manual operation screen ..........................................................................................................................................................4-8
Setup screen A ..........................................................................................................................................................................4-9
Determining pierce height factor..........................................................................................................................................................4-11
Typical pierce height factor ........................................................................................................................................................4-11
Pierce height factor for thicker materials ................................................................................................................................4-12
THC operating cycle time-lines ............................................................................................................................................................4-14
Automatic mode time-line............................................................................................................................................................4-15
Problems and solutions................................................................................................................................................................4-16
Manual mode time-line ................................................................................................................................................................4-18
THC selectable responses (DIP switch) ..............................................................................................................See section 3 Setup
Section 5 MAINTENANCE
Routine maintenance ................................................................................................................................................................................5-2
X-Y lifter sealing band removal and replacement................................................................................................................................5-2
Troubleshooting ..........................................................................................................................................................................................5-6
Diagnostic screen B........................................................................................................................................................................5-6
Error messages ................................................................................................................................................................................5-6
AC power distribution ..................................................................................................................................................................5-10
Motor drive board status lights during normal power-up ....................................................................................................5-11
DC power distribution..................................................................................................................................................................5-12
Control board status lights during normal power-up ............................................................................................................5-14
Interface board status lights during normal power-up..........................................................................................................5-16
11
Section 6 PARTS LIST
THC control module ..................................................................................................................................................................................6-2
Plasma interface assembly ......................................................................................................................................................................6-4
2 Rail X-Y lifter assembly ..........................................................................................................................................................................6-5
X-Y lifter torch mounting block kits ........................................................................................................................................................6-6
X-Y lifter torch breakaway kit – optional ................................................................................................................................................6-7
Operator pendant ......................................................................................................................................................................................6-8
Power cords ................................................................................................................................................................................................6-8
Ohmic contact wire....................................................................................................................................................................................6-9
Recommended spare parts ..................................................................................................................................................................6-10
Interface cables................................................................................................................................................See Section 3a through 3j
Section 7 WIRING DIAGRAMS........................................................................................................................................7-1
Introduction..................................................................................................................................................................................................7-1
Wiring diagrams..........................................................................................................................................................................................7-5
Appendix A PARTS LIST FOR OLDER SYSTEMS.......................................................................................................a-1
1 Rail Lifter ...................................................................................................................................................................................................a-2
Plasma interface assembly .......................................................................................................................................................................a-3
THC control module...................................................................................................................................................................................a-4
Appendix B PENDANT CONTRAST ADJUSTMENT PROCEDURE ........................................................................b-1
x CommandTHC for X-Y Table Instruction Manual
TABLE OF CONTENTS
Hypertherm 1-1
11/08
Section 1
SAFETY
In this section:
Recognize safety information...................................................................................................................................................................1-2
Follow safety instructions .........................................................................................................................................................................1-2
Cutting can cause fire or explosion........................................................................................................................................................1-2
Electric shock can kill................................................................................................................................................................................1-3
Static electricity can damage circuit boards........................................................................................................................................1-3
Toxic fumes can cause injury or death...................................................................................................................................................1-4
A plasma arc can cause injury and burns.............................................................................................................................................1-5
Arc rays can burn eyes and skin.............................................................................................................................................................1-5
Grounding safety........................................................................................................................................................................................1-6
Compressed gas equipment safety .......................................................................................................................................................1-6
Gas cylinders can explode if damaged.................................................................................................................................................1-6
Noise can damage hearing.......................................................................................................................................................................1-7
Pacemaker and hearing aid operation ...................................................................................................................................................1-7
A plasma arc can damage frozen pipes ................................................................................................................................................1-7
Additional safety information....................................................................................................................................................................1-8
Symbols and markings..............................................................................................................................................................................1-8
Warning labels............................................................................................................................................................................................1-9
Dry dust collection information.............................................................................................................................................................1-11
1-2 Hypertherm
SAFETY
11/08
RECOGNIZE SAFETY INFORMATION
The symbols shown in this section are used to identify
potential hazards. When you see a safety symbol in this
manual or on your machine, understand the potential for
personal injury, and follow the related instructions to avoid
the hazard.
FOLLOW SAFETY INSTRUCTIONS
Read carefully all safety messages in this manual and
safety labels on your machine.
• Keep the safety labels on your machine in good condition.
Replace missing or damaged labels immediately.
• Learn how to operate the machine and how to use
the controls properly. Do not let anyone operate it
without instruction.
• Keep your machine in proper working condition.
Unauthorized modifications to the machine may affect
safety and machine service life.
DANGER WARNING CAUTION
Hypertherm uses American National Standards Institute
guidelines for safety signal words and symbols. A signal
word DANGER or WARNING is used with a safety
symbol. DANGER identifies the most serious hazards.
• DANGER and WARNING safety labels are located
on your machine near specific hazards.
• DANGER safety messages precede related
instructions in the manual that will result in serious
injury or death if not followed correctly.
• WARNING safety messages precede related
instructions in this manual that may result in injury
or death if not followed correctly.
• CAUTION safety messages precede related
instructions in this manual that may result in
minor injury or damage to equipment if not
followed correctly.
Fire prevention
• Be sure the area is safe before doing any cutting.
Keep a fire extinguisher nearby.
• Remove all flammables within 35 feet (10 m) of the
cutting area.
• Quench hot metal or allow it to cool before handling
or before letting it touch combustible materials.
• Never cut containers with potentially flammable
materials inside – they must be emptied and
properly cleaned first.
• Ventilate potentially flammable atmospheres
before cutting.
• When cutting with oxygen as the plasma gas, an
exhaust ventilation system is required.
Explosion prevention
• Do not use the plasma system if explosive dust or
vapors may be present.
• Do not cut pressurized cylinders, pipes, or any
closed container.
• Do not cut containers that have held combustible
materials.
CUTTING CAN CAUSE FIRE OR EXPLOSION
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
Hydrogen Detonation
with Aluminum Cutting
• When cutting aluminum underwater, or with the water
touching the underside of the aluminum, free hydrogen
gas may collect under the workpiece and detonate
during plasma cutting operations.
• Install an aeration manifold on the floor of the water
table to eliminate the possibility of hydrogen
detonation. Refer to the Appendix section of this
manual for aeration manifold details.
Hypertherm 1-3
SAFETY
11/08
Touching live electrical parts can cause a fatal shock or
severe burn.
• Operating the plasma system completes an electrical
circuit between the torch and the workpiece. The
workpiece and anything touching the workpiece are
part of the electrical circuit.
• Never touch the torch body, workpiece or the water in
a water table when the plasma system is operating.
Electric shock prevention
All Hypertherm plasma systems use high voltage
in the cutting process (200 to 400 VDC are
common). Take the following precautions when
operating this system:
• Wear insulated gloves and boots, and keep your body
and clothing dry.
• Do not stand, sit or lie on – or touch – any wet surface
when using the plasma system.
• Insulate yourself from work and ground using dry
insulating mats or covers big enough to prevent any
physical contact with the work or ground. If you must
work in or near a damp area, use extreme caution.
• Provide a disconnect switch close to the power
supply with properly sized fuses. This switch allows
the operator to turn off the power supply quickly in
an emergency situation.
• When using a water table, be sure that it is correctly
connected to earth ground.
ELECTRIC SHOCK CAN KILL
• Install and ground this equipment according to the
instruction manual and in accordance with national
and local codes.
• Inspect the input power cord frequently for damage or
cracking of the cover. Replace a damaged power cord
immediately. Bare wiring can kill.
• Inspect and replace any worn or damaged torch leads.
• Do not pick up the workpiece, including the waste
cutoff, while you cut. Leave the workpiece in place or
on the workbench with the work cable attached during
the cutting process.
• Before checking, cleaning or changing torch parts,
disconnect the main power or unplug the power
supply.
• Never bypass or shortcut the safety interlocks.
• Before removing any power supply or system
enclosure cover, disconnect electrical input power.
Wait 5 minutes after disconnecting the main power
to allow capacitors to discharge.
• Never operate the plasma system unless the power
supply covers are in place. Exposed power supply
connections present a severe electrical hazard.
• When making input connections, attach proper
grounding conductor first.
• Each Hypertherm plasma system is designed to be
used only with specific Hypertherm torches. Do not
substitute other torches which could overheat and
present a safety hazard.
Use proper precautions when handling printed circuit
boards.
STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS
• Store PC boards in anti-static containers.
• Wear a grounded wrist strap when handling
PC boards.
1-4 Hypertherm
SAFETY
11/08
The plasma arc by itself is the heat source used for
cutting. Accordingly, although the plasma arc has not
been identified as a source of toxic fumes, the material
being cut can be a source of toxic fumes or gases that
deplete oxygen.
Fumes produced vary depending on the metal that is
cut. Metals that may release toxic fumes include, but
are not limited to, stainless steel, carbon steel, zinc
(galvanized), and copper.
In some cases, the metal may be coated with a substance
that could release toxic fumes. Toxic coatings include,
but are not limited to, lead (in some paints), cadmium
(in some paints and fillers), and beryllium.
Gases produced by plasma cutting vary based on the
material to be cut and the method of cutting, but may
include ozone, oxides of nitrogen, hexavalent chromium,
hydrogen, and other substances if such are contained
in or released by the material being cut.
Caution should be taken to minimize exposure to fumes
produced by any industrial process. Depending upon
the chemical composition and concentration of the
fumes (as well as other factors, such as ventilation),
there may be a risk of physical illness, such as birth
defects or cancer.
It is the responsibility of the equipment and site owner
to test the air quality in the area where the equipment is
used and to ensure that the air quality in the workplace
meets all local and national standards and regulations.
The air quality level in any relevant workplace depends
on site-specific variables such as:
• Table design (wet, dry, underwater).
• Material composition, surface finish, and composition
of coatings.
TOXIC FUMES CAN CAUSE INJURY OR DEATH
• Volume of material removed.
• Duration of cutting or gouging.
• Size, air volume, ventilation and filtration of the
work area.
• Personal protective equipment.
• Number of welding and cutting systems in operation.
• Other site processes that may produce fumes.
If the workplace must conform to national or local
regulations, only monitoring or testing done at the site
can determine whether the site is above or below
allowable levels.
To reduce the risk of exposure to fumes:
• Remove all coatings and solvents from the metal
before cutting.
• Use local exhaust ventilation to remove fumes from
the air.
• Do not inhale fumes. Wear an air-supplied respirator
when cutting any metal coated with, containing, or
suspected to contain toxic elements.
• Assure that those using welding or cutting equipment,
as well as air-supplied respiration devices, are
qualified and trained in the proper use of such
equipment.
• Never cut containers with potentially toxic materials
inside. Empty and properly clean the container first.
• Monitor or test the air quality at the site as needed.
• Consult with a local expert to implement a site plan
to ensure safe air quality.
Hypertherm 1-5
SAFETY
11/08
Instant-on torches
Plasma arc comes on immediately when the torch
switch is activated.
A PLASMA ARC CAN CAUSE INJURY AND BURNS
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.
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 or local codes.
• Wear eye protection (safety glasses or goggles with side shields, and a welding helmet) with appropriate
lens shading to protect your eyes from the arc’s ultraviolet and infrared rays.
Skin protection Wear protective clothing to protect against burns caused by ultraviolet light, sparks, and
hot metal.
• Gauntlet gloves, safety shoes and hat.
• Flame-retardant clothing to cover all exposed areas.
• Cuffless trousers to prevent entry of sparks and slag.
• Remove any combustibles, such as a butane lighter or matches, from your pockets before cutting.
Cutting area Prepare the cutting area to reduce reflection and transmission of ultraviolet light:
• Paint walls and other surfaces with dark colors to reduce reflection.
• Use protective screens or barriers to protect others from flash and glare.
• Warn others not to watch the arc. Use placards or signs.
ARC RAYS CAN BURN EYES AND SKIN
Arc current
(amps)
Minimum protective
shade number
(ANSI Z49.1:2005)
Suggested shade
number for comfort
(ANSI Z49.1:2005)
OSHA 29CFR
1910.133(a)(5)
Europe
EN168:2002
Less than 40 A 5 5 8 9
41 to 60 A 6 6 8 9
61 to 80 A 8 8 8 9
81 to 125 A 8 9 8
9
126 to 150 A 8 9 8 10
151 to 175 A 8 9
8
11
176 to 250 A 8 9 8 12
251 to 300 A 8 9 8 13
301 to 400 A 9 12 9 13
401 to 800 A 10 14 10
1-6 Hypertherm
SAFETY
11/08
• 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 or
local codes.
GAS CYLINDERS CAN
EXPLODE IF DAMAGED
COMPRESSED GAS EQUIPMENT SAFETY
Gas cylinders contain gas under high pressure.
If damaged, a cylinder can explode.
• Handle and use compressed gas cylinders in
accordance with applicable national or local codes.
• Never use a cylinder that is not upright and secured
in place.
• Keep the protective cap in place over valve except
when the cylinder is in use or connected for use.
• Never allow electrical contact between the plasma arc
and a cylinder.
• Never expose cylinders to excessive heat, sparks, slag
or open flame.
• Never use a hammer, wrench or other tool to open a
stuck cylinder valve.
Work cable Attach the work cable securely to the
workpiece or the work table with good metal-to-metal
contact. Do not connect it to the piece that will fall away
when the cut is complete.
Work table Connect the work table to an earth
ground, in accordance with appropriate national or local
electrical codes.
Input power
• Be sure to connect the power cord ground wire to the
ground in the disconnect box.
• If installation of the plasma system involves
connecting the power cord to the power supply, be
sure to connect the power cord ground wire properly.
• Place the power cord's ground wire on the stud first,
then place any other ground wires on top of the power
cord ground. Fasten the retaining nut tightly.
• Tighten all electrical connections to avoid excessive
heating.
GROUNDING SAFETY
Hypertherm 1-7
SAFETY
11/08
Frozen pipes may be damaged or can burst if you
attempt to thaw them with a plasma torch.
NOISE CAN DAMAGE HEARING
A PLASMA ARC CAN
DAMAGE FROZEN PIPES
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.
To reduce magnetic field hazards:
• Keep both the work cable and the torch lead to one
side, away from your body.
• Route the torch leads as close as possible to the
work cable.
• Do not wrap or drape the torch lead or work cable
around your body.
• Keep as far away from the power supply as possible.
PACEMAKER AND
HEARING AID OPERATION
Prolonged exposure to noise from cutting or gouging
can damage hearing.
• Use approved ear protection when using plasma
system.
• Warn others nearby about the noise hazard.
1-8 Hypertherm
SAFETY
11/08
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
6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in
Cylinders, Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202
7. CSA Standard W117.2, Code for Safety in Welding and Cutting,
Canadian Standards Association Standard Sales
178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada
8. NFPA Standard 51B, Cutting and Welding Processes, National Fire
Protection Association
470 Atlantic Avenue, Boston, MA 02210
9. NFPA Standard 70–1978, National Electrical Code, National Fire
Protection Association, 470 Atlantic Avenue, Boston, MA 02210
10. OSHA, Safety and Health Standards, 29FR 1910
U.S. Government Printing Office, Washington, D.C. 20402
11. AWS Safety and Health Fact Sheets, American Welding Society
550 LeJeune Road, P.O. Box 351040, Miami, FL 33135
www.aws.org/technical/facts/
SYMBOLS AND MARKS
Your Hypertherm product may have one or more of the following markings on or near the data plate. Due to differences
and conflicts in national regulations, not all marks are applied to every version of a product.
S mark symbol
The S mark symbol indicates that the power supply and torch are suit able for operations carried out in
en vi ron ments with in creased hazard of elec tri cal shock per IEC 60974-1.
CSA mark
Hypertherm products with a CSA mark meet the United States and Canadian regulations for product safety.
The products were evaluated, tested, and certified by CSA-International. Alternatively the product may have
a mark by one of the other Nationally Recognized Testing Laboratories (NRTL) accredited in both the United
States and Canada, such as Underwriters Laboratories, Incorporated (UL) or TÜV.
CE marking
The CE marking signifies the 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
Electromagnetic Compatibility (EMC) Directive. EMC filters needed to comply with the European EMC
Directive are incorporated within versions of the product with a CE marking.
GOST-R mark
CE versions of Hypertherm products that include a GOST-R mark of conformity meet the product safety
and EMC requirements for export to the Russian Federation.
c-Tick mark
CE versions of Hypertherm products with a c-Tick mark comply with the EMC regulations required for sale
in Australia and New Zealand.
CCC mark
The China Compulsory Certification (CCC) mark indicates that the product has been tested and found
compliant with product safety regulations required for sale in China.
Hypertherm 1-9
SAFETY
11/08
WARNING LABEL
This warning label is affixed to some power supplies. It is important
that the operator and maintenance technician understand the intent
of these warning symbols as described.
Read and follow these instructions, employer safety
practices, and material safety data sheets. Refer to
ANS Z49.1, “Safety in Welding, Cutting and Allied
Processes” from American Welding Society
(http://www.aws.org) and OSHA Safety and Health
Standards, 29 CFR 1910 (http://www.osha.gov).
WARNING
Plasma cutting can be injurious to operator and persons
in the work area. Consult manual before operating. Failure
to follow all these safety instructions can result in death.
1. Cutting sparks can cause explosion or fire.
1.1 Do not cut near flammables.
1.2 Have a fire extinguisher nearby and ready to use.
1.3 Do not use a drum or other closed container as a cutting table.
2. Plasma arc can injure and burn; point the nozzle away
from yourself. Arc starts instantly when triggered.
2.1 Turn off power before disassembling torch.
2.2 Do not grip the workpiece near the cutting path.
2.3 Wear complete body protection.
3. Hazardous voltage. Risk of electric shock or burn.
3.1 Wear insulating gloves. Replace gloves when wet or damaged.
3.2 Protect from shock by insulating yourself from work and ground.
3.3 Disconnect power before servicing. Do not touch live parts.
4. Plasma fumes can be hazardous.
4.1 Do not inhale fumes.
4.2 Use forced ventilation or local exhaust to remove the fumes.
4.3 Do not operate in closed spaces. Remove fumes with ventilation.
5. Arc rays can burn eyes and injure skin.
5.1 Wear correct and appropriate protective equipment to protect
head, eyes, ears, hands, and body. Button shirt collar. Protect ears
from noise. Use welding helmet with the correct shade of filter.
6. Become trained.
equipment. Use torches specified in the manual. Keep non-qualified
personnel and children away.
7. Do not remove, destroy, or cover this label.
Replace if it is missing, damaged, or worn (PN 110584 Rev C).
Only qualified personnel should operate this
AVERTISSEMENT
Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se
trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le
non respect des ces instructions de sécurité peut entraîner la mort.
1. Les étincelles de coupage peuvent provoquer une explosion
ou un incendie.
1.1 Ne pas couper près des matières inflammables.
1.2 Un extincteur doit être à proximité et prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.
2. L’arc plasma peut blesser et brûler; éloigner la buse de soi.
Il s’allume instantanément quand on l’amorce;
2.1 Couper l’alimentation avant de démonter la torche.
2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.
2.3 Se protéger entièrement le corps.
3. Tension dangereuse. Risque de choc électrique ou de brûlure.
3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou
endommagés.
3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.
3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.
4. Les fumées plasma peuvent être dangereuses.
4.1 Ne pas inhaler les fumées
4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.
4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.
5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.
5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les
oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles
contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance appropriée.
6. Suivre une formation. Seul le personnel qualifié a le droit de faire
fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le
manual. Le personnel non qualifié et les enfants doivent se tenir à l’écart.
7. Ne pas enlever, détruire ni couvrir cette étiquette.
La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C).
1-10 Hypertherm
SAFETY
11/08
WARNING LABEL
This warning label is affixed to some power supplies. It is important
that the operator and maintenance technician understand the intent of
these warning symbols as described. The numbered text corresponds
to the numbered boxes on the label.
1. Cutting sparks can cause explosion
or fire.
1.1 Do not cut near flammables.
1.2 Have a fire extinguisher nearby and
ready to use.
1.3 Do not use a drum or other closed
container as a cutting table.
2. Plasma arc can injure and burn; point
the nozzle away from yourself. Arc starts
instantly when triggered.
2.1 Turn off power before disassembling
torch.
2.2 Do not grip the workpiece near the
cutting path.
2.3 Wear complete body protection.
3. Hazardous voltage. Risk of electric
shock or burn.
3.1 Wear insulating gloves. Replace gloves
when wet or damaged.
3.2 Protect from shock by insulating yourself
from work and ground.
3.3 Disconnect power before servicing. Do
not touch live parts.
4. Plasma fumes can be hazardous.
4.1 Do not inhale fumes.
4.2 Use forced ventilation or local exhaust to
remove the fumes.
4.3 Do not operate in closed spaces.
Remove fumes with ventilation.
5. Arc rays can burn eyes and injure skin.
5.1 Wear correct and appropriate protective
equipment to protect head, eyes, ears,
hands, and body. Button shirt collar.
Protect ears from noise. Use welding
helmet with the correct shade of filter.
6. Become trained. Only qualified
personnel should operate this
equipment. Use torches specified in the
manual. Keep non-qualified personnel
and children away.
7. Do not remove, destroy, or cover this
label. Replace if it is missing, damaged,
or worn.
Hypertherm 1-11
SAFETY
11/08
Dry dust collection information
At some sites, dry dust can represent a potential explosion hazard.
The U.S. National Fire Protection Association’s 2007 edition of NFPA standard 68, “Explosion Protection by
Deflagration Venting,” provides requirements for the design, location, installation, maintenance, and use of devices and
systems to vent combustion gases and pressures after any deflagration event. Consult with the manufacturer or installer
of any dry dust collection system for applicable requirements before you install a new dry dust collection system or make
significant changes in the process or materials used with an existing dry dust collection system.
Consult your local “Authority Having Jurisdiction” (AHJ) to determine whether any edition of NFPA 68 has been
“adopted by reference” in your local building codes.
Refer to NFPA68 for definitions and explanations of regulatory terms such as deflagration, AHJ, adopted by reference,
the Kst value, deflagration index, and other terms.
Note 1 – Hypertherm’s interpretation of these new requirements is that unless a site-specific evaluation has been
completed to determine that all dust generated is not combustible, the 2007 edition of NFPA 68 requires the use of
explosion vents designed to the worst-case Kst value (see annex F) that could be generated from dust so that the
explosion vent size and type can be designed. NFPA 68 does not specifically identify plasma cutting or other thermal
cutting processes as requiring deflagration venting systems, but it does apply these new requirements to all dry dust
collection systems.
Note 2 – Users of Hypertherm manuals should consult and comply with all applicable federal, state, and local laws and
regulations. Hypertherm does not, by the publication of any Hypertherm manual, intend to urge action that is not in
compliance with all applicable regulations and standards, and this manual may never be construed as doing so.
Hypertherm 1a-1
11/08
Section 1a
SÉCURITÉ
Dans cette section :
Identifier les consignes de sécurité .....................................................................................................................................................1a-2
Suivre les instructions de sécurité .......................................................................................................................................................1a-2
Le coupage peut provoquer un incendie ou une explosion ...........................................................................................................1a-2
Les chocs électriques peuvent être fatals..........................................................................................................................................1a-3
L’électricité statique peut endommager les cartes de circuits imprimés ....................................................................................1a-3
Les vapeurs toxiques peuvent provoquer des blessures ou la mort ............................................................................................1a-4
L’arc plasma peut provoquer des blessures ou des brûlures ........................................................................................................1a-5
Les rayons de l’arc peuvent brûler les yeux et la peau....................................................................................................................1a-5
Mise à la masse et à la terre..................................................................................................................................................................1a-6
Sécurité des bouteilles de gaz comprimé ..........................................................................................................................................1a-6
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .................................................................................1a-6
Le bruit peut provoquer des problèmes auditifs ...............................................................................................................................1a-7
Pacemakers et prothèses auditives .....................................................................................................................................................1a-7
Un arc plasma peut endommager les tuyaux gelés..........................................................................................................................1a-7
Symboles et marquage...........................................................................................................................................................................1a-8
Étiquettes de sécurité .............................................................................................................................................................................1a-9
Information sur le dépoussiérage.......................................................................................................................................................1a-11
1a-2 Hypertherm
SÉCURITÉ
11/08
IDENTIFIER LES CONSIGNES
DE SÉCURITÉ
Les symboles indiqués dans cette section sont utilisés pour
identifier les risques éventuels. Si vous trouvez un symbole de
sécurité, que ce soit dans ce manuel ou sur l’équipement, soyez
conscient des risques de blessures et suivez les instructions
correspondantes afin d’éviter ces risques.
SUIVRE LES INSTRUCTIONS
DE SÉCURITÉ
Lire attentivement toutes les consignes de sécurité dans
le présent manuel et sur les étiquettes de sécurité se trouvant
sur la machine.
• Les étiquettes de sécurité doivent rester lisibles. Remplacer
immédiatement les étiquettes manquantes ou abîmées.
• Apprendre à faire fonctionner la machine et à utiliser
correctement les commandes. Ne laisser personne utiliser
la machine sans connaître son fonctionnement.
• Garder la machine en bon état. Des modifications non
autorisées sur la machine peuvent engendrer des problèmes
de sécurité et raccourcir la durée d’utilisation de l’équipement.
DANGER AVERTISSEMENT ATTENTION
Hypertherm adopte les lignes directrices de l’American
National Standards Institute relativement aux termes, aux
symboles et à la signalisation de sécurité. Les signaux
DANGER ou AVERTISSEMENT sont utilisés avec un
symbole de sécurité, DANGER correspondant aux risques
les plus sérieux.
• Les étiquettes de sécurité DANGER et AVERTISSE MENT
sont situées sur la machine pour signaler certains dangers
spécifiques.
• Les messages de sécurité DANGER précèdent les
directives associées dans le manuel qui, si elles ne sont pas
suivies scrupuleusement, entraînent des blessures graves
voire mortelles.
• Les messages d’AVERTISSEMENT précèdent les
instructions d’utilisation expliquées dans ce manuel
et signalent les risques de blessures ou de mort au cas
où ces instructions ne seraient pas suivies correctement.
• Les messages de sécurité ATTENTION précèdent les
directives associées dans le manuel qui, si elles ne sont pas
suivies scrupuleusement, peuvent entraîner des blessures
secondaires ou endommager l’équipement.
Prévention des incendies
• Avant de commencer, s’assurer que la zone de coupage ne
présente aucun danger. Conserver un extincteur à proximité.
• Éloigner toute matière inflammable à une distance d’au
moins 10 m du poste de coupage.
• Tremper le métal chaud ou le laisser refroidir avant
de le manipuler ou avant de le mettre en contact avec
des matériaux combustibles.
• Ne jamais couper des récipients pouvant contenir des
matières inflammables avant de les avoir vidés et nettoyés
correctement.
• Aérer toute atmosphère potentiellement inflammable avant
d’utiliser un système plasma.
• Lors de l’utilisation d’oxygène comme gaz plasma, un
système de ventilation par aspiration est nécessaire.
Prévention des explosions
• Ne pas couper en présence de poussière ou de vapeurs.
• Ne pas couper de bouteilles, de tuyaux ou autres récipients
fermés et pressurisés.
• Ne pas couper de récipients contenant des matières
combustibles.
LE COUPAGE PEUT PROVOQUER UN INCENDIE
OU UNE EXPLOSION
AVERTISSEMENT
Risque d’explosion
argon-hydrogène et méthane
L’hydrogène et le méthane sont des gaz inflammables et
potentiellement explosifs. Conserver à l’écart de toute flamme
les bouteilles et tuyaux contenant des mélanges à base
d’hydrogène ou de méthane. Maintenir toute flamme et étincelle
à l’écart de la torche lors de l’utilisation d’un plasma
d’argon-hydrogène ou de méthane.
AVERTISSEMENT
Détonation de l’hydrogène lors du
coupage de l’aluminium
• Lors du coupage de l’aluminium sous l’eau, ou si l’eau touche
la partie inférieure de la pièce d’aluminium, de l’hydrogène
libre peut s’accumuler sous la pièce à couper et détonner
lors du coupage plasma.
• Installer un collecteur d’aération au fond de la table à eau afin
d’éliminer les risques de détonation de l’hydrogène.
Se référer à l’annexe du manuel pour plus de renseignements
sur les collecteurs d’aération.
Toucher une pièce électrique sous tension peut provoquer
un choc électrique fatal ou des brûlures graves.
• La mise en fonctionnement du système plasma ferme
un circuit électrique entre la torche et la pièce à couper.
La pièce à couper et tout autre élément en contact avec
cette pièce font partie du circuit électrique.
• Ne jamais toucher le corps de la torche, la pièce à couper
ou l’eau de la table à eau pendant le fonctionnement
du système plasma.
Prévention des chocs électriques
Tous les systèmes plasma Hypertherm utilisent des hautes
tensions pour le coupage (souvent de 200 à 400 V).
On doit prendre les précautions suivantes quand on utilise
le système plasma :
• Porter des bottes et des gants isolants et garder le corps
et les vêtements au sec.
• Ne pas se tenir, s’asseoir ou se coucher sur une surface
mouillée, ni la toucher quand on utilise le système plasma.
• S’isoler de la surface de travail et du sol en utilisant des
tapis isolants secs ou des couvertures assez grandes pour
éviter tout contact physique avec le travail ou le sol. S’il
s’avère nécessaire de travailler dans ou près d’un endroit
humide, procéder avec une extrême prudence.
• Installer un sectionneur avec fusibles appropriés, à proximité
de la source de courant. Ce dispositif permet à l’opérateur
d’arrêter rapidement la source de courant en cas d’urgence.
• En cas d’utilisation d’une table à eau, s’assurer que cette
dernière est correctement mise à la terre.
• Installer et mettre à la terre l’équipement selon les
instructions du présent manuel et conformément aux codes
électriques locaux et nationaux.
LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS
• Inspecter fréquemment le cordon d’alimentation primaire
pour s’assurer qu’il n’est ni endommagé, ni fendu. Remplacer
immédiatement un cordon endommagé. Un câble dénudé
peut tuer.
• Inspecter et remplacer les câbles de la torche qui sont usés
ou endommagés.
• Ne pas saisir la pièce à couper ni les chutes lors du
coupage. Laisser la pièce à couper en place ou sur la table
de travail, le câble de retour connecté lors du coupage.
• Avant de vérifier, de nettoyer ou de remplacer les pièces
de la torche, couper l’alimentation ou débrancher la prise
de courant.
• Ne jamais contourner ou court-circuiter les verrouillages
de sécurité.
• Avant d’enlever le capot du système ou de la source de
courant, couper l’alimentation électrique. Attendre en
suite
5 minutes pour que les condensateurs se déchargent.
• Ne jamais faire fonctionner le système plasma sans que
les capots de la source de courant ne soient en place.
Les raccords exposés de la source de courant sont
extrêmement dangereux.
• Lors de l’installation des connexions, attacher tout d’abord
la prise de terre appropriée.
• Chaque système plasma Hypertherm est conçu pour
être utilisé uniquement avec des torches Hypertherm
spécifiques. Ne pas utiliser des torches inappropriées
qui pourraient surchauffer et présenter des risques pour
la sécurité.
On doit prendre les précautions qui s’imposent quand on
manipule les circuits imprimés.
L’ÉLECTRICITÉ STATIQUE PEUT ENDOMMAGER
LES CARTES DE CIRCUITS IMPRIMÉS
• On doit ranger les cartes de circuits imprimés dans des
contenants antistatiques.
• On doit porter un bracelet antistatique quand on manipule
les cartes de circuits imprimés.
Hypertherm 1a-3
SÉCURITÉ
11/08
1a-4 Hypertherm
SÉCURITÉ
11/08
L’arc plasma est lui-même la source de chaleur utilisée pour le
coupage. Par conséquent, bien que l’arc plasma n’ait pas été
reconnu comme une source de vapeurs toxiques, le matériau
coupé peut être une source de vapeurs ou de gaz toxiques
qui épuisent l’oxygène.
Les vapeurs produites varient selon le métal coupé.
Les métaux qui peuvent dégager des vapeurs toxiques
comprennent, entre autres, l’acier inoxydable, l’acier au
carbone, le zinc (galvanisé) et le cuivre.
Dans certains cas, le métal peut être revêtu d’une substance
susceptible de dégager des vapeurs toxiques. Les
revêtements toxiques comprennent entre autres, le plomb
(dans certaines peintures), le cadmium (dans certaines
peintures et enduits) et le béryllium.
Les gaz produits par le coupage plasma varient selon
le matériau à couper et la méthode de coupage, mais
ils peuvent comprendre l’ozone, les oxydes d’azote, le chrome
hexavalent, l’hydrogène et autres substances présentes dans
le matériau coupé ou en émanent.
On doit prendre les précautions qui s’imposent pour réduire
au minimum l’exposition aux vapeurs produites par tout
processus industriel. Selon la composition chimique et la
concentration des vapeurs (ainsi que d’autres facteurs comme
la ventilation), il peut y avoir un risque de maladie physique,
comme des malformations ou le cancer.
Il incombe au propriétaire du matériel et du site de vérifier la
qualité de l’air dans le secteur où l’on utilise le matériel et de
s’assurer que la qualité de l’air sur les lieux de travail répond
aux normes et réglementation locales et nationales.
Le niveau de qualité de l’air dans tout lieu de travail dépend
des variables propres au site comme :
• Type de table (humide, sèche, sous l’eau).
• Composition du matériau, fini de la surface et composition
des revêtements.
LES VAPEURS TOXIQUES PEUVENT PROVOQUER
DES BLESSURES OU LA MORT
• Volume de matériau enlevé.
• Durée du coupage ou du gougeage.
• Dimensions, volume d’air, ventilation et filtration de la zone
de travail.
• Équipement de protection individuelle.
• Nombre de systèmes de soudage et de coupage
en fonctionnement.
• Autres procédés du site qui peuvent produire des vapeurs.
Si les lieux de travail doivent être conformes aux règlements
nationaux ou locaux, seuls les contrôles ou les essais effectués
au site peuvent déterminer si celui-ci se situe au-dessus ou
au-dessous des niveaux admissibles.
Pour réduire le risque d’exposition aux vapeurs :
• Éliminer tout revêtement et solvant du métal avant
le coupage.
• Utiliser la ventilation d’extraction locale pour éliminer les
vapeurs de l’air.
• Ne pas inhaler les vapeurs. Porter un respirateur à adduction
d’air quand on coupe des métaux revêtus d’éléments
toxiques ou qui en contiennent ou sont susceptibles d’en
contenir.
• S’assurer que les personnes qui utilisent un matériel de
soudage ou de coupage ainsi que les dispositifs de
respiration par adduction d’air sont qualifiés et ont reçu
la formation sur la bonne utilisation d’un tel matériel.
• Ne jamais couper les contenants dans lesquels il peut
y avoir des matériaux toxiques. En premier lieu, vider
et nettoyer correctement le contenant.
• Contrôler ou éprouver la qualité de l’air au site selon les
besoins.
• Consulter un expert local pour mettre en œuvre un plan
du site afin d’assurer une qualité de l’air sûre.
Torches à allumage instantané
L’arc plasma s’allume immédiatement après que la torche soit
mise en marche.
L’ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURES
L’arc plasma coupe facilement les gants et la peau.
• Rester éloigné de l’extrémité de la torche.
• Ne pas tenir de métal près de la trajectoire de coupe.
• Ne jamais pointer la torche vers soi ou d’autres personnes.
Hypertherm 1a-5
SÉCURITÉ
11/08
Protection des yeux Les rayons de l’arc plasma produisent de puissants rayons visibles ou invisibles (ultraviolets et infrarouges)
qui peuvent brûler les yeux et la peau.
• Utiliser des lunettes de sécurité conformément aux codes locaux ou nationaux en vigueur.
• Porter des lunettes de protection (lunettes ou masque muni d’écrans latéraux et encore masque de soudure) avec des verres
teintés appropriés pour protéger les yeux des rayons ultraviolets et infrarouges de l’arc.
Protection de la peau Porter des vêtements de sécurité pour se protéger contre les brûlures que peuvent causer les rayons
ultraviolets, les étincelles et le métal brûlant :
• Gants à crispin, chaussures et casque de sécurité.
• Vêtements ignifuges couvrant toutes les parties exposées du corps.
• Pantalon sans revers pour éviter que des étincelles ou des scories puissent s’y loger.
• Avant le coupage, retirer de ses poches tout objet combustible comme les briquets au butane ou les allumettes.
Zone de coupage Préparer la zone de coupage afin de réduire la réverbération et la transmission de la lumière ultraviolette :
• Peindre les murs et autres surfaces de couleur sombre pour réduire la réflexion de la lumière.
• Utiliser des écrans et autres dispositifs de protection afin de protéger les autres personnes de la lumière et de la réverbération.
• Prévenir les autres personnes de ne pas regarder l’arc. Utiliser des affiches ou des panneaux.
LES RAYONS DE L’ARC PEUVENT BRÛLER LES YEUX ET LA PEAU
Courant de l’arc
(A)
Indice de protection
minimum (ANSI
Z49.1:2005)
Indice de protection
suggéré pour
assurer le confort
(ANSI Z49.1:2005)
OSHA 29CFR
1910.133(a)(5)
Europe
EN168:2002
Moins de 40 A 5 5 8 9
41 à 60 A 6 6 8 9
61 à 80 A 8 8 8 9
81 à 125 A 8 9 8
9
126 à 150 A 8 9 8 10
151 à 175 A 8 9
8
11
176 à 250 A 8 9 8 12
251 à 300 A 8 9 8 13
301 à 400 A 9 12 9 13
401 à 800 A 10 14 10
1a-6 Hypertherm
SÉCURITÉ
11/08
• Ne jamais lubrifier les robinets des bouteilles ou les
régulateurs avec de l’huile ou de la graisse.
• Utiliser uniquement les bouteilles, régulateurs, tuyaux et
accessoires appropriés et conçus pour chaque application
spécifique.
• Entretenir l’équipement et les pièces d’équipement à gaz
comprimé afin de les garder en bon état.
• Étiqueter et coder avec des couleurs tous les tuyaux de gaz
afin d’identifier le type de gaz contenu dans chaque tuyau.
Se référer aux codes locaux ou nationaux en vigueur.
LES BOUTEILLES DE GAZ
COMPRIMÉ PEUVENT
EXPLOSER EN CAS DE
DOMMAGES
SÉCURITÉ DES BOUTEILLES
DE GAZ COMPRIMÉ
Les bouteilles de gaz contiennent du gaz à haute pression.
Si une bouteille est endommagée, elle peut exploser.
• Manipuler et utiliser les bouteilles de gaz comprimé
conformément aux codes locaux ou nationaux.
• Ne jamais utiliser une bouteille qui n’est pas placée
à la verticale et bien assujettie.
• Le capuchon de protection doit être placé sur le robinet
sauf si la bouteille est en cours d’utilisation ou connectée
pour utilisation.
• Éviter à tout prix le contact électrique entre l’arc plasma
et une bouteille.
• Ne jamais exposer des bouteilles à une chaleur excessive,
aux étincelles, aux scories ou aux flammes nues.
• Ne jamais utiliser des marteaux, des clés ou d’autres outils
pour débloquer le robinet des bouteilles.
Câble de retour Bien fixer le câble de retour (ou de masse)
à la pièce à couper ou à la table de travail de façon à assurer
un bon contact métal-métal. Ne pas fixer le câble de retour
à la partie de la pièce qui doit se détacher.
Table de travail Raccorder la table de travail à la terre,
conformément aux codes de sécurité locaux ou nationaux
appropriés.
Alimentation
• S’assurer que le fil de terre du cordon d’alimentation est
connecté à la terre dans le coffret du sectionneur.
• S’il est nécessaire de brancher le cordon d’alimentation à la
source de courant lors de l’installation du système, s’assurer
que le fil de terre est correctement branché.
• Placer tout d’abord le fil de terre du cordon d’alimentation
sur le plot de mise à la terre puis placer les autres fils de
terre par-dessus. Bien serrer l’écrou de retenue.
• S’assurer que toutes les connexions sont bien serrées pour
éviter la surchauffe.
MISE À LA MASSE ET À LA TERRE
Hypertherm 1a-7
SÉCURITÉ
11/08
Les tuyaux gelés peuvent être endommagés ou éclater si l'on
essaie de les dégeler avec une torche plasma.
LE BRUIT PEUT PROVOQUER DES
PROBLÈMES AUDITIFS
UN ARC PLASMA PEUT
ENDOMMAGER LES
TUYAUX GELÉS
Les champs magnétiques produits par les courants à haute
tension peuvent affecter le fonctionnement des prothèses
auditives et des pacemakers. Les personnes portant ce type
d’appareil doivent consulter un médecin avant de s’approcher
d’un lieu où s’effectue le coupage ou le gougeage plasma.
Pour réduire les risques associés aux champs magnétiques :
• Garder loin de soi et du même côté du corps le câble
de retour et le faisceau de la torche.
• Faire passer le faisceau de la torche le plus près possible
du câble de retour.
• Ne pas s’enrouler le faisceau de la torche ou le câble
de retour autour du corps.
• Se tenir le plus loin possible de la source de courant.
PACEMAKERS ET
PROTHÈSES AUDITIVES
Une exposition prolongée au bruit du coupage ou du
gougeage peut provoquer des problèmes auditifs.
• Utiliser un casque de protection homologué lors de
l’utilisation du système plasma.
• Prévenir les personnes aux alentours des risques encourus
en cas d’exposition au bruit.
1a-8 Hypertherm
SÉCURITÉ
11/08
SYMBOLES ET MARQUAGE
Votre produit Hypertherm peut comporter une ou plusieurs des marques suivantes sur sa plaque signalétique ou à proximité.
En raison des différends et des conflits relatifs aux règlements nationaux, toutes les marques ne sont pas appliquées à chaque
version d’un produit.
Symbole marque S
Le symbole de marque S indique que la source de courant et la torche conviennent pour les travaux effectués dans
les milieux à risque accru de choc électrique selon l’IEC 60974-1.
Marque CSA
Les produits Hypertherm comportant la marque CSA répondent aux règlements des États-Unis et du Canada relatifs à la
sécurité du produit. Les produits sont évalués, mis à l’essai et certifiés par la CSA-International. En outre, le produit peut
porter une marque d’un des laboratoires d’essai reconnus sur le plan national (NRTL) accrédité aux États-Unis et au Canada
comme les Underwriters Laboratories, Incorporated (UL) ou TÜV.
Marque CE
La marque CE signifie la déclaration de conformité du fabricant aux directives et normes européennes applicables. Seules
les versions des produits Hypertherm portant la marque CE placée sur la plaque signalétique ou à proximité ont été mises
à l’essai de conformité à la directive européenne sur la basse tension et la compatibilité électromagnétique européenne
(CEM). Les filtres CEM qui doivent se conformer à la directive CEM européenne sont intégrés aux versions du produit
portant la marque CE.
Marque GOST-R
Les versions CE des produits Hypertherm qui portent la marque de conformité GOST-R répondent aux exigences
de sécurité du produit et de CEM en vue de l’exportation à la Fédération russe.
Marque c-Tick
Les versions CE des produits Hypertherm portant la marque c-Tick sont conformes aux règlements CEM prescrits pour
la vente en Australie et en Nouvelle-Zélande.
Marque CCC
La marque de certification obligatoire en Chine (CCC) indique que le produit a été mis à l’essai et déclaré conforme aux
règlements de sécurité du produit prescrits pour la vente en Chine.
Hypertherm 1a-9
SÉCURITÉ
11/08
ÉTIQUETTE DE SÉCURITÉ
Cette étiquette est affichée sur la source de courant. Il est important que
l’utilisateur et le technicien de maintenance comprennent la signification
des symboles de sécurité.
Read and follow these instructions, employer safety
practices, and material safety data sheets. Refer to
ANS Z49.1, “Safety in Welding, Cutting and Allied
Processes” from American Welding Society
(http://www.aws.org) and OSHA Safety and Health
Standards, 29 CFR 1910 (http://www.osha.gov).
WARNING
1. Cutting sparks can cause explosion or fire.
1.1 Do not cut near flammables.
1.2 Have a fire extinguisher nearby and ready to use.
1.3 Do not use a drum or other closed container as a cutting table.
2. Plasma arc can injure and burn; point the nozzle away
from yourself. Arc starts instantly when triggered.
2.1 Turn off power before disassembling torch.
2.2 Do not grip the workpiece near the cutting path.
2.3 Wear complete body protection.
3. Hazardous voltage. Risk of electric shock or burn.
3.1 Wear insulating gloves. Replace gloves when wet or damaged.
3.2 Protect from shock by insulating yourself from work and ground.
3.3 Disconnect power before servicing. Do not touch live parts.
4. Plasma fumes can be hazardous.
4.1 Do not inhale fumes.
4.2 Use forced ventilation or local exhaust to remove the fumes.
4.3 Do not operate in closed spaces. Remove fumes with ventilation.
6. Become trained.
Only qualified personnel should operate this
equipment. Use torches specified in the manual. Keep non-qualified
personnel and children away.
5. Arc rays can burn eyes and injure skin.
5.1 Wear correct and appropriate protective equipment to protect
head, eyes, ears, hands, and body. Button shirt collar. Protect ears
from noise. Use welding helmet with the correct shade of filter.
7. Do not remove, destroy, or cover this label.
Replace if it is missing, damaged, or worn (PN 110584 Rev C).
Plasma cutting can be injurious to operator and persons
in the work area. Consult manual before operating. Failure
to follow all these safety instructions can result in death.
AVERTISSEMENT
Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se
trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le
non respect des ces instructions de sécurité peut entraîner la mort.
1. Les étincelles de coupage peuvent provoquer une explosion
ou un incendie.
1.1 Ne pas couper près des matières inflammables.
1.2 Un extincteur doit être à proximité et prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.
2. L’arc plasma peut blesser et brûler; éloigner la buse de soi.
Il s’allume instantanément quand on l’amorce;
2.1 Couper l’alimentation avant de démonter la torche.
2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.
2.3 Se protéger entièrement le corps.
3. Tension dangereuse. Risque de choc électrique ou de brûlure.
3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou
endommagés.
3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.
3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.
4. Les fumées plasma peuvent être dangereuses.
4.1 Ne pas inhaler les fumées
4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.
4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.
5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.
5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les
oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles
contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance appropriée.
6. Suivre une formation. Seul le personnel qualifié a le droit de faire
fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le
manual. Le personnel non qualifié et les enfants doivent se tenir à l’écart.
7. Ne pas enlever, détruire ni couvrir cette étiquette.
La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C).
1a-10 Hypertherm
SÉCURITÉ
11/08
ÉTIQUETTE DE SÉCURITÉ
Cette étiquette est affichée sur la source de courant. Il est important que
l’utilisateur et le technicien de maintenance comprennent la signification
des symboles de sécurité. Les numéros de la liste correspondent aux
numéros des images.
1. Les étincelles de coupage peuvent
provoquer une explosion ou un incendie.
1.1 Ne pas couper près des matières
inflammables.
1.2 Un extincteur doit être à proximité et prêt à
être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant
fermé comme table de coupage.
2. L’arc plasma peut blesser et brûler; éloigner
la buse de soi. Il s’allume instantanément
quand on l’amorce;
2.1 Couper l’alimentation avant de démonter la
torche.
2.2 Ne pas saisir la pièce à couper de la
trajectoire de coupage.
2.3 Se protéger entièrement le corps.
3. Tension dangereuse. Risque de choc
électrique ou de brûlure.
3.1 Porter des gants isolants. Remplacer les
gants quand ils sont humides ou
endommagés.
3.2 Se protéger contre les chocs en s’isolant de
la pièce et de la terre.
3.3 Couper l’alimentation avant l’entretien.
Ne pas toucher les pièces sous tension
4. Les fumées plasma peuvent être
dangereuses.
4.1 Ne pas inhaler les fumées.
4.2 Utiliser une ventilation forcée ou un
extracteur local pour dissiper les fumées.
4.3 Ne pas couper dans des espaces clos.
Chasser les fumées par ventilation.
5. Les rayons d’arc peuvent brûler les yeux et
blesser la peau.
5.1 Porter un bon équipement de protection pour
se protéger la tête, les yeux, les oreilles, les
mains et le corps. Boutonner le col de la
chemise. Protéger les oreilles contre le bruit.
Utiliser un masque de soudeur avec un filtre
de nuance appropriée.
6. Suivre une formation. Seul le personnel
qualifié a le droit de faire fonctionner cet
équipement. Utiliser exclusivement les
torches indiquées dans le manual. Le
personnel non qualifié et les enfants doivent
se tenir à l’écart.
7. Ne pas enlever, détruire ni couvrir cette
étiquette. La remplacer si elle est absente,
endommagée ou usée (PN 110584 Rev C).
Hypertherm 1a-11
SÉCURITÉ
11/08
Information sur le dépoussiérage
À certains endroits, la poussière peut représenter un risque d’explosion potentiel.À certains endroits, la poussière peut
représenter un risque d’explosion potentiel.
La norme NFPA 68 de la National Fire Protection Association des É.-U. (édition 2007) « Explosion Protection by
Deflagration Venting » établit les exigences relatives à la conception, à l’emplacement, à l’installation, à l’entretien et à
l’utilisation de dispositifs et de systèmes pour évacuer à l’air libre les gaz de combustion et les pressions après une
éventuelle déflagration. Communiquer avec le fabricant ou avec l’installateur pour tout système de dépoussiérage afin
de connaître les exigences applicables avant d’installer un tel système neuf ou d’apporter des modifications importantes
aux procédés ou aux matériaux utilisés à un système de dépoussiérage existant.
Consultez l’autorité compétente locale pour déterminer si une édition de la NFPA 68 a été adoptée par référence dans
vos codes du bâtiment locaux.
Voir le document NFPA68 pour obtenir des définitions et des explications des termes réglementaires tels que «
déflagration, autorité compétente, adopté par référence, valeur du pire cas, indice de déflagration » et autres termes.
Note 1 – L’interprétation d’Hypertherm de ces nouvelles exigences est que, sauf évaluation particulière du site, pour
déterminer que toute la poussière produite n’est pas combustible, l’édition 2007 de la NFPA 68 exige l’utilisation
d’évents d’explosion conçus pour la valeur du pire des cas (voir annexe F) qui pourrait provenir de la poussière de sorte
que l’on puisse concevoir la dimension et le type d’évent d’explosion. La NFPA 68 ne stipule pas particulièrement le
procédé de coupage plasma particulier ou autres procédés de coupage thermique comme le prescrivent ces nouveaux
règlements à tous les systèmes de dépoussiérage.
Note 2 – Les utilisateurs des manuels d’Hypertherm doivent consulter tous les règlements et lois fédéraux et locaux
applicables et s’y conformer. Hypertherm n’a pas l’intention, en publiant un manuel d’Hypertherm, de demander des
mesures qui ne sont pas conformes aux règlements et normes applicables et ce manuel ne peut jamais être interprété
dans ce sens.
Hypertherm 1b-1
11/08
Seccíon 1b
SEGURIDAD
En esta sección:
Reconocimiento de información de seguridad .................................................................................................................................1b-2
Siga las instrucciones de seguridad ...................................................................................................................................................1b-2
Los cortes pueden provocar incendios o explosiones....................................................................................................................1b-2
El choque eléctrico puede provocar la muerte.................................................................................................................................1b-3
Electricidad estática puede dañar tablillas de circuito....................................................................................................................1b-3
Humos tóxicos pueden causar lesiones o muerte ...........................................................................................................................1b-4
El arco de plasma puede causar lesiones y quemaduras ..............................................................................................................1b-5
Los rayos del arco pueden producir quemaduras en los ojos y en la piel .................................................................................1b-5
Seguridad de toma a tierra....................................................................................................................................................................1b-6
Seguridad de los equipos de gas comprimido.................................................................................................................................1b-6
Los cilindros de gas pueden explotar si están dañados.................................................................................................................1b-6
El ruido puede deteriorar la audición...................................................................................................................................................1b-7
Operación de marcapasos y de audífonos ........................................................................................................................................1b-7
Un arco plasma puede dañar tubos congelados..............................................................................................................................1b-7
Símbolos y marcas ..................................................................................................................................................................................1b-8
Etiquetas de advertencia........................................................................................................................................................................1b-9
Información sobre la colección de polvo seco...............................................................................................................................1b-11
11/08
SEGURIDAD
1b-2 Hypertherm
RECONOCIMIENTO DE
INFORMACIÓN DE SEGURIDAD
Los símbolos que se muestran en esta sección se utilizan para
identificar los posibles peligros. Cuando vea un símbolo de
seguridad en este manual o en su máquina, recuerde que existe
la posibilidad de que se produzcan lesiones personales y siga
las instrucciones correspondientes para evitar el peligro.
SIGA LAS INSTRUCCIONES
DE SEGURIDAD
Lea atentamente todos los mensajes de seguridad de este
manual y las etiquetas de seguridad en su máquina.
• Mantenga las etiquetas de seguridad de su máquina en buen
estado. Reemplace las etiquetas que se pierdan o se dañen
inmediatamente.
• Aprenda a utilizar la máquina y a utilizar los controles de la
manera correcta. No permita que sea utilizada por alguien
que no conozca su funcionamiento.
• Mantenga su máquina en buenas condiciones de
funcionamiento. La realización de modificaciones no
autorizadas a la máquina puede comprometer la seguridad
y la vida útil de la máquina.
PELIGRO ADVERTENCIA PRECAUCIÓN
Hypertherm usa las directivas del Instituto Americano de
Normas Nacionales (American National Standards Institute)
para las palabras y símbolos que señalan seguridad. Las
palabras PELIGRO y ADVERTENCIA se utilizan
conjuntamente con un símbolo de seguridad. La palabra
PELIGRO se utiliza para identificar los mayores peligros.
• Encontrará etiquetas de seguridad con las inscripciones
PELIGRO y ADVERTENCIA en su máquina, junto a peligros
específicos.
• Los mensajes de seguridad de PELIGRO preceden
instrucciones relacionadas en el manual que resultarán
en lesión grave o muerte si no se las sigue correctamente.
• En este manual, la palabra ADVERTENCIA va seguida de
instrucciones que, si no se siguen correctamente, pueden
provocar lesiones e inclusive la muerte.
• Los mensajes de seguridad de CUIDADO o PRECAUCIÓN
preceden mensajes relacionados con instrucciones en el
manual que puede resultar en lesiones menores, o daño
a equipo, si no se siguen correctamente.
Prevención ante el fuego
• Asegúrese de que el área sea segura antes de proceder
a cortar. Tenga a mano un extinguidor de incendios.
• Retire todos los materiales inflamables, colocándolos
a por lo menos 10 metros del área de corte.
• Remoje los metales calientes o permita que se enfríen antes
de que entren en contacto con materiales combustibles.
• Nunca corte depósitos que contengan materiales
inflamables – primero es necesario vaciarlos y limpiarlos
debidamente.
• Antes de realizar cortes en atmósferas potencialmente
inflamables, asegúrese de ventilar bien.
• Al realizar cortes utilizando oxígeno como gas plasma,
se requiere tener un sistema de ventilación de escape.
Prevención ante explosiones
• No corte en atmósferas que contengan polvo o vapores
explosivos.
• No corte depósitos o tubos a presión ni cualquier depósito
cerrado.
• No corte depósitos que hayan contenido materiales
combustibles.
LOS CORTES PUEDEN PROVOCAR INCENDIOS O EXPLOSIONES
ADVERTENCIA
Peligro de explosión
Argón-Hidrógeno y metano
El hidrógeno y el metano son gases inflamables que suponen
un peligro de explosión. Mantenga el fuego lejos de los
cilindros y las mangueras que contengan mezclas de hidrógeno
o metano. Mantenga la llama y las chispas lejos de la antorcha
al utilizar metano o argón-hidrógeno como plasma.
ADVERTENCIA
Detonación de hidrógeno con
el corte de aluminio
• Al cortar aluminio bajo agua o con agua en contacto con el
lado inferior del aluminio, puede acumularse gas hidrógeno
bajo la pieza a cortar y detonar durante la operación de corte
por plasma.
• Instale un múltiple de aireación en el fondo de la mesa
de agua para eliminar la posibilidad de la detonación del
hidrógeno. Consulte la sección del apéndice de este manual
para conocer detalles acerca del múltiple de aireación.
11/08
El contacto directo con piezas eléctricas conectadas puede
provocar un electrochoque fatal o quemaduras graves.
• Al hacer funcionar el sistema de plasma, se completa
un circuito eléctrico entre la antorcha y la pieza a cortar.
La pieza a cortar es una parte del circuito eléctrico,
como también cualquier cosa que se encuentre en contacto
con ella.
• Nunca toque el cuerpo de la antorcha, la pieza a cortar
o el agua en una mesa de agua cuando el sistema de
plasma se encuentre en funcionamiento.
Prevención ante el electrochoque
Todos los sistemas por plasma de Hypertherm usan alto
voltaje en el proceso de corte (son comunes los voltajes CD
de 200 a 400). Tome las siguientes precauciones cuando se
utiliza el equipo de plasma:
• Use guantes y botas aislantes y mantenga el cuerpo y la
ropa secos.
• No se siente, se pare o se ponga sobre cualquier super ficie
húmeda cuando esté trabajando con el equipo.
• Aíslese eléctricamente de la pieza a cortar y de la tierra
utilizando alfombrillas o cubiertas de aislamiento secas lo
suficientemente grandes como para impedir todo contacto
físico con la pieza a cortar o con la tierra. Si su única opción
es trabajar en una área húmeda o cerca de ella, sea muy
cauteloso.
• Instale un interruptor de corriente adecuado en cuanto
a fusibles, en una pared cercana a la fuente de energía.
Este interruptor permitirá al operador desconectar
rápidamente la fuente de energía en caso de emergencia.
• Al utilizar una mesa de agua, asegúrese de que ésta se
encuentre correctamente conectada a la toma a tierra.
EL CHOQUE ELÉCTRICO PUEDE PROVOCAR LA MUERTE
• Instale este equipo y conéctelo a tierra según el manual
de instrucciones y de conformidad con los códigos locales
y nacionales.
• Inspeccione el cordón de alimentación primaria con
frecuencia para asegurarse de que no esté dañado ni
agrietado. Si el cordón de alimentación primaria está
dañado, reemplácelo inmediatamente. Un cable pelado
puede provocar la muerte.
• Inspeccione las mangueras de la antorcha y reemplácelas
cuando se encuentren dañadas.
• No toque la pieza ni los recortes cuando se está cortando.
Deje la pieza en su lugar o sobre la mesa de trabajo con
el cable de trabajo conectado en todo momento.
• Antes de inspeccionar, limpiar o cambiar las piezas de la
antorcha, desconecte la potencia primaria o desenchufe
la fuente de energía.
• Nunca evite o descuide los bloqueos de seguridad.
• Antes de retirar la cubierta de una fuente de energía o del
gabinete de un sistema, desconecte la potencia primaria
de entrada. Espere 5 minutos después de desconectar
la potencia primaria para permitir la descarga de los
condensadores.
• Nunca opere el sistema de plasma sin que las tapas
de la fuente de energía estén en su lugar. Las conexiones
expuestas de la fuente de energía presentan un serio riesgo
eléctrico.
• Al hacer conexiones de entrada, conecte el conductor
de conexión a tierra en primer lugar.
• Cada sistema de plasma Hypertherm está diseñado para
ser utilizado sólo con antorchas Hypertherm específicas.
No utilice antorchas diferentes, que podrían recalentarse
y ser peligrosas.
Use precauciones adecuadas cuando maneje
tablillas impresas de circuito
ELECTRICIDAD ESTÁTICA PUEDE DAÑAR TABLILLAS DE CIRCUITO
• Almacene las tablillas PC en recipientes antiestáticos.
• Use la defensa de muñeca conectada a tierra cuando
maneje tablillas PC.
SEGURIDAD
Hypertherm 1b-3
11/08
SEGURIDAD
1b-4 Hypertherm
El arco plasma es por si solo la fuente de calor que se usa
para cortar. Según esto, aunque el arco de plasma no ha sido
identificado como la fuente de humo tóxico, el material que se
corta puede ser la fuente de humo o gases tóxicos que vacían
el oxígeno.
El humo producido varía según el metal que está cortándose.
Metales que pueden liberar humo tóxico incluyen, pero no
están limitados a, acero inoxidable, acero al carbón, cinc
(galvanizado), y cobre.
En algunos casos, el metal puede estar recubierto con una
sustancia que podría liberar humos tóxicos. Los recubrimientos
tóxicos incluyen, pero no están limitados a, plomo (en algunas
pinturas), cadmio (en algunas pinturas y rellenos), y berilio.
Los gases producidos por el corte por plasma varían
basándose en el material a cortarse y el método de cortar,
pero pueden incluir ozono, óxidos de nitrógeno, cromo
hexavalente, hidrógeno, y otras substancias, si están
contenidas dentro o liberadas por el material que se corta.
Se debe tener cuidado de minimizar la exposición del humo
producido por cualquier proceso industrial. Según la
composición química y la concentración del humo (al igual que
otros factores, tales como ventilación), puede haber el riesgo
de enfermedad física, tal como defectos de natividad o cáncer.
Es la responsabilidad del dueño del equipo y instalación el
comprobar la calidad de aire en el lugar donde se está usando
el equipo para garantizar que la calidad del aire en el lugar
de trabajo cumpla con todas las normas y reglamentos locales
y nacionales.
El nivel de la calidad del aire en cualquier lugar de trabajo
relevante depende en variables específicas al sitio tales como:
• Diseño de mesa (mojada, seca, bajo agua).
• La composición del material, el acabado de la superficie,
y la composición de los recubrimientos.
• Volumen que se quita del material.
HUMOS TÓXICOS PUEDEN CAUSAR LESIONES O MUERTE
• La duración del corte o ranura.
• Tamaño, volumen del aire, ventilación y filtración del lugar
de trabajo.
• Equipo de protección personal.
• Número de sistemas de soldar y cortar en la operación.
• Otros procesos del lugar que pueden producir humo.
Si el lugar de trabajo debe cumplir reglamentos nacionales
o locales, solamente el monitoreo o las pruebas que se hacen
en el lugar pueden determinar si el sitio está encima o debajo
de los niveles permitidos.
Para reducir el riesgo de exposición a humo:
• Quite todos los recubrimientos y solventes del metal antes
de cortar.
• Use ventilación extractora local para quitar humo del aire.
• No inhale el humo. Use un respirador con fuente propia
de aire cuando corte cualquier metal recubierto con,
o sospechado de contener, elementos tóxicos.
• Garantice que aquéllos usando equipo de soldar o cortar,
al igual que aparatos de respiración con aire propio de aire,
estén capacitados y entrenados en el uso apropiado de
tal equipo.
• Nunca corte recipientes con materiales potencialmente
tóxicos adentro. Primero, vacíe y limpie el recipiente
adecuadamente.
• Monitoree o compruebe la calidad del aire en el sitio como
fuera necesario.
• Consulte con un experto local para realizar un plan al sitio
para garantizar la calidad de aire seguro.
11/08
Antorchas de encendido instantáneo
El arco de plasma se enciende inmediatamente después de
activarse el interruptor de la antorcha.
EL ARCO DE PLASMA PUEDE CAUSAR LESIONES Y QUEMADURAS
El arco de plasma puede cortar a través de guantes y de la
piel con rapidez.
• Manténgase alejado de la punta de la antorcha.
• No sostenga el metal junto al trayecto de corte.
• Nunca apunte la antorcha hacia Ud. mismo o hacia otras
personas.
SEGURIDAD
Hypertherm 1b-5
Protección para los ojos Los rayos del arco de plasma producen rayos intensos visibles e invisibles (ultravioleta e infrarrojo)
que pueden quemar los ojos y la piel.
• Utilice protección para los ojos de conformidad con los códigos locales o nacionales aplicables.
• Colóquese protectores para los ojos (gafas o anteojos protectores con protectores laterales, y bien un casco de soldar) con
lentes con sombreado adecuado para proteger sus ojos de los rayos ultravioleta e infrarrojos del arco.
Protección para la piel Vista ropa de protección para proteger la piel contra quemaduras causadas por la radiación ultravioleta
de alta intensidad, por las chispas y por el metal caliente:
• Guantes largos, zapatos de seguridad y gorro.
• Roipa de combustión retardada y que cubra todas las partes expuestas.
• Pantalones sin dobladillos para impedir que recojan chispas y escorias.
• Retire todo material combustible de los bolsillos, como encendedores a butano e inclusive cerillas, antes de comenzar a cortar.
Área de corte Prepare el área de corte para reducir la reflexión y la transmisión de la luz ultravioleta:
• Pinte las paredes y demás superficies con colores oscuros para reducir la reflexión.
• Utilice pantallas o barreras protectoras para proteger a los demás de los destellos.
• Advierta a los demás que no debe mirarse el arco. Utilice carteles o letreros.
LOS RAYOS DEL ARCO PUEDEN PRODUCIR QUEMADURAS
EN LOS OJOS Y EN LA PIEL
Corriente de arco
(amps.)
El número de matiz
protector mínimo
(ANSI Z49.1:2005)
El número de matiz
sugerido para
comodidad
(ANSI Z49.1:2005)
OSHA 29CFR
1910.133(a)(5)
Europa
EN168:2002
Menos de 40 A 5 5 8 9
41 a 60 A 6 6 8 9
61 a 80 A 8 8 8 9
81 a 125 A 8 9 8
9
126 a 150 A 8 9 8 10
151 a 175 A 8 9
8
11
176 a 250 A 8 9 8 12
251 a 300 A 8 9 8 13
301 a 400 A 9 12 9 13
401 a 800 A 10 14 10
11/08
SEGURIDAD
1b-6 Hypertherm
• Nunca lubrique reguladores o válvulas de cilindros con
aceite o grasa.
• Utilice solamente cilindros, reguladores, mangueras
y conectores de gas correctos que hayan sido diseñados
para la aplicación específica.
• Mantenga todo el equipo de gas comprimido y las piezas
relacionadas en buen estado.
• Coloque etiquetas y códigos de color en todas las
mangueras de gas para identificar el tipo de gas que
conduce cada una. Consulte los códigos locales
o nacionales aplicables.
LOS CILINDROS DE GAS
PUEDEN EXPLOTAR SI ESTÁN
DAÑADOS
SEGURIDAD DE LOS EQUIPOS DE GAS
COMPRIMIDO
Los cilindros de gas contienen gas bajo alta presión.
Un cilindro dañado puede explotar.
• Manipule y utilice los cilindros de gas comprimido de
acuerdo con los códigos locales o nacionales aplicables.
• No use nunca un cilindro que no esté de pie y bien sujeto.
• Mantenga la tapa de protección en su lugar encima de la
válvula, excepto cuando el cilindro se encuentre en uso
o conectado para ser utilizado.
• No permita nunca el contacto eléctrico entre el arco de
plasma y un cilindro.
• No exponga nunca los cilindros a calor excesivo, chispas,
escorias o llamas.
• No emplee nunca martillos, llaves u otro tipo de
herramientas para abrir de golpe la válvula del cilindro.
Cable de trabajo La pinza del cable de trabajo debe estar
bien sujetada a la pieza y hacer un buen contacto de metal
a metal con ella o bien con la mesa de trabajo. No conecte
el cable con la parte que va a quedar separada por el corte.
Mesa de trabajo Conecte la mesa de trabajo a una buena
toma de tierra, de conformidad con los códigos eléctricos
nacionales o locales apropiados.
Potencia primaria de entrada
• Asegúrese de que el alambre de toma a tierra del cordón
de alimentación está conectado al terminal de tierra en la
caja del interruptor de corriente.
• Si la instalación del sistema de plasma supone la conexión
del cordón de alimentación primaria a la fuente de energía,
asegúrese de conectar correctamente el alambre de toma
a tierra del cordón de alimentación primaria.
• Coloque en primer lugar el alambre de toma a tierra del
cordón de alimentación primaria en el espárrago luego
coloque cualquier otro alambre de tierra sobre el conductor
de tierra del cable. Ajuste firmemente la tuerca de retención.
• Asegúrese de que todas las conexiones eléctricas están
firmemente realizadas para evitar sobrecalentamientos.
SEGURIDAD DE TOMA A TIERRA
11/08
SEGURIDAD
Hypertherm 1b-7
Se puede hacer daño a los tubos congelados, o se los puede
reventar, si uno trata de descongelarlos con una antorcha por
plasma.
EL RUIDO PUEDE DETERIORAR
LA AUDICIÓN
UN ARCO PLASMA
PUEDE DAÑAR TUBOS
CONGELADOS
Los campos magnéticos producidos por las elevadas corrientes
pueden afectar la operación de marcapasos y de audífonos.
Las personas que lleven marcapasos y audífonos deberán
consultar a un médico antes de acercarse a sitios donde se
realizan operaciones de corte y ranurado por plasma.
Para reducir los peligros de los campos magnéticos:
• Mantenga el cable de trabajo y la manguera de la antorcha
a un lado, lejos del cuerpo.
• Dirija la manguera antorcha lo más cerca posible del cable
de trabajo.
• No envuelva el cable de trabajo ni la manguera de la
antorcha en su cuerpo.
• Manténgase tan lejos de la fuente de energía como
sea posible.
OPERACIÓN DE MARCAPASOS
Y DE AUDÍFONOS
La exposición prolongada al ruido propio de las operaciones
de corte y ranurado puede dañar la audición.
• Utilice un método de protección de los oídos aprobado
al utilizar el sistema de plasma.
• Advierta a las demás personas que se encuentren en las
cercanías acerca del peligro que supone el ruido excesivo.
11/08
SEGURIDAD
1b-8 Hypertherm
SÍMBOLOS Y MARCAS
Su producto de Hypertherm puede tener una o más de las marcas que siguen en, o cerca de la placa de datos. Debido
a diferencias y conflictos en reglamentos nacionales, no todas las marcas se aplican a toda versión del producto.
Símbolo de marca S
El símbolo de marca S indica que la fuente de energía y antorcha son aptas para operaciones que se llevan
a cabo en entornos con peligro aumentado de choque o descarga eléctrica según IEC 60974-1.
Marca CSA
Los productos de Hypertherm con la marca CSA cumplen con los reglamentos de Estados Unidos y Canadá
para la seguridad del producto. Estos productos fueron evaluados, comprobados, y certificados por
CSA-Internacional. Alternativamente, el producto puede tener la marca según uno de los otros Laboratorios de
Prueba Reconocidos nacionalmente (NRTL siglas en inglés) acreditados en ambos Estados Unidos y Canadá,
tales como Underwriters Laboratories, Incorporated (UL) ó TÜV.
Marcas CE
Las marcas CE significan una declaración del fabricante de conformidad a las directivas y estándares
aplicables Europeos. Sólo aquellas versiones del producto Hypertherm con la marca CE ubicada en o cerca
de la placa de datos han sido comprobadas para cumplir con la Directiva Europea de Voltaje Bajo, la
Compatibilidad Electromagnético Europea (EMC). Los filtros EMC que necesitan cumplir con la Directiva
Europea EMC están incorporados dentro de las versiones del producto con la marca CE.
Marca GOST-R
Las versiones de los productos Hypertherm CE que incluye la marca de conformidad GOST-R cumplen con
la seguridad del productos y los requisitos EMC para exportarse a la Federación Rusa.
Marca c-Tick
Las versiones CE de los productos Hypertherm con la marca c-Tick cumple con los reglamentos EMC
requeridos para venta en Australia y Nueva Zelandia.
Marca CCC
La marca de Certificación Obligatoria China (CCC en inglés) indica que el producto ha sido comprobado y se
lo ha encontrado que cumple con los reglamentos de seguridad del producto requeridos para venta en China.
11/08
SEGURIDAD
Hypertherm 1b-9
ETIQUETA DE ADVERTENCIA
Esta etiqueta de advertencia se encuentra adherida a la fuente de energía. Es importante
que el operador y el técnico de mantenimiento comprendan el sentido de estos símbolos
de advertencia según se describen.
Read and follow these instructions, employer safety
practices, and material safety data sheets. Refer to
ANS Z49.1, “Safety in Welding, Cutting and Allied
Processes” from American Welding Society
(http://www.aws.org) and OSHA Safety and Health
Standards, 29 CFR 1910 (http://www.osha.gov).
WARNING
Plasma cutting can be injurious to operator and persons
in the work area. Consult manual before operating. Failure
to follow all these safety instructions can result in death.
1. Cutting sparks can cause explosion or fire.
1.1 Do not cut near flammables.
1.2 Have a fire extinguisher nearby and ready to use.
1.3 Do not use a drum or other closed container as a cutting table.
2. Plasma arc can injure and burn; point the nozzle away
from yourself. Arc starts instantly when triggered.
2.1 Turn off power before disassembling torch.
2.2 Do not grip the workpiece near the cutting path.
2.3 Wear complete body protection.
3. Hazardous voltage. Risk of electric shock or burn.
3.1 Wear insulating gloves. Replace gloves when wet or damaged.
3.2 Protect from shock by insulating yourself from work and ground.
3.3 Disconnect power before servicing. Do not touch live parts.
4. Plasma fumes can be hazardous.
4.1 Do not inhale fumes.
4.2 Use forced ventilation or local exhaust to remove the fumes.
4.3 Do not operate in closed spaces. Remove fumes with ventilation.
5. Arc rays can burn eyes and injure skin.
5.1 Wear correct and appropriate protective equipment to protect
head, eyes, ears, hands, and body. Button shirt collar. Protect ears
from noise. Use welding helmet with the correct shade of filter.
6. Become trained.
equipment. Use torches specified in the manual. Keep non-qualified
personnel and children away.
7. Do not remove, destroy, or cover this label.
Replace if it is missing, damaged, or worn (PN 110584 Rev C).
Only qualified personnel should operate this
AVERTISSEMENT
Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se
trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le
non respect des ces instructions de sécurité peut entraîner la mort.
1. Les étincelles de coupage peuvent provoquer une explosion
ou un incendie.
1.1 Ne pas couper près des matières inflammables.
1.2 Un extincteur doit être à proximité et prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.
2. L’arc plasma peut blesser et brûler; éloigner la buse de soi.
Il s’allume instantanément quand on l’amorce;
2.1 Couper l’alimentation avant de démonter la torche.
2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.
2.3 Se protéger entièrement le corps.
3. Tension dangereuse. Risque de choc électrique ou de brûlure.
3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou
endommagés.
3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.
3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.
4. Les fumées plasma peuvent être dangereuses.
4.1 Ne pas inhaler les fumées
4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.
4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.
5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.
5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les
oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles
contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance appropriée.
6. Suivre une formation. Seul le personnel qualifié a le droit de faire
fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le
manual. Le personnel non qualifié et les enfants doivent se tenir à l’écart.
7. Ne pas enlever, détruire ni couvrir cette étiquette.
La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C).
11/08
SEGURIDAD
1b-10 Hypertherm
ETIQUETA DE ADVERTENCIA
Esta etiqueta de advertencia se encuentra adherida a la fuente de energía.
Es importante que el operador y el técnico de mantenimiento comprendan
el sentido de estos símbolos de advertencia según se describen. El texto
numerado corresponde a los cuadros numerados de la etiqueta.
1. Las chispas producidas por el corte pueden
causar explosiones o incendios.
1.1 Mantenga los materiales inflamables lejos
del lugar de corte.
1.2 Tenga a mano un extinguidor de incendios
y asegúrese de que alguien esté preparado
para utilizarlo.
1.3 No corte depósitos cerrados.
2. El arco de plasma puede causar quemaduras
y lesiones.
2.1 Apague la fuente de energía antes de
desarmar la antorcha.
2.2 No sostenga el material junto al trayecto
de corte.
2.3 Proteja su cuerpo completamente.
3. Los electrochoques provocados por
la antorcha o el cableado pueden ser fatales.
Protéjase del electrochoque.
3.1 Colóquese guantes aislantes. No utilice
guantes dañados o mojados.
3.2 Aíslese de la pieza de trabajo y de la tierra.
3.3 Antes de trabajar en una máquina,
desconecte el enchufe de entrada
o la potencia primaria.
4. La inhalación de los humos provenientes del
área de corte puede ser nociva para la salud.
4.1 Mantenga la cabeza fuera de los gases
tóxicos.
4.2 Utilice ventilación forzada o un sistema local
de escape para eliminar los humos.
4.3 Utilice un ventilador para eliminar los humos.
5. Los rayos del arco pueden producir
quemaduras en los ojos y en la piel.
5.1 Utilice un sombrero y gafas de seguridad.
Utilice protección para los oídos y abróchese
el botón del cuello de la camisa. Utilice un
casco de soldar con el filtro de sombreado
adecuado. Proteja su cuerpo completamente.
6. Antes de trabajar en la máquina
o de proceder a cortar, capacítese y lea las
instrucciones completamente.
7. No retire las etiquetas de advertencia ni las
cubra con pintura.
SEGURIDAD
Hypertherm 1b-11
11/08
Información sobre la colección de polvo seco
En algunos sitios, el polvo seco puede representar un peligro potencial de explosión.
La edición del 2007 de “U.S. National Fire Protection Association” iniciales en inglés NFPA (La Asociación Americana
Nacional de Protección Contra Incendios) del estándar 68 “Protección de Explosión por medio de Respiradero de
Deflagración” proporciona requisitos para el diseño, ubicación, instalación, mantenimiento, y uso de aparatos y sistemas
para dar salida a gases de combustión y presiones después de todo evento de deflagración. Consulte con el fabricante
o instalador de cualquier sistema de colección de polvo seco para los requisitos aplicables antes de que instale un
sistema nuevo de colección de polvo seco, o haga cambios significativos en el proceso o materiales que se usen con
un sistema existente de colección de polvo seco.
Consulte su “Autoridad que Tenga Jurisdicción” (iniciales en inglés AHJ) local para determinar si cualquier edición
de la NFPA 68 ha sido “adoptada por referencia” en los códigos de construcción locales.
Remítase a la NFPA 68 para definiciones y explicaciones de los términos reguladores como “deflagración, AHJ,
adoptada por referencia, el valor Kst, índice de deflagración” y otros términos.
Nota 1 – La interpretación de Hypertherm de estos nuevos requisitos es que, a no ser que se haya completado una
evaluación específica del sitio para determinar que todo polvo generado no es combustible, la edición del 2007 de
la NFPA 68 requiere el uso de respiraderos de explosión diseñados para el peor caso del valor Kst (vea anexo F) que
pudiera ser generado por el polvo, de manera que el tamaño y tipo del respiradero de explosión pueda diseñarse.
La NFPA 68 no identifica específicamente corte por plasma u otros procesos de cortes termales como si requirieran
sistemas de respiraderos de deflagración, pero en realidad aplica estos nuevos requisitos a todos los sistemas de
colección de polvos secos.
Nota 2 – Los usuarios de los manuales de Hypertherm deberían consultar y cumplir con todas las leyes y reglamentos
federales, estatales y locales aplicables. Hypertherm, al publicar todo manual de Hypertherm, no intenta urgir acción
que no esté en cumplimiento con todos los reglamentos y normas, y este manual nunca debe interpretarse como si lo
hiciera así.
11
CommandTHC for X-Y Table Instruction Manual 2-1
Section 2
SPECIFICATIONS
In this section:
General .........................................................................................................................................................................................................2-3
Specifications..............................................................................................................................................................................................2-4
THC control module........................................................................................................................................................................2-4
Plasma interface assembly ............................................................................................................................................................2-5
X-Y lifter assembly............................................................................................................................................................................2-6
Operator pendant.............................................................................................................................................................................2-7
X-Y lifter breakaway option ............................................................................................................................................................2-8
SPECIFICATIONS
5
2-2 CommandTHC for X-Y Table Instruction Manual
Figure 2-1 X-Y CommandTHC system
interfaced with plasma cutting system and CNC
X-Y lifter assembly
Plasma
interface assembly
THC
control module
Operator
pendant
SPECIFICATIONS
11
CommandTHC for X-Y Table Instruction Manual 2-3
General
Hypertherm’s X-Y CommandTHC is a torch height control/initial height sensing (THC/IHS) system designed for plasma
cutting applications on a X-Y cutting table (Figure 2-1). The system uses the plasma arc voltage to control the physical
stand-off (distance) between the torch and workpiece during plasma arc cutting. IHS is accomplished by ohmic contact
sensing or by a limited force stall detection method. The system includes the following:
• THC control module (Figure 2-2) The THC control module houses 2 microcontrollers, a realtime controller
and an interface controller. This unit provides initial height sensing, arc voltage control and interfaces with
the torch lifter, the CNC machine, operator pendant and the plasma power supply through standard discrete
I/O interfaces and optional extended RS-422 serial interfaces.
• Plasma interface assembly with voltage divider (Figure 2-3) The plasma interface houses an interface
PCB which provides a communications link between the THC control module and the plasma power supply.
The voltage divider provides a 41 : 1 signal which is derived from the cutting arc voltage. For example, if the arc
voltage is 150 volts, the resultant 3.66-volt output signal is used to control the stand-off distance between the
torch and workpiece during plasma cutting.
Note: HyPerformance (HPR) plasma systems do not have an interface assembly. HPR systems have an
interface board that mounts in the power supply.
• X-Y lifter assembly (Figure 2-4) The torch lifter station, under control of the THC control module, positions a
torch head vertically above the workpiece. Its maximum stroke is 8 inches (200 mm) between the home and
lower limit switches. It is driven by a stepper motor attached to a leadscrew. An encoder is provided for stall
IHS sensing, and to detect gross errors during normal operation. A lower limit switch detects maximum travel
in the downward direction. A home switch is provided to detect when the lifter is in the uppermost position.
A power-off brake is energized after power up, and allows controlled motion of the torch. It is powered off during
“Maintenance Mode” to prevent the torch from being accidentally moved. An optional torch breakaway kit is
also available.
• Operator pendant (optional) (Figure 2-5) The operator pendant is a remote control which includes an
LCD display and keypad used for THC setup and control (parameter entry and menu selection).
• Torch breakaway kit (optional) (Figure 2-6) The torch breakaway (collision sensor) provides a level of
protection for the torch, lifter and X-Y table. Air pressure locks the torch to the THC lifter assembly. The air
pressure can be adjusted to change the force required to trip the breakaway. Upon side impact, the breakaway
releases from the lock position and allows the torch to float. See Figure 2-4 for torch mounting dimensions with
and with out the breakaway.
SPECIFICATIONS
5
2-4 CommandTHC for X-Y Table Instruction Manual
Specifications
THC control module
Electrical
Input power (automatic selecting dual range) ..........115 VAC or 230 VAC, 1 phase,
50/60 Hz
Parallel digital I/O............................................................+ 12 VDC
Serial digital I/O (RS-422) ..........................................+ 5 VDC (operator pendant), CNC
Figure 2-2 THC control module
5.6"
(142 mm)
14"
(355 mm)
(457 mm)
24 lb
(11 kg)
18"
THC.89
SPECIFICATIONS
11
CommandTHC for X-Y Table Instruction Manual 2-5
Figure 2-3 Plasma interface assembly
Plasma interface assembly
Electrical
Input power ......................................................................+ 24 VDC
Parallel digital I/O............................................................+ 12 VDC
Serial digital I/O (RS-422)............................................+ 5 VDC
Voltage divider function............................................41 :1 Arc voltage (isolated)
HT4400 and HPR installation
Note: Instructions to install the plasma interface PCB into the HT4400 power supply are included in
section 3h.
Instructions to install the plasma interface PCB into the HPR power supply are included in
section 3i.
The plasma interface enclosure is not used for the HT4400.
3.1"
(78 mm)
10.7"
(271 mm)
2.2"
(56 mm)
THC.90
4.6 lb
(2 kg)
6.6"
(168 mm)
SPECIFICATIONS
11
2-6 CommandTHC for X-Y Table Instruction Manual
X-Y lifter assembly
Electrical
Motor ..................................................................................+ 2.48 VDC, 2 phase (3.3 amp per phase)
Limit switches....................................................................+ 24 VDC
Lifter control function
Motor ................................................................................Stepper
Motor drive........................................................................Stepper, chopped constant current
Lifter feedback ................................................................Encoder
Lifter limit switches..........................................................Home switch and lower limit switch
Maximum Z axis speed ..................................................200 inches (508 cm) per minute
Maximum Z axis stroke ..................................................8- inches (203 mm)
Figure 2-4 X-Y lifter assembly
Torch mounting dimensions
Without breakaway With breakaway
22.4"
(570 mm)
(71 mm)
2.8"
THC.66a
18 lb
(8.2 kg)
5"
(127 mm)
4.67"
119 mm
5.78"
164 mm
SPECIFICATIONS
5
CommandTHC for X-Y Table Instruction Manual 2-7
Figure 2-5 Operator pendant
Operator pendant
Electrical
Input power ......................................................................+ 12 VDC
Serial digital I/O (RS-422) ..........................................+ 5 VDC
7 oz
(0.2 kg)
4.1"
(104 mm)
1.1"
(28 mm)
THC.69
25'
(7.6 m)
8.25"
(210 mm)
SPECIFICATIONS
5
2-8 CommandTHC for X-Y Table Instruction Manual
Figure 2-6 X-Y lifter breakaway option
X-Y lifter breakaway option
Electrical
Pressure switch ................................................................CNC emergency stop circuit voltage
Breakaway control function
Shop air pressure............................................................100 psi (6.9 bar) maximum
Size
Breakaway width ............................................................3.8 inches (97 mm)
Breakaway height (thickness)........................................2.25 inches (57 mm)
Air filter/regulator height ................................................7.06 inches (179 mm)
Air filter/regulator width ................................................1.56 inches (40 mm)
Air filter/regulator depth (from gauge to back)..........3.125 inches (79 mm)
Weight
Breakaway..........................................................................1.9 pounds (0.86 kg)
Air filter/regulator..............................................................1.0 pounds (0.45 kg)
Pressure switch
Breakaway unit
Air pressure
inlet port
Air filter/regulator
CommandTHC for X-Y Table Instruction Manual 3-1
11
Section 3
SETUP
In this section:
Upon receipt................................................................................................................................................................................................3-2
Standard components ....................................................................................................................................................................3-2
Optional components .....................................................................................................................................................................3-2
Claims ...........................................................................................................................................................................................................3-2
Power requirements...................................................................................................................................................................................3-2
System unit mounting................................................................................................................................................................................3-3
THC control module........................................................................................................................................................................3-3
Plasma interface assembly ............................................................................................................................................................3-4
X-Y lifter assembly............................................................................................................................................................................3-5
Torch mounting block kit.................................................................................................................................................................3-6
Torch breakaway kit (optional) ......................................................................................................................................................3-8
Install the torch (without torch breakaway option).................................................................................................................3-10
Install the torch (with torch breakaway option) ......................................................................................................................3-11
System interconnections........................................................................................................................................................................3-12
THC system cables.......................................................................................................................................................................3-12
Machine interface cable...............................................................................................................................................................3-14
THC selectable responses....................................................................................................................................................................3-16
DIP switch positions .....................................................................................................................................................................3-17
CommandTHC serial protocol..............................................................................................................................................................3-18
Grounding requirements ........................................................................................................................................................................3-20
Power cord grounding .................................................................................................................................................................3-20
Protective earth ground ...............................................................................................................................................................3-20
Lifter I/O Cable.........................................................................................................................................................................................3-21
Plasma interface cable............................................................................................................................................................................3-22
CNC interface cable ...............................................................................................................................................................................3-23
Pendant extension cable........................................................................................................................................................................3-25
Motor drive cable .....................................................................................................................................................................................3-26
HD3070 system interconnections .......................................................................................................................................................3a-1
HT2000 system interconnections........................................................................................................................................................3b-1
HT2000LHF system interconnections................................................................................................................................................3c-1
HT4001 system interconnections........................................................................................................................................................3d-1
MAX100 System interconnections......................................................................................................................................................3e-1
MAX200 System interconnections.......................................................................................................................................................3f-1
POWERMAX system interconnections..............................................................................................................................................3g-1
HT4400 system interconnections........................................................................................................................................................3h-1
HPR system interconnections................................................................................................................................................................3i-1
HSD system interconnections................................................................................................................................................................3j-1
HD4070 system interconnections..................................................................................................................................See IM 803760
SETUP
3-2 CommandTHC for X-Y Table Instruction Manual
5
Upon receipt
The THC system is shipped in two containers: one container holds the units; the other holds the cables. The containers
should include the following standard and optional components, if ordered:
Standard components
• THC control module
• 2 Power cords, 6.5 ft./2 m
• Plasma interface assembly
• X-Y lifter assembly
• Interface cables
– Lifter motor drive cable (9 pin)
– 3 Interface cables (37 pin)
– Ohmic contact wire
– Power supply interface cable (for Hypertherm power supplies only)
• Command X-Y THC system instruction manual
Optional components
• Operator pendant with 25 ft. (7.5 m) cable
• Pendant extension cable (9 pin)
• Torch mounting block kit
• Torch breakaway kit
Claims
Claims for damage during shipment — If your unit was damaged during shipment, you must file a claim with the
carrier. Hypertherm will furnish you with a copy of the bill of lading upon request. If you need additional assistance, call
Customer Service listed in the front of this manual, or your authorized Hypertherm distributor.
Claims for defective or missing merchandise — If any of the merchandise is defective or missing, call your
authorized Hypertherm distributor. If you need additional assistance, call Customer Service listed in the front of this
manual.
Power requirements
See THC control module in Section 2.
SETUP
CommandTHC for X-Y Table Instruction Manual 3-3
5
System unit mounting
Before interconnecting the THC system, mount the units as required, using customer-supplied hardware. Do not allow
the units to lie unsecured on top of cabinets or on the floor. Refer to Section 2, Specifications, for unit dimensions.
THC control module
• Mount the THC control module close to the CNC controller for easy access to the THC system power and to
provide easy access for routing and connecting cables. The unit can be mounted in any position except with the
power module (AC receptacle and switch) facing up. Four mounting holes, requiring 1/4-inch (6 mm) fasteners,
are provided. See Figure 3-1.
Figure 3-1 THC control module mounting
17.25 in.
(438 mm)
12 in.
(305 mm)
THC.70
SETUP
3-4 CommandTHC for X-Y Table Instruction Manual
9
Plasma interface assembly
Figure 3-2 Plasma interface assembly mounting
HT4400 and HPR installation
Note: Instructions to install the plasma interface PCB into the HT4400 power supply are included in
section 3h.
Instructions to install the plasma interface PCB into the HPR power supply are included in section
3i.
The plasma interface enclosure is not used for the HT4400.
• Mount the plasma interface assembly close to the plasma power supply for easy connection of control and
process signal wires between the units. The unit can be mounted in any position. The mounting holes require
#8 (4 mm) fasteners. See Figure 3-2.
1.25"
(32 mm)
4.6"
(117 mm)
7.0"
(178 mm)
0.25"
(6 mm)
THC.99
9.5"
(241 mm)
SETUP
CommandTHC for X-Y Table Instruction Manual 3-5
11
X-Y lifter assembly
• Mount the X-Y lifter assembly on the cutting table. See Figure 3-3.
Figure 3-3 X-Y lifter assembly mounting
1/4" (6 mm)
22.4"
(570 mm)
3.5"
(89 mm)
1.26"
(32 mm)
3.5"
(89 mm)
3.5"
(89 mm)
2.875"
(73 mm)
1.41"
(36 mm)
4.5"
(114 mm)
(127 mm)
5.0"
2.12"
(54 mm)
1.75"
(44.5 mm)
1.42"
(36 mm)
1/4-20
(203 mm)
8.0"
2.8"
(71 mm)
3.25"
(82.6 mm)
THC.68
SETUP
3-6 CommandTHC for X-Y Table Instruction Manual
7
Torch mounting block kit
• Mount the torch mounting block kit to the X-Y lifter assembly. See Figure 3-4. Refer to Section 6, Parts List for a
complete list of available kits and kit parts breakdowns.
Figure 3-4 X-Y lifter assembly torch mounting block
Spacer
Hex screws (4)
Hex screws (2)
Block
SETUP
CommandTHC for X-Y Table Instruction Manual 3-7
5
Blank
SETUP
3-8 CommandTHC for X-Y Table Instruction Manual
5
Torch breakaway kit (optional)
Install the torch breakaway kit as follows. Refer to Figure 3-5.
1. Mount the fiberglass bracket to the X-Y lifter using the 4 hex screws.
2. Mount the breakaway to fiberglass bracket using the 6 screws.
3. Attach the torch mounting block to the breakaway with the collar and 2 screws.
4. Wire the electrical output of the breakaway to the emergency stop circuit at CNC.
5. Mount the filter/regulator.
6. Connect tubing between regulator and breakaway.
7. Install air supply to the regulator inlet port at 100 psi (6.9 bar) (recommended maximum pressure).
8. Adjust the regulator to indicate 30 psi (2 bar) (recommended starting pressure) on the gauge.
9. By hand, force the breakaway to trip to simulate a crash.
Manually reposition breakaway to the lock position.
10. Adjust air pressure until the desired trip force is achieved.
11. Enable the emergency stop circuit at CNC after the breakaway is installed.
Notes:
• Installing the torch breakaway kit to the X-Y lifter assembly also requires using parts of the torch mounting block kit
of the proper diameter. Refer to Section 6, Part List for details.
• The maximum pressure regulator inlet pressure is 150 psi (10.2 bar). Typically, the maximum inlet pressure should
be set at 100 psi (6.9 bar).
• The routing of the leads, stall force, IHS speed, and acceleration/deceleration movements can affect the pressure
setting required to achieve reliable operation.
• If air pressure is removed (for example, overnight), the breakaway will have to be manually repositioned when air is
applied. The breakaway will not rest in its position when air pressure is lost.
10
SETUP
CommandTHC for X-Y Table Instruction Manual 3-9
9
Figure 3-5 X-Y lifter assembly optional torch breakaway kit mounting details
Fiberglass bracket
Breakaway
X-Y Lifter
Hex screws (4)
Hex screws (2)
Wire to emergency stop
circuit
Tubing
6 screws
Collar
Collar
Block
Brown = 4
1-5/16 inch
(33.34 mm)
Filter/regulator
Breakaway
Breakaway
pressure switch,
Normally Open
Moisture drain
Inlet port
1/4 in. NPTF
100 psi (6.9 bar)
Customer supplied
hex screws (2)
8-32 X 1-1/2 inch
or 4 mm x 40 mm
Blue = 3
(Not connected)
Black = 1
Tube connector
Spacer and 4 hex screws not
used if breakaway is installed.
10
1
1
2
3
3
6
4
5
5
7
8
8
3
2
Pressure gauge
Pin 4
Pin 3
Pin 1
SETUP
3-10 CommandTHC for X-Y Table Instruction Manual
7
Install the torch (without torch breakaway option)
Mount the torch to the lifter with the mounting block and 2 screws. See Figure 3-6.
Install the shield to the mounting block with 4 screws.
Figure 3-6 Torch installed without torch breakaway option
1
2
SETUP
CommandTHC for X-Y Table Instruction Manual 3-11
7
Install the torch (with torch breakaway option)
Install the shield to the mounting block with 4 screws. See Figure 3-7.
Mount the torch to the lifter with the mounting block and 2 screws.
Figure 3-7 Torch installed with torch breakaway option
1
2
SETUP
3-12 CommandTHC for X-Y Table Instruction Manual
9
System interconnections
Cable part numbers and signal lists are provided in figures 3-14 through 3-18.
THC system cables
HT4400 and HPR installation
Note: Instructions to install the plasma interface PCB into the HT4400 power supply are
included in section 3h.
Instructions to install the plasma interface PCB into the HPR power supply are
included in section 3i.
The plasma interface enclosure is not used for the HT4400.
Caution: Do not run the pendant cable in parallel and near to the torch lead.
There is a possibility that electrical noise will cause erratic
operation of the operator pendant or damage it.
Install system cables as shown in Figure 3-8.
SETUP
CommandTHC for X-Y Table Instruction Manual 3-13
11
Figure 3-8 X-Y THC system diagram
X-Y Lifter Assembly
THC Control Module
Plasma Interface
Assembly
Optional Operator Pendant:
shown with optional extension cable
Lifter I/O
interface cable
Motor drive
cable
IHS ohmic
contact wire
Plasma
interface cable
HT4400:
See NOTE
on page 3-12
Electrode and work leads
Power supply
interface cable
Machine interface
cable
Power Supply
SETUP
3-14 CommandTHC for X-Y Table Instruction Manual
6
Machine interface cable
1. Cable-installed signal – See Figure 3-9.
The machine interface cable provides a signal to verify that the cable is installed properly. Continuity must be
provided through pins 3 and 22 so that the signal is not interrupted.
Install a jumper wire in the CNC to provide continuity between pins 3 and 22 when the machine interface cable is
installed to the CNC receptacle.
2. Emergency stop signal – See Figure 3-10.
The machine interface cable provides a signal for emergency stop. Continuity must be provided through pins 16 and
35 so that the signal is not interrupted.
Install a normally closed switch in the CNC to provide continuity between pins 16 and 35 when the machine
interface cable is installed to the CNC receptacle.
Figure 3-9 CNC cable-installed signal
Machine interface cable
CNC receptacle
Jumper wire,
customer supplied
16
17
18
35
3637
19
3
2
1
THC.85
Figure 3-10 CNC emergency stop signal
Machine interface cable
CNC receptacle
Stop switch,
customer supplied
CNC
CNC
To THC
control module
1
2
1
3
2
1
2
20
2122
THC.86
3
3
1
2
3
SETUP
CommandTHC for X-Y Table Instruction Manual 3-15
11
2
1
THC.87
1
3. Install the machine interface cable as shown in Figure 3-11.
Figure 3-11 Machine interface cable
Figure 3-12 Machine interface cable grounding
4. If installation requires removal of a cable connector, all
wires must be properly terminated, including shield, or
system problems may occur. See Figure 3-12.
Machine interface cable
Not used
CNC
THC
Control
Module
1
2
SETUP
3-16 CommandTHC for X-Y Table Instruction Manual
10
THC selectable responses
The DIP switch, on the motor drive board, provides adjustable arc voltage control response.
DIP switch
Remove the THC control module cover to access the
DIP switch on the motor drive board.
Note: The DIP switch positions are set to ON (default settings) at Hypertherm.
DANGER
ELECTRIC SHOCK CAN KILL
Turn off all electrical power before removing the power supply cover. Press the power
supply OFF (0) pushbutton switch and set the line disconnect switch to OFF. In the
U.S., use a “lock-out and tag-out” procedure until the service or maintenance is
complete. In other countries, follow appropriate local or national safety procedures.
1 2 3 4
SETUP
CommandTHC for X-Y Table Instruction Manual 3-17
11
*DIP Switch Settings
12 34
Plasma Fast/Slow Conv/HyDef Limited Down HPR
Systems Response Resolution Speed pierce
complete
HD3070 OFF OFF OFF OFF
HT2000 OFF ON ON OFF
HT2000LHF OFF ON ON OFF
MAX100 ON ON ON OFF
MAX200 OFF ON ON OFF
HT4001 ON ON ON OFF
HT4400 ON ON ON OFF
HD4070 ON OFF OFF OFF
Powermax ON ON ON OFF
HPR/HSD ON ON ON ON
DIP switch positions
1 Fast/Slow response
• ON slows response speed of lifter by approximately one half in both up and down directions.
• OFF enables "normal" or fast response.
2 Conventional/HyDefinition resolution
• ON enables the THC to respond to larger voltage error changes.
• OFF enables the THC to respond to smaller error voltage changes.
3 Limited down speed
• ON enables lifter to move up at the normal speed, but down at slower speed. This is designed to help where
corner diving is a problem.
• OFF enables the lifter to move up and down at the "normal" speed.
4 HPR pierce complete
* These are recommended switch settings. Since cutting machine installations vary, these switches can be
adjusted in any combination to achieve desired results.
As shipped
DIP switch ON/OFF positions
OFF
SETUP
3-18 CommandTHC for X-Y Table Instruction Manual
11
CommandTHC serial protocol
Commands can be sent over a serial link to control the function of the torch height control. The interface is 4 wire
RS422 on the MACHINE INTERFACE CABLE (pins (1) RX–, (20) RX+, (2) TX–, (21) TX+).
The serial frame runs at:
Old protocol (041507 control PCB) – 9600 baud, 8 data bits, 2 stop bits, and even parity
New protocol (041706 control PCB) – 19200 baud, 8 data bits, 1 stop bit, and no parity
All bytes in a serial message are ASCII characters. A message consists of a start of message character (>, 0x3E),
2 byte message ID (all message ID’s should be capitalized), variable length data, 2 byte checksum, and end of message
character (<, 0x3C). For example to put the THC into remote mode >RM1D0<. ‘RM’ is the message ID, ‘1’ is the data
field, and 0xD0 is the checksum (2 hex digits sent as 2 ASCII characters). The response to an accepted command is
(^, 0x5E) and the response to an invalid command is (#, 0x23).
Some of the commands can be queried by using (?, 0x3F) as the data. For example to query the actual arc voltage
>AV?D6<. The response to this query would be >AV100058<, which represents an actual arc voltage of 100.0 volts
with a checksum of 0x58.
Errors can be retrieved over the serial link. There is a discrete output on the machine interface cable (THC Error pins
14,33) which indicates an error has occurred. Using the command >CL8F< errors can be cleared and retrieved.
A typical response might be >ERR-Motor Current Fault46< or if there is no error (^, 0x5E) is returned.
Command listing:
Command ID Data Query Notes
Pierce Delay PD 0 – 9000 (0 to 9.000 seconds) yes Delay before motion output
Pierce Height Factor PH 50 – 300 (50% to 300%) yes Used to set pierce height
Preflow During IHS PF 0,1 (0 = off, 1 = on) yes Improves cycle time
IHS Stall Current SC 1 – 10 (1 = least force) yes Used to set stall force
IHS Speed IV 1 – 10 (1= slowest) yes Used to set IHS speed
IHS Test IH 0,1 (0 = run, 1 = test) no Perform IHS test
Nozzle Contact Active NC 0,1 (0 = off, 1 = on) yes Enable nozzle contact IHS
Machine Acceleration MA 0 – 9000 (0 to 9.000 seconds) yes Delay voltage control
Maintenance Mode MT No data no Maintenance mode
Auto Kerf AK 0,1 (0 = off, 1 = on) yes Disable voltage control in kerf
Actual Arc Voltage AV ? (query only) yes Returned value is 1/10 volts
Automatic Voltage Control AA 0,1 (0 = manual, 1 = auto) yes Voltage control or manual
Retract RE 0,1 (0 = full, 1 = partial) yes Full or partial retract
Retract Distance RH 0 – 8000 (0 to 8.000 inches) yes Must be in partial retract
Remote Mode RM 0,1 (0 = off, 1 = on) yes Must be ON to use serial link
IO Rev RI ? (query only) yes IO revision
RT Rev RR ? (query only) yes Real Time revision
Homing Speed HS 1 – 10 (1 = slowest) yes Home speed
Unit Conversion UN 0,1 (0 = inches, 1 = metric) yes Units
Lifter Test LT No data no Perform lifter test
Cut Height CH 0 – 1000 (0 to 1.000 inches) yes Used to set cut height
Arc Voltage Setpoint VS 500 – 3000 (50.0 to 300.0 volts) yes Used to set voltage control
Step Up S+ No data no Move up fixed increment
Step Down S– No data no Move down fixed increment
Jog Up J+ No data no Continuous movement up
Jog Down J– No data no Continuous movement down
Clear Error CL No data no Clear error, send error string
Flush Buffers FL No data no Reset RX and TX buffers
Error code EC ? (query only) yes Send error code number
SETUP
CommandTHC for X-Y Table Instruction Manual 3-19
6
Application notes:
1. To do manual movements Jog up, down and Step up, down the THC must be in manual mode (Automatic Voltage
Control = 0).
2. When the THC receives a Jog up or down command, it will move the torch up/down for 50 milliseconds. If a new
command is not received after this time the motion will stop. To achieve continuous movement the Jog command
must be repeatedly sent faster than once every 50 milliseconds.
3. The Error code command will ONLY retrieve an error code, it will not clear an error. To clear an error the CL (Clear
error command must be sent).
4. The revision commands (RR and RI) return the decimal representations of the revisions that are stored (as ASCII
characters) in the firmware.
5. Setting the Retract distance (RH) only applies when the THC is in partial retract (Retract = 1).
6. To force the lifter station to go home send the following series of commands : RE1, RE0 (partial retract, then full
retract this will force a homing sequence).
Error codes:
Code Error string
0
“
ERR-Torch is in LOWER LIMIT”
1
“
ERR-Torch is in HOME LIMIT”
2
“
ERR-EEPROM checksum Error”
3
“
ERR-Lifter NOT Installed”
4
“
ERR-Motion FAIL”
5
“
ERR-Watch Dog Timeout FAIL”
6
“
ERR-InterProcessor Comm Fail”
7
“
ERR-Nozzle Contact at Home”
8
“
ERR-Cycle Start ON at INIT”
9
“
ERR-Motor Current Fault”
10
“
ERR-Machine Cable Missing”
11
“
ERR-Plasma Cable Missing”
12
“
ERR-Robotic Limit FAIL”
13
“
ERR-DIAG FAIL REPOWER THC”
14
“
ERR-IOP CHECKSUM FAIL”
15
“
ERR-RTP CHECKSUM FAIL”
16
“
ERR-NO ERROR”
SETUP
3-20 CommandTHC for X-Y Table Instruction Manual
7
Grounding requirements
To ensure personal safety and proper operation, and to reduce electromagnetic interference (EMI), the THC system
must be properly grounded.
Power cord grounding
The THC control module must be properly grounded through the power cord according to national or local electrical
codes.
Protective earth ground
• Install protective earth (PE) grounding cables to the 3 THC components as shown in Figure 3-13. Grounding
must comply with national or local electrical requirements.
• The PE cables must be supplied by the customer.
Figure 3-13 THC component PE grounding
THC control module
Plasma interface
assembly *
* HT4400: See note on page 3-12.
Pin Pin
number Color Signal name Function number
1 Input Black Encoder Power – Encoder power 1 Output
20 Red Encoder Power (5V)+ 20
2 Input Black Encoder B – A quad B position signal. 2 Output
21 Green Encoder B + 21
3 Input Black Encoder A – A quad B position signal. 3 Output
22 Blue Encoder A + 22
5 Input Black Drive ID2 – Lifter ID Most Significant Bit (Binary 3) 5 Output
24 Brown Drive ID2 + 24
6 Input Black Drive ID1 – Lifter ID (Binary 2) 6 Output
25 Orange Drive ID1 + 25
7 Input Red Drive ID0 – Lifter ID Least Significant Bit (Binary 1)
– Lifter jumper connection ID Code
7 Output
26 White Drive ID0 + 26
8 Output Red Lifter Up – Active when lifter is moving up. 8 Input
27 Green Lifter Up + 27
9 Input Red Lower Limit Switch Com. Limit switch common. 9 Output
28 Input Blue Lower Limit Switch Signal Logic low between signal and common.
10 Output Red Lower Limit Switch +24V Limit switch power. 10 Input
11 Output Red Home Switch Signal Logic low between signal and common.
29 Output Yellow Home Switch Common Home switch common. 29 Input
30 Output Brown Home Switch +24V Home switch power. 30 Input
16 Output Green Lifter Down – Active when lifter is moving down. 16 Input
35 Brown Lifter Down + 35
17 Output Green Lifter Brake Out – Powers electro-mechanical brake on lifter. 17 Input
36 Orange Lifter Brake Out + 36
4 Input Black Lifter Spare In 5 – Spare 4 Output
23 Yellow Lifter Spare In 5 + 23
12 Output Red Crash Detect – Spare 12 Input
31 Orange Crash Detect + 31
13 Output Green Lifter Spare 3 – Spare 13 Input
32 White Lifter Spare 3 + 32
14 Output Green Reserved Spare 14 Input
33 Blue Reserved 33
15 Output Green Lifter Spare 1 – Spare 15 Input
34 Yellow Lifter Spare 1 + 34
18 White 24 VDC Common Available 24 VDC, 500 mA maximum. 18 Input
37 Black 24 VDC + 37
19 Reserved Not connected 19
SETUP
CommandTHC for X-Y Table Instruction Manual 3-21
11
Part number Length
123209 5 ft./1.5 m
123210 10 ft./3 m
123211 15 ft./4.6 m
123212 20 ft./6.1 m
123022 25 ft./7.6 m
123213 30 ft./9.1 m
123214 35 ft./10.6 m
Part number
Length
123215 40 ft./12.2 m
123216 45 ft./13.7 m
123023 50 ft./15.2 m
123217 75 ft./23 m
123218 100 ft./30.5 m
123219 125 ft./38 m
123220 150 ft./45.6 m
To THC
control
module
To lifter
assembly
Lifter I/O cable
Figure 3-14 Lifter I/O cable – part numbers and signal list
THC.84
SETUP
3-22 CommandTHC for X-Y Table Instruction Manual
11
Part number Length
123209 5 ft./1.5 m
123210 10 ft./3 m
123211 15 ft./4.6 m
123212 20 ft./6.1 m
123022 25 ft./7.6 m
123213 30 ft./9.1 m
123214 35 ft./10.6 m
Part number
Length
123215 40 ft./12.2 m
123216 45 ft./13.7 m
123023 50 ft./15.2 m
123217 75 ft./23 m
123218 100 ft./30.5 m
123219 125 ft./38 m
123220 150 ft./45.6 m
Pin Pin
number Color Signal name Function Signal name number
1 Input Black RX– RS-422 serial inverting receiver. TX– 1 Output
20 Red RX+ RS-422 serial non-inverting receiver. TX+ 20
2 Output Black TX– RS-422 serial inverting transmitter. RX– 2 Input
21 Green TX+ RS-422 serial non-inverting transmitter. RX+ 21
3 Input Black Plasma Cable – Plasma cable recognition used for automatic detection of 3 Output
17 Green Plasma Cable + plasma interface board. 17
7 Input Red Nozzle Contact – Nozzle Contact is active when nozzle or shield is in ohmic 7 Output
26 White Nozzle Contact + contact with the plate. 26
8 Input Red Pilot Arc In – Pilot Arc input verifies that a successful pilot arc has been 8 Output
27 Green Pilot Arc In + established. 27
9 Input Red Transfer In – Transfer In input verifies that a transfer has occurred. 9 Output
28 Blue Transfer In + 28
10 Output Red Nozzle H.V. Relay – Relay active during arc initiation to isolate the THC interface PCB from
10 Input
29 Yellow Nozzle H.V. Relay + high voltage. 29
13 Input Green Pierce Complete – Pierce Complete output verifies that the THC internal pierce 13 Output
32 White Pierce Complete + complete timer has timed out. 32
14 Output Green Hold Ignition – Hold Ignition holds the torch from firing, but allows preflow 14 Input
33 Blue Hold Ignition + gas to flow. 33
15 Output Green Plasma Start – Plasma Start signal is used to initiate the arc. 15 Input
34 Yellow Plasma Start + 34
16 Input Green Arc Volts – Arc Volts is the measured arc voltage between the 16 Output
35 Brown Arc Volts + electrode and work, divided by 41. 35
18 Output White 24 VDC Common Available 24 VDC, 500 mA maximum 18 Input
37 Black 24 VDC + 37
36 Output Orange 24 VDC Common Available 24 VDC, 500 mA maximum 36 Input
4 Input Black Torch 2 Select – Spare 4 Output
23 Yellow Torch 2 Select + 23
5 Input Black Torch 1 Select – Spare 5 Output
24 Brown Torch 1 Select + 24
6 Input Black Spare 1 – Spare 6 Output
25 Orange Spare 1 + 25
11 Output Red Plasma Spare 2 – Spare 11 Input
30 Brown Plasma Spare 2 + 30
12 Output Red Plasma Spare 1 – Spare 12 Input
31 Orange Plasma Spare 1 + 31
19 Not connected 19
22 Blue Not used 22
To THC
control
module
To interface
assembly
Plasma interface cable
Figure 3-15 Plasma interface cable – part numbers and signal list
THC.84
SETUP
CommandTHC for X-Y Table Instruction Manual 3-23
11
Part number Length
123209 5 ft./1.5 m
123210 10 ft./3 m
123211 15 ft./4.6 m
123212 20 ft./6.1 m
123022 25 ft./7.6 m
123213 30 ft./9.1 m
123214 35 ft./10.6 m
Part number
Length
123215 40 ft./12.2 m
123216 45 ft./13.7 m
123023 50 ft./15.2 m
123217 75 ft./23 m
123218 100 ft./30.5 m
123219 125 ft./38 m
123220 150 ft./45.6 m
THC.84
Pin Signal Pin Notes,
number Color Signal name Function name number page 3-24
1 Input Black RX– RS-422 serial inverting receiver. TX– 1 Output
20 Red RX+ RS-422 serial non-inverting receiver. TX+ 20
2 Output Black TX– RS-422 serial inverting transmitter. RX– 2 Input
21 Green TX+ RS-422 serial non-inverting transmitter. RX+ 21
3 Input Black Machine Cable – Machine cable recognition used for verifying installation of 3 Output 3
22 Blue Machine Cable + Machine interface cable to CNC. 22
5 Input Black IHS Sync – IHS Sync holds torch firing, but allows preflow gas to flow. 5 Output 2
24 Brown IHS Sync + 24
8 Input Red Auto Height On/Off – Auto Height On/Off enables or disables Auto Height. 8 Output 2
27 Green Auto Height On/Off + Auto Height is Off when input is active. 27
9 Input Red Cycle Start – Cycle Start (plasma start) initiates start of programmed cycle. 9 Output 2
28 Blue Cycle Start + CNC must provide a contact closure to activate this input. 28
10 Output Red IHS Complete – IHS Complete output to CNC to synchronize multiple torch 10 Input 1
29 Yellow IHS Complete + installations. When all connected torches are in position, 29
IHS Sync In signal is deactivated to proceed with torch ignition.
12 Output Red Retract Complete – Retract Complete output verifies to CNC that the torch has 12 Input 1
31 Orange Retract Complete + retracted and it is safe to move to next start position. 31
13 Output Green Pilot Arc – Pilot Arc output verifies to CNC that a pilot arc has been 13 Input 1
32 White Pilot Arc + established. 32
14 Output Green THC Error – THC Error output alerts CNC that an error has occurred. 14 Input 1
33 Blue THC Error + 33
15 Output Green Machine Motion – Machine Motion output verifies to CNC that a pierce delay 15 Input 1
34 Yellow Machine Motion + has been completed and notifies CNC to start movement of 34
the cutting machine.
16 Input Green Ext. Emergency Interlock– Allows installation of an emergency stop switch (normally 16 Output 4
35 Brown Ext. Emergency Interlock+ closed). 35
18 Output White 24 VDC Common Available 24 VDC, 500 mA maximum 18 Input 1
37 Black 24 VDC + 37
36 Output Orange 24 VDC Common Available 24 VDC, 500 mA maximum 36 Input 1
4 Input Black Spare 3 – Spare 4 Output
23 Yellow Spare 3 + 23
6 Input Black Spare 2 – Spare 6 Output
25 Orange Spare 2 + 25
7 Input Red Spare 1 – Spare 7 Output
26 White Spare 1 + 26
11 Output Red Spare 1 – Spare 11 Input
30 Brown Spare 1 + 30
17 Green Not used 17
19 Not connected 19
*
Minimum connections needed for proper operation of CommandTHC
Figure 3-16 CNC interface cable – part numbers and signal list
*
*
*
*
*
To THC
control
module
To CN C
CNC interface cable
SETUP
3-24 CommandTHC for X-Y Table Instruction Manual
5
Notes to Figure 3-16
Note 1. All THC outputs are optically coupled
transistors with maximum ratings of 24 VDC
and 10 mA.
Note 2. All THC inputs are optically isolated 12 VDC signals.
Signals are made active by sinking 3 mA per input.
Note 3. Jumper required in CNC. See instructions on page 3-14.
Note 4. Stop switch required in CNC. See instructions on page 3-14.
12 VDC
3,3 K
12V Return
Input
+
–
THC input
THC output
24 VDC maximum
10 mA maximum
Output
+
–
SETUP
CommandTHC for X-Y Table Instruction Manual 3-25
11
Part number Length
123018 25 ft./7.6 m
123019 50 ft./15.2 m
Pin Pin
number Color Signal name Function Signal name number
1 Input Black RX– RS-422 serial inverting receiver. TX– 1 Output
2 Green RX+ RS-422 serial non-inverting receiver. TX+ 2
6 Output Black TX– RS-422 serial inverting transmitter output. RX– 6 Input
3 White TX+ RS-422 serial non-inverting transmitter output. RX+ 3
5 Output Black 12 VDC common 12 VDC, 500 mA maximum 5 Input
9 Red 12 VDC + 9
4,7,8 Not connected 4,7,8
Figure 3-17 Pendant extension cable – part numbers and signal list
To THC
control
module
To operator
pendant
Pendant extension cable
THC.83
SETUP
3-26 CommandTHC for X-Y Table Instruction Manual
11
Part number Length
123197 5 ft./1.5 m
123198 10 ft./3 m
123199 15 ft./4.6 m
123200 20 ft./6.1 m
123020 25 ft./7.6 m
123201 30 ft./9.1 m
123202 35 ft./10.6 m
Part number
Length
123203 40 ft./12.2 m
123204 45 ft./13.7 m
123021 50 ft./15.2 m
123205 75 ft./23 m
123206 100 ft./30.5 m
123207 125 ft./38 m
123208 150 ft./45.6 m
Pin Pin
number Color Signal name Function number
5 Output Red Motor Phase A + Powers lifter motor, phase A+. 5 Input
4 Black Motor Phase A – 4
9 Output Red Motor Phase A + Powers lifter motor, phase A–. 9 Input
8 Black Motor Phase A – 8
3 Not connected 3
7 Output Red Motor Phase B + Powers lifter motor, phase B+. 7 Input
6 Black Motor Phase B – 6
2 Output Red Motor Phase B + Powers lifter motor, phase B–. 2 Input
1 Black Motor Phase B – 1
Figure 3-18 Motor drive cable – part numbers and signal list
Motor drive cable
To THC
control
module
To THC lifter
motor
THC.83
HD3070 SETUP
CommandTHC for X-Y Table Instruction Manual 3a-1
5
Section 3a
HD3070 SYSTEM INTERCONNECTIONS
HD3070 SETUP
3a-2 CommandTHC for X-Y Table Instruction Manual
11
See Figure 3a-1.
1. Remove access covers from the power supply, as required.
2. Locate the 1XPCB1 PC board inside the power supply.
3. Install the arc voltage wires:
Fabricate the wires as follows:
• Use 18AWG (≈0.9 mm2), single pair, unshielded wire, rated for 600V or greater.
• Wire length: As required, from the power supply to the plasma interface assembly.
• After installing the wires from the power supply to the plasma interface assembly, install appropriate
size fork or ring terminals on the wire ends.
Connect one of the wires to the 1XPCB1 PC board where wire No. 126 is connected. Label this wire
positive (+).
Connect the other wire to the 1XPCB1 PC board where wire No. 140 is connected. Label this wire
negative (–).
At the plasma interface assembly, connect the negative (–) wire to the J5-2 terminal labeled
ELECTRODE. Connect the positive (+) wire to the J5-3 terminal labeled WORK.
Electrode and work lead arc voltage wires
DANGER
ELECTRIC SHOCK CAN KILL
Turn off all electrical power before removing the power supply cover. Press the power
supply OFF (0) pushbutton switch and set the line disconnect switch to OFF. In the
U.S., use a “lock-out and tag-out” procedure until the service or maintenance is
complete. In other countries, follow appropriate local or national safety procedures.
HD3070 SETUP
CommandTHC for X-Y Table Instruction Manual 3a-3
11
A
B
126
140
+
-
2
3
1
4
5
J5
D
+
-
C
THC.80
Plasma interface
assembly
1XPCB1 PC board
Figure 3a-1 HD3070 electrode and work lead arc voltage wires connection
HD3070 SETUP
3a-4 CommandTHC for X-Y Table Instruction Manual
Power supply interface cable
The HD3070 power supply is equipped with a potentiometer for adjusting the
pierce delay time. Disable the pierce delay potentiometer in the power supply
per Section 3 of the HD3070 instruction manual.
See Figure 3a-2.
Connect the interface cable plug to the 1X1 receptacle on the back of the power supply.
Connect the other plug of the interface cable to the CNC.
Install the 5 pairs of wires of the interface cable to the plasma interface assembly as shown
in Figure 3a-2.
Install the wire with the fork terminal to the plasma interface assembly as shown
in Figure 3a-2.
See Figure 3a-3 for the interface cable part numbers and signal list.
6/9/00
HD3070 SETUP
CommandTHC for X-Y Table Instruction Manual 3a-5
5
Figure 3a-2 HD3070 Power supply interface cable connections
Plasma interface
assembly
Plasma Interface assembly
Power supply
CNC
Green wire
Black wire
Orange wire
Black wire
Black wire
White wire
Black wire
Red wire
Black wire
Yellow wire
Power Plasma
Supply CNC Interface
Signal Name Color End (1X1) End End Function
Hold I/O – Black 1 Not J4-6 (Optional) Hold Ignition (I/O) signal used for preflow
Hold I/O + Red 5 Connected J4-5 during IHS. Also used by power unit to synchronize
Drain Drain 10 operation of multiple torch installations.
Pierce Complete + Black 2 Not J4-8 (Optional) Pierce Complete signal used by power
Pierce Complete – White 6 Connected J4-7 unit to time transition from pierce gas flow to cut gas
Drain Drain 11 flow. User enters this time delay into THC.
Pilot Arc Out + Black 3 Not J3-4 (Optional) Pilot Arc Out signal. Maintained during
Pilot Arc Out – Green 7 Connected J3-3 torch ignition. Contact closes after torch ignition. Dry
Drain Drain 12 contact closure.
Plasma Start – Black 9 Not J4-4 Plasma On signal maintained during plasma cut. If
Plasma Start + Yellow 15 Connected J4-3 signal is lost, system must be restarted.
Drain Drain 14
Transfer Out + Black 37 Not J3-2 Arc Transfer signal. Contact closes after arc transfer
Transfer Out – Orange 32 Connected J3-1 and pierce delay (set on power supply front panel).
Drain Drain 26 Dry contact closure.
Power Off Black 4 4 Not
Power Off Blue 8 8 Connected
Drain Drain 13 13
External Interlock Red 16 16 Not
External Interlock Blue 17 17 Connected
Drain Drain 18 18
Power On Input Black 29 29 Not These signals connect to the CNC. Refer to HD3070
Power On Input Brown 34 34 Connected Instruction manual for signal information.
Drain Drain 23 23
Power Interlocks Red 35 35 Not
Power Interlocks White 30 30 Connected
Drain Drain 24 24
1/50 AC Volts Red 33 33 Not
1/50 AC Volt Green 28 28 Connected
Drain Drain 37 37
HD3070 SETUP
3a-6 CommandTHC for X-Y Table Instruction Manual
9
Figure 3a-3 HD3070 interface cable – part number and signal list
Part number Description Length
123270 HD3070 Power Supply Interface Cable 6 ft./1.8 m
Shaded area indicates plasma interface assembly connections.
Plasma interface assembly other J3 and J4 connection points:
• J3-5 (+) and J3-6 (–) – Alternate Nozzle Contact. An optically isolated signal that indicates nozzle is in ohmic contact with work.
Ohmic contact is represented by a logic 1.
• J3-7 through J3-12 – Reserved for future use.
• J3-13 and J3-14 – Protective earth ground.
• J4-1 (+) and J4-2 (–) – Available 24 VDC, 500 mA maximum
• J4-9 through J4-12 – Reserved for future use.
1X1
1X1
HD3070 SETUP
CommandTHC for X-Y Table Instruction Manual 3a-7
5
Ohmic contact wire
Install the ohmic contact wire through the strain relief of the
plasma interface assembly.
Install appropriate size fork terminal on the wire end and attach
the wire to the J5-5 terminal labeled SHIELD.
Install the other end of the ohmic contact wire to the IHS tab on
the torch retaining cap.
Plasma interface
assembly
Torch retaining cap with IHS tab
PAC184 P/N 120543
PAC186 P/N 020687
Ohmic contact wire
Figure 3a-4 HD3070 ohmic contact wire connection
A
1
2
3
B
4
C
SHIELD
J5
5
THC.76
HT2000 SETUP
CommandTHC for X-Y Table Instruction Manual 3b-1
6
Section 3b
HT2000 SYSTEM INTERCONNECTIONS
HT2000 SETUP
3b-2 CommandTHC for X-Y Table Instruction Manual
11
See Figure 3b-1.
1. Remove access covers from the power supply, as required.
2. Locate the input/output panel on the back of the power supply.
3. Install the arc voltage wires:
Fabricate the wires as follows:
• Use 18AWG (≈0.9 mm2), single pair, unshielded wire, rated for 600V or greater.
• Wire length: As required, from the power supply to the plasma interface assembly.
• After installing the wires from the power supply to the plasma interface assembly, install appropriate
size fork or ring terminals on the wire ends.
Connect one of the wires to the WORK LEAD (+) connection of the input/output panel. Label this wire
positive (+).
Connect the other wire to the NEGATIVE LEAD (–) connection of the input/output panel. Label this wire
negative (–).
At the plasma interface assembly, connect the negative (–) wire to the J5-2 terminal labeled
ELECTRODE. Connect the positive (+) wire to the J5-3 terminal labeled WORK.
Electrode and work lead arc voltage wires
DANGER
ELECTRIC SHOCK CAN KILL
Turn off all electrical power before removing the power supply cover. Press the power
supply OFF (0) pushbutton switch and set the line disconnect switch to OFF. In the
U.S., use a “lock-out and tag-out” procedure until the service or maintenance is
complete. In other countries, follow appropriate local or national safety procedures.
HT2000 SETUP
CommandTHC for X-Y Table Instruction Manual 3b-3
11
2
3
1
4
5
J5
+
-
THC.75
A
B
C
D
Plasma interface
assembly
Input/Output panel
Figure 3b-1 HT2000 electrode and work Lead arc voltage wires connection
HT2000 SETUP
3b-4 CommandTHC for X-Y Table Instruction Manual
6
Power supply interface cable
See Figure 3b-2.
Connect the interface cable plug to the 1X6 receptacle on the back of the power supply.
Connect the other plug of the interface cable to the CNC.
Install the 3 pairs of wires of the interface cable to the plasma interface assembly as shown
in Figure 3b-2.
See Figure 3b-3 for the interface cable part numbers and signal list.
HT2000 SETUP
CommandTHC for X-Y Table Instruction Manual 3b-5
6
C
Figure 3b-2 HT2000 power supply interface cable connections
Plasma interface
assembly
Plasma interface
assembly
Power supply
CNC
Red wire
Black wire
Black wire
White wire
Black wire
Blue wire
A
B
THC.79
Pilot Arc-
Pilot Arc+
Transfer IN-
Transfer IN+
Pierce Complete+
Pierce Complete-
Hold Ignition-
Hold Ignition+
Plasma Start
Plasma Start
24V -
24V +
J3
J4
4
3
2
1
8
7
6
5
4
3
2
1
C
HT2000 SETUP
3b-6 CommandTHC for X-Y Table Instruction Manual
7
Figure 3b-3 HT2000 interface cable – part number and signal list
Part number
Description Length
123329 HT2000 Power Supply Interface Cable 6 ft./1.8 m
Shaded area indicates plasma interface assembly connections.
Plasma interface assembly other J3 and J4 connection points:
• J3-5 (+) and J3-6 (–) – Alternate Nozzle Contact. An optically isolated signal that indicates nozzle is in ohmic contact with work.
Ohmic contact is represented by a logic 1.
• J3-7 through J3-12 – Reserved for future use.
• J3-13 and J3-14 – Protective earth ground.
• J4-1 (+) and J4-2 (–) – Available 24 VDC, 500 mA maximum
• J4-7 and J4-8 – Pierce Complete signal used by power supply to time transition from pierce gas flow to cut gas flow. User enters
this time delay into THC. Output signal.
• J4-9 through J4-12 – Reserved for future use.
Power Plasma
Supply CNC Interface
Signal Name Color End (1X6) End End Function
Hold – Black 5 Not J4-6 (Optional) Hold Ignition (I/O) signal used for preflow
during
Hold + White 1 Connected J4-5 IHS. Also used by power unit to synchronize operation
Drain Drain 10 of multiple torch installations. Output signal.
Plasma Start – Black 9 Not J4-4 Plasma Start signal maintained during plasma cut. If
Plasma Start + Blue 15 Connected J4-3 signal is lost, system must be restarted. Output signal.
Drain Drain 14
Arc Transfer – Black 32 Not J3-2 Arc Transfer signal. Contact closes after arc transfer
Arc Transfer + Red 37 Connected J3-1 and pierce delay (set on power supply front panel).
Drain Drain 26 Dry contact closure. Input signal.
Arc Voltage Black 28 28 Not
Arc Voltage Yellow 33 33 Connected
Drain Drain 27 27
Not Used Black 7 7 Not These signals connect to the CNC. Refer to HT2000
Not Used Brown 3 3 Connected Instruction manual for signal information.
Drain Drain 12 12
Not Used Black 16 16 Not
Not Used Green 17 17 Connected
Drain Drain 18 18
HT2000 SETUP
CommandTHC for X-Y Table Instruction Manual 3b-7
6
Plasma interface
assembly
Ohmic contact wire
Torch retaining cap with IHS tab
P/N 120837
Figure 3b-4 HT2000 ohmic contact wire connection
Ohmic contact wire
See Figure 3b-4.
Install the ohmic contact wire through the strain relief of the
plasma interface assembly.
Install appropriate size fork terminal on the wire end and attach
the wire to the J5-5 terminal labeled SHIELD.
Install the other end of the ohmic contact wire to the IHS tab on
the torch retaining cap.
A
1
2
C
B
SHIELD
3
4
5
J5
THC.71
HT2000LHF SETUP
CommandTHC for X-Y Table Instruction Manual 3c-1
5
Section 3c
HT2000LHF SYSTEM INTERCONNECTIONS
HT2000LHF SETUP
3c-2 CommandTHC for X-Y Table Instruction Manual
11
See Figure 3c-1.
1. Remove access covers from the power supply, as required.
2. Locate the input/output panel on the back of the power supply.
3. Install the arc voltage wires:
Fabricate the sensing wires as follows:
• Use 18AWG (≈0.9 mm2), single pair, unshielded wire, rated for 600V or greater.
• Wire length: As required, from the power supply to the plasma interface assembly.
• After installing the wires from the power supply to the plasma interface assembly, install appropriate
size fork or ring terminals on the wire ends.
Connect one of the wires to the WORK LEAD (+) connection of the input/output panel. Label this wire
positive (+).
Connect the other wire to the NEGATIVE LEAD (–) connection of the input/output panel. Label this wire
negative (–).
At the plasma interface assembly, connect the negative (–) wire to the J5-2 terminal labeled
ELECTRODE. Connect the positive (+) wire to the J5-3 terminal labeled WORK.
Electrode and work lead arc voltage wires
DANGER
ELECTRIC SHOCK CAN KILL
Turn off all electrical power before removing the power supply cover. Press the power
supply OFF (0) pushbutton switch and set the line disconnect switch to OFF. In the
U.S., use a “lock-out and tag-out” procedure until the service or maintenance is
complete. In other countries, follow appropriate local or national safety procedures.
HT2000LHF SETUP
CommandTHC for X-Y Table Instruction Manual 3c-3
11
A
Plasma interface
assembly
Input/Output panel
Figure 3c-1 HT2000LHF electrode and work lead arc voltage wires connection
THC.75
B
C
J5
+
-
D
3
4
5
2
1
HT2000LHF SETUP
3c-4 CommandTHC for X-Y Table Instruction Manual
5
Power supply interface cable
See Figure 3c-2.
Connect the interface cable plug to the 1X6 receptacle on the back of the power supply.
Connect the other plug of the interface cable to the CNC.
Install the 3 pairs of wires of the interface cable to the plasma interface assembly as shown
in Figure 3c-2.
See Figure 3c-3 for the interface cable part numbers and signal list.
HT2000LHF SETUP
CommandTHC for X-Y Table Instruction Manual 3c-5
5
C
Figure 3c-2 HT2000LHF power supply interface cable connections
Plasma interface
assembly
Plasma interface
assembly
Power supply
CNC
Red wire
Black wire
Black wire
White wire
Black wire
Blue wire
A
B
THC.79
Pilot Arc-
Pilot Arc+
Transfer IN-
Transfer IN+
Pierce Complete+
Pierce Complete-
Hold Ignition-
Hold Ignition+
Plasma Start
Plasma Start
24V -
24V +
J3
J4
4
3
2
1
8
7
6
5
4
3
2
1
C
Power Plasma
Supply CNC Interface
Signal Name Color End (1X6) End End Function
Hold – Black 5 Not J4-6 (Optional) Hold Ignition (I/O) signal used for preflow
Hold + White 1 Connected J4-5 during IHS. Also used by power unit to synchronize
Drain Drain 10 operation of multiple torch installations. Output signal.
Plasma Start – Black 9 Not J4-4 Plasma Start signal maintained during plasma cut. If
Plasma Start + Blue 15 Connected J4-3 signal is lost, system must be restarted. Output signal.
Drain Drain 14
Arc Transfer – Black 32 Not J3-2 Arc Transfer signal. Contact closes after arc transfer
Arc Transfer + Red 37 Connected J3-1 and pierce delay (set on power supply front panel).
Drain Drain 26 Dry contact closure. Input signal.
Ramp Down Error Black 28 28 Not
Ramp Down Error Yellow 33 33 Connected
Drain Drain 27 27
Not Used Black 7 7 Not These signals connect to the CNC. Refer to
Not Used Brown 3 3 Connected HT2000 LHF Instruction manual for signal information.
Drain Drain 12 12
Not Used Black 16 16 Not
Not Used Green 17 17 Connected
Drain Drain 18 18
HT2000LHF SETUP
3c-6 CommandTHC for X-Y Table Instruction Manual
7
Figure 3c-3 HT2000LHF interface cable – part number and signal list
Part number
Description Length
123329 HT2000LHF Power Supply Interface Cable 6 ft./1.8 m
Shaded area indicates plasma interface assembly connections.
Plasma interface assembly other J3 and J4 connection points:
• J3-5 (+) and J3-6 (–) – Alternate Nozzle Contact. An optically isolated signal that indicates nozzle is in ohmic contact with work.
Ohmic contact is represented by a logic 1.
• J3-7 through J3-12 – Reserved for future use.
• J3-13 and J3-14 – Protective earth ground.
• J4-1 (+) and J4-2 (–) – Available 24 VDC, 500 mA maximum
• J4-7 and J4-8 – Pierce Complete signal used by power supply to time transition from pierce gas flow to cut gas flow. User enters
this time delay into THC. Output signal.
• J4-9 through J4-14 – Reserved for future use.
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